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KOMATSU PC210LC-10 HYDRAULIC EXCAVATOR SHOP REPAIR MANUAL SL NO A10001 & up – PDF DOWNLOAD
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KOMATSU PC210LC-10 HYDRAULIC EXCAVATOR SHOP REPAIR MANUAL
SERIAL NUMBERS : PC210LC-10 A10001 and up
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Description
KOMATSU PC210LC-10 HYDRAULIC EXCAVATOR SHOP REPAIR MANUAL
FILE DETAILS:
KOMATSU PC210LC-10 HYDRAULIC EXCAVATOR SHOP REPAIR MANUAL
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC210LC-10
Serial Number: A10001 and up
Book Code: CEBM026702
Language: English
Pages: 1710
File Format: Portable Document Format (PDF)
KOMATSU PC210LC-10 HYDRAULIC EXCAVATOR SHOP REPAIR MANUAL SL NO A10001 & UP – PDF DOWNLOAD:
DESCRIPTION:
KOMATSU PC210LC-10 HYDRAULIC EXCAVATOR SHOP REPAIR MANUAL
How to read the shop manual:
Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification:
This section explains the specifications of the machine.
10. Structure, function and maintenance standard:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and weight of components are also explained.
90. Diagrams and drawings:
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
TABLE OF CONTENTS:
KOMATSU PC210LC-10 HYDRAULIC EXCAVATOR SHOP REPAIR MANUAL
PC210LC-10 COVER.......................................................................................................................... 1 00 Index and foreword ..................................................................................................................... 3 Index ................................................................................................................................. 4 Foreword, safety and general information .............................................................................................. 16 Important safety notice ........................................................................................................... 16 How to read the shop manual ....................................................................................................... 23 Explanation of terms for maintenance standard ..................................................................................... 25 Handling equipment of fuel system devices ......................................................................................... 27 Handling of intake system parts ................................................................................................... 28 Handling of hydraulic equipment ................................................................................................... 29 Method of disconnecting and connecting of push-pull type coupler .................................................................. 31 Handling of electrical equipment .................................................................................................. 34 How to read electric wire code .................................................................................................... 42 Precautions when performing operation ............................................................................................. 45 Practical use of KOMTRAX .......................................................................................................... 49 Standard tightening torque table .................................................................................................. 50 List of abbreviation .............................................................................................................. 54 Conversion table .................................................................................................................. 59 01 Specification .......................................................................................................................... 65 Table of contents ..................................................................................................................... 66 Specifications ........................................................................................................................ 66 Specification drawing ............................................................................................................. 66 Working range drawings ............................................................................................................ 67 Specifications .................................................................................................................... 68 Weight table ...................................................................................................................... 71 Table of fuel, coolant, and lubricants ............................................................................................ 73 10 Structure and function ................................................................................................................. 75 Table of contents ..................................................................................................................... 76 Engine and cooling system ............................................................................................................. 77 Engine related parts .............................................................................................................. 77 KVGT .............................................................................................................................. 79 EGR system piping drawing ......................................................................................................... 86 EGR system circuit diagram ........................................................................................................ 88 EGR valve ......................................................................................................................... 90 EGR cooler ........................................................................................................................ 92 KCCV layout drawing ............................................................................................................... 93 KCCV ventilator ................................................................................................................... 95 KDPF .............................................................................................................................. 97 Cooling system .................................................................................................................... 101 Power train ........................................................................................................................... 103 Power train system ................................................................................................................ 103 Swing circle ...................................................................................................................... 105 Swing machinery ................................................................................................................... 106 Final drive ....................................................................................................................... 108 Undercarriage and frame ............................................................................................................... 110 Track frame and idler cushion ..................................................................................................... 110 Hydraulic system ...................................................................................................................... 112 Hydraulic equipment layout drawing ................................................................................................ 112 Valve control ..................................................................................................................... 114 Hydraulic tank .................................................................................................................... 116 CLSS .............................................................................................................................. 118 Main pump ......................................................................................................................... 123 Control valve ..................................................................................................................... 148 Swing motor ....................................................................................................................... 205 Travel motor ...................................................................................................................... 217 PPC valve ......................................................................................................................... 230 Solenoid valve .................................................................................................................... 252 Attachment circuit selector valve (for high pressure circuit) ..................................................................... 255 Attachment circuit selector valve (for low pressure circuit) ...................................................................... 257 Center swivel joint ............................................................................................................... 260 Accumulator ....................................................................................................................... 262 Work equipment ........................................................................................................................ 263 Work equipment .................................................................................................................... 263 Work equipment shim ............................................................................................................... 264 Bucket play adjustment shim ....................................................................................................... 265 Cab and its attachments ............................................................................................................... 266 Cab mount and cab tipping stopper ................................................................................................. 266 ROPS cab .......................................................................................................................... 267 Electrical system ..................................................................................................................... 268 Electrical control system ......................................................................................................... 268 Machine monitor system ............................................................................................................ 319 KOMTRAX system .................................................................................................................... 341 Sensor ............................................................................................................................ 