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KOMATSU PC290LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL – PDF Download
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- KOMATSU PC290LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- SERIAL NUMBERS:A25001 and up
- PUBLICATION NUMBER:CEBM025103
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Description
KOMATSU PC290LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
Screenshot of the Manual:
KOMATSU PC290LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL – PDF DOWNLOAD:
Description:
KOMATSU PC290LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
- GENERAL
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts. - STRUCTURE AND FUNCTION
This 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. - 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. - TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. - TROUBLESHOOTING
Troubleshooting charts correlating “Problems” to “Causes” are also included in this section. - DISASSEMBLY AND ASSEMBLY This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
- MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts - DIAGRAMS AND SCHEMATICS
This section has the foldout drawings for the machine
Table of Contents:
KOMATSU PC290LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
CEBM025103 - PC290LC-10................................................................................................................... 1 CONTENTS.............................................................................................................................. 2 SAFETY................................................................................................................................ 19 Safety Notice..................................................................................................................... 19 Important Safety Notice....................................................................................................... 19 General Precautions........................................................................................................... 19 Preparations For Work......................................................................................................... 20 Precautions During Work....................................................................................................... 20 GENERAL............................................................................................................................... 23 HOW TO READ THE SHOP MANUAL........................................................................................................... 24 Volumes........................................................................................................................... 24 Distribution And Updating......................................................................................................... 24 Filing Method..................................................................................................................... 24 Revised Edition Mark.............................................................................................................. 24 Revisions......................................................................................................................... 24 Symbols........................................................................................................................... 24 HOISTING INSTRUCTIONS................................................................................................................. 25 Hoisting.......................................................................................................................... 25 Making Signs...................................................................................................................... 25 Precautions....................................................................................................................... 25 Precautions for Sling Work.................................................................................................... 25 Precautions for Using Mobile Crane............................................................................................ 26 Precautions for Using Overhead Hoist Crane.................................................................................... 26 Selecting Wire Ropes.............................................................................................................. 27 HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS.................................................................................. 28 Points to Remember When Handling Electric Equipment............................................................................... 28 Points to Remember When Handling Hydraulic Equipment.............................................................................. 39 PUSH PULL COUPLER..................................................................................................................... 41 Type 1............................................................................................................................ 41 Disconnection................................................................................................................. 41 Connection.................................................................................................................... 41 Type 2............................................................................................................................ 42 Disconnection................................................................................................................. 42 Connection.................................................................................................................... 42 Type 3............................................................................................................................ 43 Disconnection................................................................................................................. 43 Connection.................................................................................................................... 43 EXPLANATION OF MAINTENANCE STANDARD TERMS............................................................................................. 44 HANDLING OF FUEL SYSTEM DEVICES....................................................................................................... 45 HANDLING OF INTAKE SYSTEM PARTS....................................................................................................... 46 STANDARD TIGHTENING TORQUE............................................................................................................ 47 Bolts And Nuts.................................................................................................................... 47 Tightening Torque Of Hose Nuts.................................................................................................... 48 Tightening Torque Of Split Flange Bolts........................................................................................... 48 Tightening Torque For Flared Nuts................................................................................................. 48 Tightening Torques for Split Flanged Bolts........................................................................................ 49 Tightening Torques For O-ring Boss Piping Joints.................................................................................. 49 Table Of Tightening Torques For O-ring Boss Plugs................................................................................. 49 Tightening Torque For Hoses (Taper Seal Type And Face Seal Type).................................................................. 50 Tightening Torque For Face Seal Joints........................................................................................ 