344 20 Standard value tables .................................................................................................................. 365 Table of contents ..................................................................................................................... 366 Standard service value table .......................................................................................................... 367 Standard value table for engine ................................................................................................... 367 Standard value table for machine .................................................................................................. 369 Standard value table for electrical system ........................................................................................ 382 30 Testing and adjusting .................................................................................................................. 393 Table of contents ..................................................................................................................... 394 General information on testing and adjusting .......................................................................................... 395 Tools for testing and adjusting ................................................................................................... 395 Sketch of tools for testing and adjusting ......................................................................................... 399 Engine and cooling system ............................................................................................................. 400 Testing engine speed .............................................................................................................. 400 Testing boost pressure ............................................................................................................ 401 Testing exhaust gas color ......................................................................................................... 403 Measuring and adjusting valve clearance ........................................................................................... 405 Testing compression pressure ...................................................................................................... 408 Testing blowby pressure ........................................................................................................... 412 Testing engine oil pressure ....................................................................................................... 413 Testing EGR valve and KVGT oil pressures .......................................................................................... 414 Measuring fuel pressure ........................................................................................................... 415 Measuring fuel delivery, return and leakage ....................................................................................... 421 Bleeding air from fuel system ..................................................................................................... 426 Checking fuel circuit for leakage ................................................................................................. 428 Handling cylinder cutout mode operation ........................................................................................... 429 Handling no injection cranking operation .......................................................................................... 430 Checking and adjusting air conditioner compressor belt tension .................................................................... 431 Replacing fan belt ................................................................................................................ 433 Power train ........................................................................................................................... 434 Testing swing circle bearing clearance ............................................................................................ 434 Undercarriage and frame ............................................................................................................... 435 Testing and adjusting track shoe tension .......................................................................................... 435 Hydraulic system ...................................................................................................................... 436 Releasing remaining pressure from hydraulic circuit ............................................................................... 436 Testing and adjusting oil pressure in work equipment, swing, and travel circuits .................................................. 437 Testing oil pressure of control circuit ........................................................................................... 441 Testing and adjusting oil pressure in pump PC control circuit ..................................................................... 444 Testing and adjusting oil pressure in pump LS control circuit ..................................................................... 447 Testing output pressure of solenoid valve ......................................................................................... 452 Testing PPC valve output pressure ................................................................................................. 456 Adjusting play of work equipment and swing PPC valves ............................................................................. 458 Testing pump swash plate sensor ................................................................................................... 459 Isolating the parts causing hydraulic drift in work equipment ..................................................................... 460 Testing oil leakage ............................................................................................................... 461 Bleeding air from hydraulic circuit ............................................................................................... 464 Cab and its attachments ............................................................................................................... 466 Checking cab tipping stopper ...................................................................................................... 466 Adjusting mirrors ................................................................................................................. 467 Electrical system ..................................................................................................................... 469 Special functions of machine monitor .............................................................................................. 469 Adjusting rearview camera angle ................................................................................................... 541 Handling voltage circuit of engine controller ..................................................................................... 543 Handling battery disconnect switch ................................................................................................ 544 Testing diodes .................................................................................................................... 545 Pm clinic ............................................................................................................................. 546 Pm Clinic service ................................................................................................................. 546 40 Troubleshooting ........................................................................................................................ 557 Table of contents ..................................................................................................................... 558 General information on troubleshooting ................................................................................................ 565 Troubleshooting points ............................................................................................................ 565 Sequence of events in troubleshooting ............................................................................................. 567 Testing before troubleshooting .................................................................................................... 569 Inspection procedure before troubleshooting ....................................................................................... 571 Preparation work for troubleshooting of electrical system ......................................................................... 590 Classification and procedure for troubleshooting .................................................................................. 594 Symptom of probable failure and troubleshooting No. ............................................................................... 597 Information in troubleshooting table .............................................................................................. 600 Diagnostic procedure for wiring harness open curcuit of pressure sensor system .................................................... 602 Connector list and layout ......................................................................................................... 604 Connector contact identification .................................................................................................. 615 T-branch box and T-branch adapter table ........................................................................................... 651 Fuse location table ............................................................................................................... 657 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ..................................................................... 659 Fabrication of dummy temperature sensor (for KDOC and KDPF temperature sensors) ................................................... 662 Fabrication of short-circuit connector (for CA1883 and CA3135) .................................................................... 663 Failure codes table ............................................................................................................... 664 Troubleshooting by failure code (Display of code) ..................................................................................... 673 Failure code [879AKA] A/C Inner Sensor Open Circuit ............................................................................... 673 Failure code [879AKB] A/C Inner Sensor Short Circuit .............................................................................. 674 Failure code [879BKA] A/C Outer Sensor Open Circuit ............................................................................... 675 Failure code [879BKB] A/C Outer Sensor Short Circuit .............................................................................. 676 Failure code [879CKA] Ventilating Sensor Open Circuit ............................................................................. 677 Failure code [879CKB] Ventilating Sensor Short Circuit ............................................................................ 678 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ....................................................................... 679 Failure code [879EMC] Ventilation Damper Abnormality .............................................................................. 680 Failure code [879FMC] Air Mix Damper Abnormality .................................................................................. 681 Failure code [879GKX] Refrigerant Abnormality ..................................................................................... 682 Failure code [989L00] Engine Controller Lock Caution1 ............................................................................. 683 Failure code [989M00] Engine Controller Lock Caution2 ............................................................................. 684 Failure code [989N00] Engine Controller Lock Caution3 ............................................................................. 685 Failure code [A1U0N3]: KDPF Dry Request (HC Release) .............................................................................. 686 Failure code [A1U0N4] KDPF Dry Request (HC Release) ............................................................................... 688 Failure code [AA10NX] Air Cleaner Clogging ........................................................................................ 690 Failure code [AB00KE] Charge Voltage Low .......................................................................................... 692 Failure code [B@BAZG] Engine Oil Pressure Low ..................................................................................... 694 Failure code [B@BAZK] Eng Oil Level Low ........................................................................................... 695 Failure code [B@BCNS] Engine Coolant Overheat ..................................................................................... 696 Failure code [B@BCZK] Radiator Coolant Level Low .................................................................................. 697 Failure code [B@HANS] Hyd Oil Overheat ............................................................................................ 699 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ............................................................................. 700 Failure code [CA122] Chg Air Press Sensor High Error .............................................................................. 701 Failure code [CA123] Chg Air Press Sensor Low Error ............................................................................... 703 Failure code [CA131] Throttle Sensor High Error ................................................................................... 705 Failure code [CA132] Throttle Sensor Low Error .................................................................................... 707 Failure code [CA144] Coolant Temp Sens High Error ................................................................................. 709 Failure code [CA145] Coolant Temp Sens Low Error .................................................................................. 711 Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................... 713 Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................................ 715 Failure code [CA187] Sensor 2 Supply Volt Low Error ............................................................................... 717 Failure code [CA221] Ambient Press Sens High Error ................................................................................ 719 Failure code [CA222] Ambient Press Sens Low Error ................................................................................. 721 Failure code [CA227] Sensor 2 Supply Volt High Error .............................................................................. 723 Failure code [CA234] Eng Overspeed ................................................................................................ 724 Failure code [CA238] Ne Speed Sensor Supply Volt Error ............................................................................ 725 Failure code [CA239] Ne Speed Sens Supply Volt High Error ......................................................................... 726 Failure code [CA271] IMV/PCV1 Short Error ......................................................................................... 727 Failure code [CA272] IMV/PCV1 Open Error .......................................................................................... 729 Failure code [CA295] Ambient Press Sens In Range Error ............................................................................ 731 Failure code [CA322] Inj #1(L#1) Open/Short Error ................................................................................. 732 Failure code [CA323] Inj #5(L#5) Open/Short Error ................................................................................. 734 Failure code [CA324] Inj #3(L#3) Open/Short Error ................................................................................. 736 Failure code [CA325] Inj #6(L#6) Open/Short Error ................................................................................. 738 Failure code [CA331] Inj #2(L#2) Open/Short Error ................................................................................. 740 Failure code [CA332] Inj #4(L#4) Open/Short Error ................................................................................. 742 Failure code [CA343] ECM Critical Internal Failure ................................................................................ 744 Failure code [CA351] Injectors Drive Circuit Error ................................................................................ 745 Failure code [CA352] Sensor 1 Supply Volt Low Error ............................................................................... 746 Failure code [CA356] Mass Air Flow Sensor High Error .............................................................................. 748 Failure code [CA357] Mass Air Flow Sensor Low Error ............................................................................... 750 Failure code [CA386] Sensor 1 Supply Volt High Error .............................................................................. 752 Failure code [CA428] Water in Fuel Sensor High Error .............................................................................. 753 Failure code [CA429] Water in Fuel Sensor Low Error ............................................................................... 755 Failure code [CA435] Eng Oil Press Sw Error ....................................................................................... 757 Failure code [CA441] Battery Voltage Low Error .................................................................................... 758 Failure code [CA442] Battery Voltage High Error ................................................................................... 760 Failure code [CA449] Rail Press Very High Error ................................................................................... 761 Failure code [CA451] Rail Press Sensor High Error ................................................................................. 762 Failure code [CA452] Rail Press Sensor Low Error .................................................................................. 764 Failure code [CA488] Chg Air Temp High Torque Derate .............................................................................. 766 Failure code [CA515] Rail Press Sens Sup Volt High Error .......................................................................... 767 Failure code [CA516] Rail Press Sens Sup Volt Low Error ........................................................................... 769 Failure code [CA553] Rail Press High Error ........................................................................................ 771 Failure code [CA555] Crankcase Press High Error 1 ................................................................................. 772 Failure code [CA556] Crankcase Press High Error 2 ................................................................................. 773 Failure code [CA559] Rail Press Low Error ......................................................................................... 774 Failure code [CA595] Turbo Speed High Error 2 ..................................................................................... 776 Failure code [CA687] Turbo Speed Low Error ........................................................................................ 777 Failure code [CA689] Eng Ne Speed Sensor Error .................................................................................... 779 Failure code [CA691] Intake Air Temp Sens High Error .............................................................................. 781 Failure code [CA692] Intake Air Temp Sens Low Error ............................................................................... 783 Failure code [CA697] ECM Int Temp Sensor High Error ............................................................................... 785 Failure code [CA698] ECM Int Temp Sensor Low Error ................................................................................ 786 Failure code [CA731] Eng Bkup Speed Sens Phase Error .............................................................................. 787 Failure code [CA778] Eng Bkup Speed Sensor Error .................................................................................. 789 Failure code [CA1117] Persistent Data Lost Error .................................................................................. 794 Failure code [CA1664] KDOC Malfunction ............................................................................................ 795 Failure code [CA1691] Regeneration Ineffective .................................................................................... 797 Failure code [CA1695] Sensor 5 Supply Volt High Error ............................................................................. 800 Failure code [CA1696] Sensor 5 Supply Volt Low Error .............................................................................. 802 Failure code [CA1843] Crankcase Press Sens High Error ............................................................................. 804 Failure code [CA1844] Crankcase Press Sens Low Error .............................................................................. 806 Failure code [CA1879] KDPF Delta P Sensor High Error .............................................................................. 808 Failure code [CA1881] KDPF Delta P Sensor Low Error ............................................................................... 810 Failure code [CA1883] KDPF Delta P Sens In Range Error ............................................................................ 812 Failure code [CA1921] KDPF Soot Load High Error 1 ................................................................................. 