50 For 102, 107, and 114 Engine Series (Bolts and Nuts).......................................................................... 50 For 102, 107, and 114 Engine Series (Eye Joints).............................................................................. 51 For 102, 107, and 114 Engine Series (Taper Screws)............................................................................ 51 ELECTRIC WIRE CODE.................................................................................................................... 52 Classification By Thickness....................................................................................................... 52 Classification By Color And Code.................................................................................................. 52 How To Read Electric Wire Code.................................................................................................... 53 PRECAUTIONS FOR OPERATIONS............................................................................................................ 56 Precautions when Carrying Out Removal Work........................................................................................ 56 Precautions when Carrying Out Installation Work................................................................................... 57 Precautions when Completing the Operation......................................................................................... 58 CONVERSION TABLES..................................................................................................................... 59 Method Of Using The Conversion Table.............................................................................................. 59 COATING MATERIALS..................................................................................................................... 65 LIST OF ABBREVIATIONS................................................................................................................. 68 List of Abbreviations Used in the Shop Manual..................................................................................... 68 List of Abbreviations Used in the Circuit Diagrams................................................................................ 72 01 GENERAL................................................................................................................................ 73 01 GENERAL............................................................................................................................ 78 SPECIFICATION DIMENSION DRAWINGS.................................................................................................. 74 Dimensions.................................................................................................................... 74 Working Ranges................................................................................................................ 75 SPECIFICATIONS.................................................................................................................... 76 WEIGHT TABLE...................................................................................................................... 80 FUEL, COOLANT AND LUBRICANTS...................................................................................................... 82 Lubrication Chart............................................................................................................. 84 10 STRUCTURE AND FUNCTION................................................................................................................. 85 ENGINE AND COOLING SYSTEM............................................................................................................. 88 Engine Related Parts.............................................................................................................. 88 Radiator, Oil Cooler, After Cooler, and Fuel Cooler............................................................................... 90 POWER TRAIN........................................................................................................................... 92 Power Train....................................................................................................................... 92 Swing Machinery................................................................................................................... 94 Swing Circle...................................................................................................................... 96 Final Drive....................................................................................................................... 98 UNDERCARRIAGE AND FRAME............................................................................................................... 100 Track Frame and Idler Cushion..................................................................................................... 100 HYDRAULIC SYSTEM...................................................................................................................... 102 Hydraulic Equipment Layout........................................................................................................ 102 Valve Control..................................................................................................................... 104 Hydraulic Tank.................................................................................................................... 106 Oil Filler Cap.................................................................................................................... 107 CLSS.............................................................................................................................. 108 Structure of CLSS............................................................................................................. 108 Basic Principle............................................................................................................... 109 Main Pump......................................................................................................................... 112 Operation..................................................................................................................... 116 LS Valve...................................................................................................................... 118 PC Valve...................................................................................................................... 124 LS(PC)-EPC Valve.............................................................................................................. 131 Control Valve..................................................................................................................... 134 Functions and Operation by Valve.................................................................................................. 146 Hydraulic Circuit Diagram and Name of Valves.................................................................................. 146 Unload Valve.................................................................................................................. 150 Introduction of LS Pressure................................................................................................... 151 LS By-Pass Plug............................................................................................................... 152 Pressure Compensation Valve................................................................................................... 153 Shuttle Valve In Pressure Compensation Valve.................................................................................. 156 Boom Regeneration Circuit..................................................................................................... 