815 Failure code [CA1922] KDPF Soot Load High Error 2 ................................................................................. 818 Failure code [CA1942] Crankcase Press Sens In Range Error ......................................................................... 823 Failure code [CA1993] KDPF Delta Pressure Low Error ............................................................................... 824 Failure code [CA2185] Throt Sensor Sup Volt High Error ............................................................................ 827 Failure code [CA2186] Throt Sensor Sup Volt Low Error ............................................................................. 829 Failure code [CA2249] Rail Press Very Low Error ................................................................................... 831 Failure code [CA2271] EGR Valve Pos Sens High Error ............................................................................... 832 Failure code [CA2272] EGR Valve Pos Sens Low Error ................................................................................ 834 Failure code [CA2288] Turbo Speed High Error 1 .................................................................................... 837 Failure code [CA2311] IMV Solenoid Error .......................................................................................... 838 Failure code [CA2349] EGR Valve Solenoid Open Error ............................................................................... 839 Failure code [CA2353] EGR Valve Solenoid Short Error .............................................................................. 841 Failure code [CA2357] EGR Valve Servo Error ....................................................................................... 843 Failure code [CA2373] Exhaust Manifold Press Sens High error ...................................................................... 844 Failure code [CA2374] Exhaust Manifold Press Sens Low error ....................................................................... 846 Failure code [CA2375] EGR Orifice Temp Sens High Error ............................................................................ 848 Failure code [CA2376] EGR Orifice Temp Sens Low Error ............................................................................. 850 Failure code [CA2381] KVGT Pos Sens High Error .................................................................................... 852 Failure code [CA2382] KVGT Pos Sens Low Error ..................................................................................... 854 Failure code [CA2383] KVGT Solenoid Open Error .................................................................................... 857 Failure code [CA2386] KVGT Solenoid Short Error ................................................................................... 859 Failure code [CA2387] KVGT Servo Error ............................................................................................ 861 Failure code [CA2554] Exh Manifold Press Sens In Range Error ...................................................................... 862 Failure code [CA2555] Grid Htr Relay Volt Low Error ............................................................................... 863 Failure code [CA2556] Grid Htr Relay Volt High Error .............................................................................. 865 Failure code [CA2637] KDOC Face Plugging .......................................................................................... 867 Failure code [CA2639] Manual Stationary Regeneration Request ...................................................................... 869 Failure code [CA2961] EGR Orifice Temp High Error 1 ............................................................................... 872 Failure code [CA2973] Chg Air Press Sensor In Range Error ......................................................................... 873 Failure code [CA3133] KDPF Outlet Press Sens High Error ........................................................................... 874 Failure code [CA3134] KDPF Outlet Press Sens Low Error ............................................................................ 876 Failure code [CA3135] KDPF Outlet Press Sens In Range Error ....................................................................... 878 Failure code [CA3251] KDOC Inlet Temp High Error .................................................................................. 882 Failure code [CA3253] KDOC Temp Error - Non Regeneration .......................................................................... 885 Failure code [CA3254] KDOC Outlet Temp High Error 1 ............................................................................... 888 Failure code [CA3255] KDPF Temp Error - Non Regeneration .......................................................................... 891 Failure code [CA3256] KDPF Outlet Temp High Error 1 ............................................................................... 894 Failure code [CA3311] KDOC Outlet Temp High Error 2 ............................................................................... 897 Failure code [CA3312] KDPF Outlet Temp High Error 2 ............................................................................... 900 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ............................................................................ 903 Failure code [CA3314] KDOC Inlet Temp Sens High Error ............................................................................. 906 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ......................................................................... 909 Failure code [CA3316] KDOC Outlet Temp Sens Low Error ............................................................................. 913 Failure code [CA3317] KDOC Outlet Temp Sens High Error ............................................................................ 916 Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ........................................................................ 920 Failure code [CA3319] KDPF Outlet Temp Sens High Error ............................................................................ 924 Failure code [CA3321] KDPF Outlet Temp Sens Low Error ............................................................................. 928 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ........................................................................ 931 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error .................................................................... 935 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ..................................................................... 937 Failure code [CA3741] Rail Press Valve Trip Error ................................................................................. 939 Failure code [D110KB] Battery Relay Output Voltage ................................................................................ 940 Failure code [D19JKZ] Personal Code Relay Abnormality ............................................................................. 942 Failure code [D811MC] KOMTRAX Error ............................................................................................... 945 Failure code [D862KA] GPS Antenna Open Circuit .................................................................................... 946 Failure code [D8ALKA] System Operating Lamp Disconnection (KOMTRAX) ............................................................... 947 Failure code [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) ............................................................... 949 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ....................................................................................... 950 Failure code [DA20MC] Pump Controller ............................................................................................. 951 Failure code [DA22KK] Pump Solenoid Power Low Error ............................................................................... 952 Failure code [DA25KP] 5V Sensor 1 Power Abnormality ............................................................................... 954 Failure code [DA29KQ] Model Selection Abnormality ................................................................................. 957 Failure code [DA2LKA] System Operating Lamp Disconnection (Pump Con) .............................................................. 959 Failure code [DA2LKB] System Operating Lamp Short Circuit (Pump Con) .............................................................. 961 Failure code [DA2QKR] CAN2 Discon (Pump Con) ...................................................................................... 962 Failure code [DA2RKR] CAN1 Discon (Pump Con) ...................................................................................... 965 Failure code [DAF0MB] Monitor ROM Abnormality ..................................................................................... 966 Failure code [DAF0MC] Monitor Error ............................................................................................... 967 Failure code [DAF8KB] Camera Power Supply Short Circuit ........................................................................... 968 Failure code [DAF9KQ] Model Selection Abnormality ................................................................................. 970 Failure code [DAFGMC] GPS Module Error ............................................................................................ 971 Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) ........................................................................ 972 Failure code [DAFLKB] System Operating Lamp Short Circuit (Monitor) ............................................................... 974 Failure code [DAFQKR] CAN2 Discon (Monitor) ....................................................................................... 975 Failure code [DAZ9KQ] A/C Model Selection Abnormality ............................................................................. 976 Failure code [DAZQKR] CAN2 Discon (AC) ............................................................................................ 977 Failure code [DB2QKR] CAN2 Discon (Engine Con) .................................................................................... 982 Failure code [DB2RKR] CAN1 Discon (Engine Con) .................................................................................... 987 Failure code [DGH2KB] Hyd Oil Sensor Short ........................................................................................ 991 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ........................................................................ 993 Failure code [DHPAMA] F Pump Press Sensor Abnormality ............................................................................. 994 Failure code [DHPBMA] R Pump Press Sensor Abnormality ............................................................................. 