158 Arm Regeneration Circuit...................................................................................................... 160 Merge-Divider Valve........................................................................................................... 162 LS Selector Valve............................................................................................................. 165 Self-Pressure Reducing Valve.................................................................................................. 166 Travel Junction Valve......................................................................................................... 170 Travel PPC Shuttle Valve...................................................................................................... 174 Boom Hydraulic Drift Prevention Valve......................................................................................... 176 Arm Hydraulic Drift Prevention Valve (If Equipped)............................................................................ 179 Suction Safety Valve For Drift Prevention Valve............................................................................... 182 Arm Quick Return Valve........................................................................................................ 184 Variable Back Pressure Valve.................................................................................................. 186 Main Relief Valve............................................................................................................. 188 Suction 2-Stage Safety Valve.................................................................................................. 190 Swing Motor....................................................................................................................... 192 Swing Holding Brake........................................................................................................... 194 Relief Valve.................................................................................................................. 196 Swing 2-Stage Relief Valve.................................................................................................... 198 Swing Motor Reverse Prevention Valve.......................................................................................... 199 Travel Motor...................................................................................................................... 202 Operation of Travel Motor..................................................................................................... 205 Operation of Parking Brake.................................................................................................... 207 Brake Valve................................................................................................................... 208 Counterbalance Valve.......................................................................................................... 209 Suction Safety Valve.......................................................................................................... 210 PPC Valve......................................................................................................................... 213 Work Equipment and Swing PPC Valve............................................................................................ 213 Travel PPC Valve.............................................................................................................. 219 1st-Line Attachment PPC Valve (with EPC Valve) (If Equipped).................................................................. 223 EPC Valve (If Equipped)....................................................................................................... 225 2nd-Line Attachment PPC Valve (If Equipped)................................................................................... 229 Solenoid Valve.................................................................................................................... 231 Attachment Circuit Selector Valve (For High Pressure Circuit) (If Equipped)....................................................... 235 Attachment Circuit Selector Valve (For Low Pressure Circuit) (If Equipped)........................................................ 237 Center Swivel Joint............................................................................................................... 239 Accumulator....................................................................................................................... 240 PPC Accumulator............................................................................................................... 240 WORK EQUIPMENT........................................................................................................................ 241 Work Equipment.................................................................................................................... 241 Work Equipment Shim............................................................................................................... 242 Bucket Play Adjustment Shim....................................................................................................... 242 CAB AND ITS ATTACHMENTS............................................................................................................... 243 Cab Mount and Cab Tipping Stopper................................................................................................. 243 ROPS Cab.......................................................................................................................... 245 ELECTRICAL SYSTEM..................................................................................................................... 247 Electrical Control System......................................................................................................... 247 Machine Control System Diagram................................................................................................ 247 Engine Control Function....................................................................................................... 249 Engine and Pump Combined Control Function..................................................................................... 251 Pump and Valve Control Function............................................................................................... 257 One-Touch Power Maximizing Function........................................................................................... 259 Auto-Deceleration Function.................................................................................................... 261 Engine Automatic Warm-Up Function............................................................................................. 263 Overheat Prevention Function.................................................................................................. 265 Turbocharger Protection Function.............................................................................................. 266 Swing Control Function........................................................................................................ 267 Quick Warm-Up Function........................................................................................................ 269 Swing 2-Stage Relief Function................................................................................................. 269 Travel Control Function....................................................................................................... 271 PPC Lock Function............................................................................................................. 273 Attachment Flow Control Function.............................................................................................. 275 System Component Part............................................................................................................. 277 Engine Controller............................................................................................................. 277 Pump Controller............................................................................................................... 281 Fuel Control Dial............................................................................................................. 285 Resistor for PC-EPC Valve..................................................................................................... 286 CAN Terminating Resistor...................................................................................................... 287 Engine Oil Pressure Switch.................................................................................................... 288 PPC Oil Pressure Switch....................................................................................................... 289 MACHINE MONITOR SYSTEM................................................................................................................ 291 Machine Monitor................................................................................................................... 293 Input and Output Signals...................................................................................................... 294 Display....................................................................................................................... 297 Gauges........................................................................................................................ 299 Caution Monitor............................................................................................................... 301 Pilot Monitor................................................................................................................. 305 Switches.......................................................................................................................... 307 Guidance ICON and Function Switch............................................................................................. 309 Operator Mode Function........................................................................................................ 312 Service Mode Function......................................................................................................... 314 KOMTRAX SYSTEM........................................................................................................................ 316 Komtrax Terminal.................................................................................................................. 317 Input and Output Signals.......................................................................................................... 318 SENSORS............................................................................................................................... 320 Ambient Pressure Sensor........................................................................................................... 320 Charge (Boost) Pressure and Temperature Sensor.................................................................................... 321 Coolant Temperature Sensor........................................................................................................ 322 Ne (Crankshaft) Speed Sensor...................................................................................................... 322 Bkup (Camshaft) Speed Sensor...................................................................................................... 323 Common Rail Pressure Sensor....................................................................................................... 323 Exhaust Manifold Pressure Sensor.................................................................................................. 324 EGR Orifice Temperature Sensor.................................................................................................... 324 EGR Valve Lift Sensor............................................................................................................. 325 Turbo Speed Sensor................................................................................................................ 326 KVGT Position Sensor.............................................................................................................. 327 Mass Air Flow and Temperature Sensor.............................................................................................. 328 KDPF Differential Pressure and Outlet Pressure Sensor............................................................................. 328 KDOC Inlet Temperature Sensor..................................................................................................... 329 KDOC Outlet Temperature Sensor.................................................................................................... 329 KDPF Outlet Temperature Sensor.................................................................................................... 330 Crankcase Pressure Sensor......................................................................................................... 330 Engine Oil Level Sensor........................................................................................................... 331 Fuel Level Sensor................................................................................................................. 332 Coolant Level Sensor.............................................................................................................. 333 Hydraulic Oil Temperature Sensor.................................................................................................. 333 Front Pump Oil Pressure Sensor.................................................................................................... 334 Rear Pump Oil Pressure Sensor..................................................................................................... 335 PPC Oil Pressure Sensor........................................................................................................... 336 Air Cleaner Clogging Sensor....................................................................................................... 337 Front Pump Swash Plate Sensor..................................................................................................... 338 Rear Pump Swash Plate Sensor...................................................................................................... 340 Water-In Fuel Sensor.............................................................................................................. 342 20 STANDARD VALUE TABLES.................................................................................................................. 343 STANDARD SERVICE VALUE TABLES......................................................................................................... 344 Standard Value Table for Engine Related Parts..................................................................................... 344 Standard Value Table for Chassis Related Parts.................................................................................... 346 Engine Speed.................................................................................................................. 346 Control Valve Spool Stroke.................................................................................................... 346 Control Lever Stroke.......................................................................................................... 347 Operating Effort of Control Lever and Pedal................................................................................... 347 Hydraulic Pressure............................................................................................................ 