997 Failure code [DHS3MA] Arm IN PPC Sen. Abnormality .................................................................................1000 Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality ....................................................................1002 Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality .....................................................................1005 Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality .........................................................................1008 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality .......................................................................1011 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality .......................................................................1014 Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality .......................................................................1017 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ....................................................................1020 Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality ..................................................................1023 Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality ..................................................................1026 Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality ..................................................................1029 Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality ..................................................................1032 Failure code [DKR0MA] F pump S/P sensor Abnormality ...............................................................................1035 Failure code [DKR1MA] R pump S/P sensor Abnormality ...............................................................................1037 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality .....................................................................1039 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality .....................................................................1041 Failure code [DV20KB] Travel Alarm Short Circuit ..................................................................................1043 Failure code [DW43KA] Travel Speed Sol Open Circuit ...............................................................................1045 Failure code [DW43KB] Travel Speed Sol Short Circuit ..............................................................................1047 Failure code [DW45KA] Swing holding brake Sol Open Circuit ........................................................................1049 Failure code [DW45KB] Swing holding brake Sol Short Circuit .......................................................................1052 Failure code [DW91KA] Travel Junction Sol Open Circuit ............................................................................1055 Failure code [DW91KB] Travel Junction Sol Short Circuit ...........................................................................1057 Failure code [DWA2KA] Attachment Sol Open Circuit .................................................................................1059 Failure code [DWA2KB] Attachment Sol Short Circuit ................................................................................1061 Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit .............................................................................1063 Failure code [DWK0KB] 2-stage Relief Sol Short Circuit ............................................................................1065 Failure code [DWK2KA] Variable Back Press Sol Open Circuit ........................................................................1067 Failure code [DWK2KB] Variable Back Press Sol Short Circuit .......................................................................1069 Failure code [DWK8KA] Swing Press C/O Sol Open Circuit ............................................................................1071 Failure code [DWK8KB] Swing Press C/O Sol Short Circuit ...........................................................................1073 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit .................................................................................1075 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit ................................................................................1077 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit .................................................................................1079 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ................................................................................1081 Failure code [DXE0KA] LS-EPC Sol Open Circuit .....................................................................................1083 Failure code [DXE0KB] LS-EPC Sol Short Circuit ....................................................................................1085 Failure code [DXE4KA] Attachment Flow EPC Open Circuit ............................................................................1087 Failure code [DXE4KB] Attachment Flow EPC Short Circuit ...........................................................................1089 Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ..........................................................................1091 Failure code [DXE5KB] Merge-divide Main Sol Short Circuit .........................................................................1093 Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ............................................................................1095 Failure code [DXE6KB] Merge-divide LS Sol Short Circuit ...........................................................................1097 Failure code [DY20KA] Wiper Working Abnormality ...................................................................................1099 Failure code [DY20MA] Wiper Parking Abnormality ...................................................................................1101 Failure code [DY2CKB] Washer Drive Short Circuit ..................................................................................1103 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit .............................................................................1105 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit .............................................................................1107 Troubleshooting of electrical system (E-mode) .........................................................................................1109 E-1 Engine does not start (Engine does not crank) .................................................................................1109 E-2 Manual preheating system does not work ........................................................................................1115 E-3 Automatic preheating system does not work .....................................................................................1118 E-4 Preheating monitor does not light up when preheater is operated ...............................................................1120 E-5 When starting switch is turned to ON position, machine monitor displays nothing ...............................................1122 E-6 When starting switch is turned to ON position (before starting engine), engine oil level monitor lights up in yellow ..........1125 E-7 When starting switch is turned to ON position (before starting engine), radiator coolant level monitor lights up in yellow ....1126 E-8 Coolant temperature monitor lights up in white while engine is running ........................................................1127 E-9 Hydraulic oil temperature monitor lights up in white while engine is running ..................................................1128 E-10 Charge level monitor lights up while engine is running .......................................................................1129 E-11 Fuel level monitor lights up in red while engine is running ..................................................................1130 E-12 Air cleaner clogging monitor lights up in yellow while engine is running .....................................................1131 E-13 Water separator monitor lights up while engine is running ....................................................................1132 E-14 Coolant temperature monitor lights up in red while engine is running .........................................................1133 E-15 Hydraulic oil temperature monitor lights up in red while engine is running ...................................................1134 E-16 Engine oil pressure monitor lights up in red while engine is running .........................................................1135 E-17 Fuel gauge indicates either full or empty and does not move ..................................................................1136 E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty) .....................................................1137 E-19 Coolant temperature gauge indicates either Min. or Max. and does not move ....................................................1138 E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min. nor Max.) ..................................1139 E-21 Hydraulic oil temperature gauge indicates either Min. or Max. and does not move ..............................................1140 E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min. nor Max.) ............................1142 E-23 Content of display on machine monitor is different from that of actual machine ...............................................1143 E-24 Machine monitor does not display some items ..................................................................................1144 E-25 Function switch does not work ................................................................................................1145 E-26 Automatic preheating system does not work (In cold season) ...................................................................1146 E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration switch is operated .....................1147 E-28 Auto-deceleration is not actuated or canceled when lever is operated .........................................................1148 E-29 Working mode selection screen is not diplayed when working mode switch is operated ...........................................1149 E-30 Engine or hydraulic pump setting does not change when working mode is changed ................................................1150 E-31 Travel speed monitor does not change when travel speed switch is operated ....................................................1151 E-32 Travel speed does not change while travel speed selection is changed .........................................................1152 E-33 Alarm buzzer does not stop sounding ..........................................................................................1153 E-34 When starting switch is turned to OFF position, service meter is not displayed ...............................................1154 E-35 Service mode cannot be selected ..............................................................................................1155 E-36 Any of work equipment, swing and travel does not work ........................................................................1156 