348 Swing......................................................................................................................... 349 Travel........................................................................................................................ 350 Work Equipment................................................................................................................ 351 Performance in Combined Operation............................................................................................. 353 Pump Swash Plate Sensor....................................................................................................... 353 Characteristics of PC Flow Control............................................................................................ 353 Hydraulic Pump................................................................................................................ 354 Posture of Machine for Measuring Performance and Measurement Procedure............................................................ 355 Control Valve: Spool Stroke................................................................................................... 355 Swing 1: Swing Brake Angle, Time Taken to Start Swing, Time Taken to Swing.................................................... 355 Swing 2: Hydraulic Drift of Swing............................................................................................. 355 Travel 1: Travel Speed, Idle Running (Without Load)........................................................................... 355 Travel 2: Travel Speed (Actual Run), Travel Deviation......................................................................... 356 Travel 3: Travel Deviation.................................................................................................... 356 Travel 4: Hydraulic Drift of Travel........................................................................................... 356 Work Equipment 1: Hydraulic Drift of Work Equipment........................................................................... 356 Work Equipment 2: Boom Speed.................................................................................................. 357 Work Equipment 3: Arm Speed................................................................................................... 357 Work Equipment 4: Bucket Speed................................................................................................ 357 Work Equipment 5: Boom Time Lag............................................................................................... 357 Work Equipment 6: Arm Time Lag................................................................................................ 358 Work Equipment 7: Bucket Time Lag............................................................................................. 358 Work Equipment 8: PC Flow Characteristics Control............................................................................. 358 30 TESTING AND ADJUSTING.................................................................................................................. 359 GENERAL INFORMATION ON TESTING AND ADJUSTING.......................................................................................... 362 Tools for Testing, Adjusting, and Troubleshooting................................................................................. 362 Sketch of Tools for Testing and Adjusting......................................................................................... 367 ENGINE AND COOLING SYSTEM............................................................................................................. 370 Checking Engine Speed............................................................................................................. 370 Measuring Boost Pressure.......................................................................................................... 372 Measuring Exhaust Gas Color....................................................................................................... 374 Measuring and Adjusting Valve Clearance........................................................................................... 376 Testing....................................................................................................................... 376 Adjusting..................................................................................................................... 379 Measuring Compression Pressure.................................................................................................... 380 Measuring Blow-By Pressure........................................................................................................ 386 Measuring Engine Oil Pressure..................................................................................................... 388 Measuring EGR Valve and KVGT Oil Pressure......................................................................................... 390 Measuring Fuel Pressure........................................................................................................... 392 Testing Low-Pressure Circuit (Fuel Main Filter Inlet Side).................................................................... 394 Testing Low-Pressure Circuit (Pressure Difference)............................................................................ 395 Testing Return Circuit........................................................................................................ 396 Testing Negative-Pressure Circuit............................................................................................. 397 Measuring Fuel Delivery, Return and Leakage....................................................................................... 398 Testing Supply Pump Delivery.................................................................................................. 400 Testing Supply Pump Return Rate............................................................................................... 402 Testing Leakage from Pressure Limiter......................................................................................... 403 Testing Injector Return Rate from Injector.................................................................................... 404 Bleeding Air from Fuel System..................................................................................................... 406 Bleeding Air.................................................................................................................. 406 Route for Bleeding Air from Fuel Circuit...................................................................................... 407 Checking Fuel Circuit for Leakage................................................................................................. 408 Handling Cylinder Cut-Out Mode Operation.......................................................................................... 409 Handling No-Injection Cranking Operation.......................................................................................... 409 Checking and Adjusting Air Conditioner Compressor Belt Tension.................................................................... 410 Checking...................................................................................................................... 410 Adjusting..................................................................................................................... 411 Replacing Fan Belt................................................................................................................ 412 POWER TRAIN........................................................................................................................... 414 Testing Swing Circle Bearing Clearance............................................................................................ 414 Testing....................................................................................................................... 414 UNDERCARRIAGE AND FRAME............................................................................................................... 416 Testing and Adjusting Track Shoe Tension.......................................................................................... 416 Testing....................................................................................................................... 416 Adjusting..................................................................................................................... 416 HYDRAULIC SYSTEM...................................................................................................................... 418 Releasing Remaining Pressure from Hydraulic Circuit............................................................................... 418 Measuring and Adjusting of Oil Pressure in Work Equipment, Swing, and Travel Circuits............................................. 420 Testing....................................................................................................................... 420 Adjusting..................................................................................................................... 422 Measuring Oil Pressure in Control Circuit......................................................................................... 424 Measuring and Adjusting Oil Pressure in Pump PC Control Circuit................................................................... 426 Testing....................................................................................................................... 426 Adjusting..................................................................................................................... 429 Measuring and Adjusting Oil Pressure in Pump LS Control Circuit................................................................... 430 Testing....................................................................................................................... 431 Checking Oil Pressure with Sensor Adapter (Special Tool)...................................................................... 435 Adjusting..................................................................................................................... 436 Measuring Solenoid Valve Output Pressure.......................................................................................... 438 Testing....................................................................................................................... 438 Operating Condition........................................................................................................... 440 Measuring PPC Valve Output Pressure............................................................................................... 442 Adjusting Play of Work Equipment and Swing PPC Valves............................................................................. 444 Testing Pump Swash Plate Sensor................................................................................................... 445 Isolating the Parts Causing Hydraulic Drift in Work Equipment..................................................................... 446 Measuring Oil Leakage............................................................................................................. 448 Bleeding Air From Hydraulic Circuit............................................................................................... 451 CAB AND ITS ATTACHMENTS............................................................................................................... 454 Checking Cab Tipping Stopper...................................................................................................... 454 Adjusting Mirrors................................................................................................................. 456 ELECTRICAL SYSTEM..................................................................................................................... 458 Special Functions of Machine Monitor.............................................................................................. 458 Upper Part of machine monitor (display portion)............................................................................... 459 Upper Part of Machine Monitor (Switch Portion)................................................................................ 459 Lower Part of Machine Monitor (Switch Portion)................................................................................ 459 Ordinary Functions and Special Functions of Machine Monitor....................................................................... 459 Operator Mode (Outline)....................................................................................................... 462 Service Mode.................................................................................................................. 482 Angle Adjustment of Rear View Camera.............................................................................................. 547 Handling Voltage Circuit of Engine Controller..................................................................................... 549 Handling Battery Disconnect Switch................................................................................................ 550 Testing Diodes.................................................................................................................... 551 PM CLINIC............................................................................................................................. 552 PM Clinic Service................................................................................................................. 552 Check Items Related to Engine................................................................................................. 554 Check Items Related to Oil Pressure........................................................................................... 555 Check Sheet....................................................................................................................... 556 40 TROUBLESHOOTING........................................................................................................................ 563 GENERAL INFORMATION ON TROUBLESHOOTING................................................................................................ 572 Points to Remember When Troubleshooting........................................................................................... 572 Sequence of Events in Troubleshooting............................................................................................. 574 Checks Before Troubleshooting..................................................................................................... 576 Testing Procedure Before Troubleshooting.......................................................................................... 578 Walk-Around Check............................................................................................................. 578 Testing in Accordance with Testing Procedure.................................................................................. 580 Check of Water Separator, and Drainage of Water and Sediments............................................................. 582 Replacing Fuel Pre-Filter Cartridge....................................................................................... 584 Preparation Work for Troubleshooting of Electrical System......................................................................... 606 Preparation Work.............................................................................................................. 606 Classification and Procedure for Troubleshooting.................................................................................. 