E-37 Any of work equipment, swing and travel cannot be locked .....................................................................1158 E-38 Machine cannot swing while swing brake cancel switch is canceled .............................................................1159 E-39 Swing brake does not operate while swing brake cancel switch is locked .......................................................1161 E-40 One-touch power maximizing function does not work or monitor is not displayed ................................................1163 E-41 One-touch power maximizing function cannot be canceled .......................................................................1165 E-42 Travel alarm does not sound when machine travels .............................................................................1166 E-43 Alarm does not stop sounding while machine is stopped ........................................................................1167 E-44 Horn does not sound ..........................................................................................................1168 E-45 Horn does not stop sounding ..................................................................................................1170 E-46 Wiper monitor does not light up or go out when wiper switch is operated ......................................................1171 E-47 Wiper does not operate when wiper switch is operated .........................................................................1172 E-48 Window washer does not operate when window washer switch is operated .........................................................1174 E-49 BOOM LOWER indication is not displayed properly with monitoring function .....................................................1175 E-50 ARM DUMP indication is not displayed properly with monitoring function .......................................................1176 E-51 ARM IN indication is not displayed properly with monitoring function .........................................................1177 E-52 BOOM RAISE indication is not displayed properly with monitoring function .....................................................1178 E-53 BUCKET CURL indication is not displayed properly with monitoring function ....................................................1179 E-54 BUCKET DUMP indication is not displayed properly with monitoring function ....................................................1180 E-55 SWING indication is not displayed properly with monitoring function ..........................................................1181 E-56 TRAVEL indication is not displayed properly with monitoring function .........................................................1182 E-57 Service is not displayed properly with monitoring function ...................................................................1183 E-58 Attachment hydraulic circuit cannot be changed ...............................................................................1186 E-59 KOMTRAX system does not operate normally .....................................................................................1187 Troubleshooting of hydraulic and mechanical system (H-mode) ...........................................................................1189 Information described in troubleshooting table (H-mode) ...........................................................................1189 System chart for hydraulic system .................................................................................................1190 Failure mode and cause table ......................................................................................................1192 H-1 All of work equipment, swing and travel operation lacks speed or power ........................................................1200 H-2 Engine speed drops significantly or engine stalls .............................................................................1203 H-3 All work equipment, swing and travel does not work ............................................................................1206 H-4 Unusual sound is heard from around hydraulic pump .............................................................................1207 H-5 Fine control performance or response is poor ..................................................................................1208 H-6 Boom speed or power is low ....................................................................................................1210 H-7 Arm speed or power is low .....................................................................................................1214 H-8 Bucket speed or power is low ..................................................................................................1219 H-9 Work equipment does not move in single operation ..............................................................................1222 H-10 Hydraulic drift of boom is large .............................................................................................1223 H-11 Hydraulic drift of arm is large ..............................................................................................1224 H-12 Hydraulic drift of bucket is large ...........................................................................................1225 H-13 Time lag of work equipment is large ..........................................................................................1226 H-14 When part of work equipment is relieved singly, other parts of work equipment move ...........................................1228 H-15 One-touch power maximizing function does not operate .........................................................................1229 H-16 In combined operation of work equipment, equipment having heavier load moves slower ..........................................1230 H-17 In combined operations of swing and boom RAISE, boom rising speed is low .....................................................1231 H-18 In combined operations of swing and travel, travel speed drops largely .......................................................1232 H-19 Machine does not travel straight .............................................................................................1233 H-20 Travel speed is slow .........................................................................................................1236 H-21 Machine is hard to steer or travel power is low ..............................................................................1238 H-22 Travel speed does not change, or travel speed is too slow or fast ............................................................1241 H-23 One of tracks does not run ...................................................................................................1242 H-24 Upper structure does not swing to the right or left ..........................................................................1244 H-25 Upper structure swing only to the right or left ..............................................................................1245 H-26 Swing acceleration or swing speed is low in both directions (right and left) .................................................1246 H-27 Swing acceleration performance is poor or swing speed is slow in only one direction ..........................................1247 H-28 Upper structure overruns excessively when it stops swinging (both right and left) ............................................1248 H-29 Upper structure overruns excessively when it stops swinging (either right or left) ...........................................1249 H-30 Shock is large when upper structure stops swinging ...........................................................................1250 H-31 Large unusual noise is heard when upper structure stops swinging .............................................................1251 H-32 Swing drift on a slope is large while swing holding brake is applied .........................................................1252 H-33 Swing drift on a slope is large while swing holding brake is released ........................................................1253 H-34 Attachment hydraulic circuit cannot be changed while attachment is installed .................................................1254 H-35 Oil flow in attachment circuit cannot be controlled ..........................................................................1255 Troubleshooting of engine (S-mode) ....................................................................................................1256 Information mentioned in troubleshooting table (S mode) ...........................................................................1256 S-1 When starting switch is turned to START position, engine does not crank .......................................................1257 S-2 Engine cranks but no exhaust smoke comes out ..................................................................................1258 S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) ................................1259 S-4 Engine startability is poor ...................................................................................................1260 S-5 Engine does not pick up smoothly ..............................................................................................1262 S-6 Engine stops during operation .................................................................................................1264 S-7 Engine runs rough or is unstable ..............................................................................................1266 S-8 Engine lacks power ............................................................................................................1267 S-9 Exhaust smoke is black (KDPF clogs up early) ..................................................................................1269 S-10 Engine oil consumption is excessive ..........................................................................................1271 S-11 Engine oil becomes contaminated early ........................................................................................1272 S-12 Fuel consumption is excessive ................................................................................................1273 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) .............................................................1274 S-14 Engine oil pressure drops ....................................................................................................1275 S-15 Fuel is contaminated in engine oil ...........................................................................................1276 S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white) .............................................................1277 S-17 Coolant temperature rises too high (overheating) .............................................................................1278 S-18 Unusual noise is heard .......................................................................................................1279 S-19 Vibration is excessive .......................................................................................................1280 S-20 Air cannot be bled from fuel circuit .........................................................................................1281 S-21 Active regeneration is executed frequently ...................................................................................1282 S-22 Active regeneration takes time ...............................................................................................1283 S-23 White smoke is exhausted during active regeneration ..........................................................................1284 50 Disassembly and assembly ...............................................................................................................1285 Table of contents .....................................................................................................................1286 General information on disassembly and assembly .......................................................................................1288 How to read this manual ...........................................................................................................1288 Coating materials list ............................................................................................................1290 Special tools list ................................................................................................................1294 Sketches of special tools .........................................................................................................1299 Engine and cooling system .............................................................................................................1303 Removal and installation of supply pump assembly ..................................................................................1303 Removal and installation of injector assembly .....................................................................................1308 Removal and installation of cylinder head assembly ................................................................................1317 Removal and installation of radiator assembly .....................................................................................1337 Removal and installation of hydraulic oil cooler assembly .........................................................................1339 Removal and installation of aftercooler assembly ..................................................................................1342 Removal and installation of engine and main pump assembly .........................................................................1344 Removal and installation of engine front oil seal .................................................................................1356 Removal and installation of engine rear oil seal ..................................................................................1360 Removal and installation of fuel cooler assembly ..................................................................................1363 Removal and installation of fuel tank assembly ....................................................................................1364 Removal and installation of engine hood assembly ..................................................................................1367 Removal and installation of KDPF assembly .........................................................................................1370 Disassembly and assembly of KDPF ..................................................................................................1378 Removal and installation of KCCV assembly .........................................................................................1386 Removal and installation of air cleaner assembly ..................................................................................1390 Power train ...........................................................................................................................1393 Removal and installation of travel motor and final drive assembly .................................................................1393 Disassembly and assembly of final drive ...........................................................................................1394 Removal and installation of swing motor and swing machinery assembly ..............................................................1402 Disassembly and assembly of swing machinery .......................................................................................1405 Removal and installation of swing circle assembly .................................................................................1412 Undercarriage and frame ...............................................................................................................1413 Separation and connection of track shoe assembly ..................................................................................1413 Removal and installation of sprocket ..............................................................................................1416 Removal and installation of idler and idler cushion assembly ......................................................................1417 Disassembly and assembly of idler assembly ........................................................................................1418 Disassembly and assembly of idler cushion .........................................................................................1421 Disassembly and assembly of track roller assembly .................................................................................1423 Disassembly and assembly of carrier roller ........................................................................................1425 Removal and installation of revolving frame assembly ..............................................................................1428 Removal and installation of counterweight assembly ................................................................................1430 Hydraulic system ......................................................................................................................1433 Removal and installation of center swivel joint assembly ..........................................................................1433 Disassembly and assembly of center swivel joint ...................................................................................1436 Removal and installation of hydraulic tank assembly ...............................................................................1437 Removal and installation of main pump assembly ....................................................................................1441 Removal and installation of control valve assembly ................................................................................1445 Disassembly and assembly of control valve .........................................................................................1452 Disassembly and assembly of work equipment PPC valve ..............................................................................1457 Disassembly and assembly of travel PPC valve ......................................................................................1459 Work equipment ........................................................................................................................1462 Removal and installation of work equipment assembly ...............................................................................1462 Disassembly and assembly of work equipment cylinder ...............................................................................1465 Cab and its attachments ...............................................................................................................1471 Removal and installation of operator's cab assembly ...............................................................................1471 Removal and installation of operator cab glass (adhered glass) ....................................................................1476 Removal and installation of front window assembly .................................................................................1486 Removal and installation of floor frame assembly ..................................................................................1492 Removal and installation of air conditioner unit assembly .........................................................................1498 Removal and installation of operator's seat .......................................................................................1502 Removal and installation of seat belt .............................................................................................1504 Removal and installation of front wiper assembly ..................................................................................1506 Electrical system .....................................................................................................................1513 Removal and installation of air conditioner compressor assembly ...................................................................1513 Removal and installation of air conditioner condenser assembly ....................................................................1516 Removal and installation of engine controller assembly ............................................................................1518 Removal and installation of pump controller assembly ..............................................................................1520 Removal and installation of machine monitor assembly ..............................................................................1523 Removal and installation of pump swash plate sensor ...............................................................................1525 Removal and installation of mass air flow and temperature sensor ..................................................................1526 Removal and installation of KOMTRAX terminal assembly .............................................................................1527 60 Maintenance standard ...................................................................................................................1529 Table of contents .....................................................................................................................1530 Engine and cooling system .............................................................................................................1531 Engine mount ......................................................................................................................1531 Cooling system ....................................................................................................................1532 Power train ...........................................................................................................................1533 Swing circle ......................................................................................................................1533 Swing machinery ...................................................................................................................1534 