612 Classification of Troubleshooting............................................................................................. 612 Procedure for Troubleshooting................................................................................................. 612 Symptom of Probable Failure and Troubleshooting No................................................................................ 616 Information Mentioned in Troubleshooting Table.................................................................................... 620 Diagnostic Procedure for Wiring Harness Open Circuit of Pressure Sensor System.................................................... 622 Connection Table for Connector Pin Numbers........................................................................................ 626 T-Branch Box and T-Branch Adapter Table........................................................................................... 660 Fuse List and Location............................................................................................................ 664 Connection Table of Fuse Box.................................................................................................. 664 Locations of Fusible Links.................................................................................................... 665 Location of Fuse Box and Fuse Numbers......................................................................................... 665 Precautions for Cleaning and Replacing KDPF (KCSF, KDOC).......................................................................... 666 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)..................................................................................... 670 Failure Codes Table............................................................................................................... 670 Failure Code [879AKA] A/C Inner Sensor Open Circuit............................................................................... 680 Failure Code [879AKB] A/C Inner Sensor Short Circuit.............................................................................. 680 Failure Code [879BKA] A/C Outer Sensor Open Circuit............................................................................... 680 Failure Code [879BKB] A/C Outer Sensor Short Circuit.............................................................................. 680 Failure Code [879CKA] Ventilating Sensor Open Circuit............................................................................. 680 Failure Code [879CKB] Ventilating Sensor Short Circuit............................................................................ 680 Failure Code [879DKZ] Sunlight Sensor Open or Short Circuit....................................................................... 680 Failure Code [879EMC] Ventilation Damper Abnormality.............................................................................. 681 Failure Code [879FMC] Air Mix Damper Abnormality.................................................................................. 681 Failure Code [879GKX] Refrigerant Abnormality..................................................................................... 681 Failure Code [989L00] Engine Controller Lock Caution 1............................................................................ 682 Failure Code [989M00] Engine Controller Lock Caution 2............................................................................ 682 Failure Code [989N00] Engine Controller Lock Caution 2............................................................................ 683 Failure Code [A1U0N3] HC Desorb Request 1......................................................................................... 684 Failure Code [A1U0N4] HC Desorb Request 2......................................................................................... 686 Failure Code [AA10NX] Air Cleaner Clogging........................................................................................ 688 Failure Code [AB00KE] Charge Voltage Low.......................................................................................... 690 Failure Code [B@BAZG] Engine Oil Pressure Low..................................................................................... 692 Failure Code [B@BAZK] Eng Oil Level Low........................................................................................... 694 Failure Code [B@BCNS] Engine Coolant Overheat..................................................................................... 696 Failure Code [B@BCZK] Radiator Coolant Level Low.................................................................................. 698 Failure Code [B@HANS] Hyd Oil Overheat............................................................................................ 700 Failure Code [CA115] Eng Ne and Bkup Speed Sens Error............................................................................. 701 Failure Code [CA122] Chg Air Press Sensor High Error.............................................................................. 702 Failure Code [CA123] Chg Air Press Sensor Low Error............................................................................... 704 Failure Code [CA131] Throttle Sensor High Error................................................................................... 706 Failure Code [CA132] Throttle Sensor Low Error.................................................................................... 708 Failure Code [CA144] Coolant Temp Sens High Error................................................................................. 710 Failure Code [CA145] Coolant Temp Sens Low Error.................................................................................. 712 Failure Code [CA153] Chg Air Temp Sensor High Error............................................................................... 714 Failure Code [CA154] Chg Air Temp Sensor High Error............................................................................... 716 Failure Code [CA187] Sensor 2 Supply Volt Low Error............................................................................... 718 Failure Code [CA221] Ambient Press Sensor High Error.............................................................................. 720 Failure Code [CA222] Ambient Press Sensor Low Error............................................................................... 722 Failure Code [CA227] Sensor 2 Supply Volt High Error.............................................................................. 724 Failure Code [CA234] Eng Overspeed................................................................................................ 725 Failure Code [CA238] Ne Speed Sensor Supply Volt Error............................................................................ 726 Failure Code [CA239] Ne Speed Sens Supply Volt High Error......................................................................... 728 Failure Code [CA271] IMV/PCV1 Short Error......................................................................................... 730 Failure Code [CA272] IMV/PCV1 Open Error.......................................................................................... 732 Failure Code [CA295] Ambient Press Sens In Range Error............................................................................ 734 Failure Code [CA322] Inj #1 (L#1) Open/Short Error................................................................................ 736 Failure Code [CA323] Inj #5 (L#5) Open/Short Error................................................................................ 738 Failure Code [CA324] Inj #3 (L#3) Open/Short Error................................................................................ 