Final drive .......................................................................................................................1536 Sprocket ..........................................................................................................................1538 Undercarriage and frame ...............................................................................................................1540 Track frame and idler cushion .....................................................................................................1540 Idler .............................................................................................................................1542 Track roller ......................................................................................................................1544 Carrier roller ....................................................................................................................1545 Track shoe ........................................................................................................................1546 Hydraulic system ......................................................................................................................1552 Hydraulic tank ....................................................................................................................1552 Main pump .........................................................................................................................1553 Control valve .....................................................................................................................1554 Swing motor .......................................................................................................................1564 Travel motor ......................................................................................................................1566 Work equipment and swing PPC valve ................................................................................................1569 Travel PPC valve ..................................................................................................................1572 1st-line attachment PPC valve (with EPC valve) ....................................................................................1575 2nd-line attachment PPC valve .....................................................................................................1578 Solenoid valve ....................................................................................................................1580 Attachment circuit selector valve (for high-pressure circuit) .....................................................................1581 Attachment circuit selector valve (for low-pressure circuit) ......................................................................1582 Center swivel joint ...............................................................................................................1583 Work equipment ........................................................................................................................1584 Work equipment ....................................................................................................................1584 Boom cylinder (large diameter piston) .............................................................................................1593 Arm cylinder ......................................................................................................................1594 Bucket cylinder ...................................................................................................................1595 80 Appendix ...............................................................................................................................1597 Table of contents .....................................................................................................................1598 Air conditioner components ............................................................................................................1599 Precautions for refrigerant .......................................................................................................1599 Air conditioner component .........................................................................................................1600 Configuration and function of refrigeration cycle .................................................................................1603 Outline of refrigeration cycle ....................................................................................................1604 Air conditioner unit ..............................................................................................................1606 Dual pressure switch ..............................................................................................................1613 Air conditioner controller ........................................................................................................1614 Compressor ........................................................................................................................1615 Air conditioner condenser .........................................................................................................1616 Sunlight sensor ...................................................................................................................1618 Outer temperature sensor (outside air temperature sensor) .........................................................................1619 Procedure for testing and troubleshooting .........................................................................................1620 Circuit diagram and arrangement of connector pins .................................................................................1622 System diagram ....................................................................................................................1624 Input and output signals of the air conditioner controller ........................................................................1625 Parts and connectors layout .......................................................................................................1627 Testing air leakage (duct) ........................................................................................................1631 Testing with self-diagnosis function ..............................................................................................1634 Testing vent (mode) changeover ....................................................................................................1636 Testing FRESH/RECIRC air changeover ...............................................................................................1638 Testing sunlight sensor ...........................................................................................................1639 Testing (dual) pressure switch for refrigerant ....................................................................................1640 Testing relays ....................................................................................................................1641 Troubleshooting chart 1 ...........................................................................................................1642 Troubleshooting chart 2 ...........................................................................................................1643 Information in troubleshooting table ..............................................................................................1646 Failure code list related to air conditioner ......................................................................................1647 Failure code [879AKA] A/C Inner Sensor Open Circuit ...............................................................................1648 Failure code [879AKB] A/C Inner Sensor Short Circuit ..............................................................................1649 Failure code [879BKA] A/C Outer sensor Open Circuit ...............................................................................1650 Failure code [879BKB] A/C Outer sensor Short Circuit ..............................................................................1652 Failure code [879CKA] Ventilating Sensor Open Circuit .............................................................................1654 Failure code [879CKB] Ventilating Sensor Short Circuit ............................................................................1655 Failure code [879DKZ] Sunlight sensor Open or Short Circuit .......................................................................1656 Failure code [879EMC] Ventilation Damper Abnormality ..............................................................................1658 Failure code [879FMC] Air Mix Damper Abnormality ..................................................................................1659 Failure code [879GKX] Refrigerant Abnormality .....................................................................................1660 A-1 Troubleshooting for power supply system (Air conditioner does not operate) ....................................................1661 A-2 Troubleshooting of compressor system (Air is not cooled) ......................................................................1663 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ............................................1666 A-4 Troubleshooting for FRESH/RECIRC air changeover ...............................................................................1668 Troubleshooting with gauge pressure ...............................................................................................1670 Connection of service tool ........................................................................................................1673 Precautions for disconnecting and connecting air conditioner piping ...............................................................1675 Handling of compressor oil ........................................................................................................1677 Desiccant replacement .............................................................................................................1679 90 Diagrams and drawings ..................................................................................................................1683 Table of contents .....................................................................................................................1684 Hydraulic circuit diagram .............................................................................................................1685 Symbols in hydraulic circuit diagram ..............................................................................................1685 Electric circuit diagram ..............................................................................................................1690 Symbols in electric circuit diagram ...............................................................................................1690
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