740 Failure Code [CA325] Inj #6 (L#6) Open/Short Error................................................................................ 742 Failure Code [CA331] Inj #2 (L#2) Open/Short Error................................................................................ 744 Failure Code [CA332] Inj #4 (L#4) Open/Short Error................................................................................ 746 Failure Code [CA343] ECM Critical Internal Failure................................................................................ 748 Failure Code [CA351] Injectors Drive Circuit Error................................................................................ 749 Failure Code [CA352] Sensor 1 Supply Volt Low Error............................................................................... 750 Failure Code [CA356] Mass Air Flow Sensor High Error.............................................................................. 752 Failure Code [CA357] Mass Air Flow Sensor Low Error............................................................................... 754 Failure Code [CA386] Sensor 1 Supply Volt High Error.............................................................................. 757 Failure Code [CA428] Water in Fuel Sensor High Error.............................................................................. 758 Failure Code [CA429] Water in Fuel Sensor Low Error............................................................................... 760 Failure Code [CA435] Eng Oil Press Sw Error....................................................................................... 762 Failure Code [CA441] Battery Voltage Low Error.................................................................................... 764 Failure Code [CA442] Battery Voltage High Error................................................................................... 766 Failure Code [CA449] Rail Press Very High Error................................................................................... 767 Failure Code [CA451] Rail Press Sensor High Error................................................................................. 768 Failure Code [CA452] Rail Press Sensor Low Error.................................................................................. 770 Failure Code [CA488] Chg Air Temp High Torque Derate.............................................................................. 772 Failure Code [CA515] Rail Press Sens Sup Volt High Error.......................................................................... 774 Failure Code [CA516] Rail Press Sens Sup Volt Low Error........................................................................... 776 Failure Code [CA553] Rail Press High Error........................................................................................ 778 Failure Code [CA555] Crankcase Press High Error 1................................................................................. 779 Failure Code [CA556] Crankcase Press High Error 2................................................................................. 780 Failure Code [CA559] Rail Press Low Error......................................................................................... 782 Failure Code [CA595] Turbo Speed High Error 2..................................................................................... 783 Failure Code [CA687] Turbo Speed Low Error........................................................................................ 784 Failure Code [CA689] Eng Ne Speed Sensor Error.................................................................................... 786 Failure Code [CA691] Intake Air Temp Sens High Error.............................................................................. 790 Failure Code [CA692] Intake Air Temp Sens Low Error............................................................................... 792 Failure Code [CA697] ECM Int Temp Sensor High Error............................................................................... 794 Failure Code [CA698] ECM Int Temp Sensor Low Error................................................................................ 795 Failure Code [CA731] Eng Bkup Speed Sens Phase Error.............................................................................. 796 Failure Code [CA778] Eng Bkup Speed Sensor Error.................................................................................. 798 Failure Code [CA1117] Persistent Data Lost Error.................................................................................. 802 Failure Code [CA1664] KDOC Malfunction............................................................................................ 804 Failure Code [CA1691] Regeneration Ineffective.................................................................................... 806 Failure Code [CA1695] Sensor 5 Supply High Error.................................................................................. 810 Failure Code [CA1696] Sensor 5 Supply Volt Low Error.............................................................................. 812 Failure Code [CA1843] Crankcase Press Sens High Error............................................................................. 814 Failure Code [CA1844] Crankcase Press Sens Low Error.............................................................................. 816 Failure Code [CA1879] KDPF Delta P Sensor High Error.............................................................................. 820 Failure Code [CA1881] KDPF Delta P Sensor Low Error............................................................................... 822 Failure Code [CA1883] KDPF Delta P Sens In Range Error............................................................................ 826 Failure Code [CA1921] KDPF Soot Load High Error 1................................................................................. 830 Failure Code [CA1922] KDPF Soot Load High Error 2................................................................................. 832 Failure Code [CA1942] Crankcase Press Sens In Range Error......................................................................... 836 Failure Code [CA1993] KDPF Delta Pressure Low Error............................................................................... 837 Failure Code [CA2185] Throt Sensor Sup Volt High Error............................................................................ 838 Failure Code [CA2186] Throt Sensor Sup Volt Low Error............................................................................. 840 Failure Code [CA2249] Rail Press Very Low Error................................................................................... 842 Failure Code [CA2271] EGR Valve Pos Sens High Error............................................................................... 844 Failure Code [CA2272] EGR Valve Pos Sens Low Error................................................................................ 848 Failure Code [CA2288] Turbo Speed High Error 1.................................................................................... 852 Failure Code [CA2311] IMV Solenoid Error.......................................................................................... 853 Failure Code [CA2349] EGR Valve Solenoid Open Error............................................................................... 854 Failure Code [CA2353] EGR Valve Solenoid Short Error.............................................................................. 856 Failure Code [CA2357] EGR Differential Pressure................................................................................... 858 Failure Code [CA2373] Exh Manifold Press. Sens Volt............................................................................... 860 Failure Code [CA2374] Exhaust Manifold Press Sens Low Error....................................................................... 862 Failure Code [CA2375] EGR Orifice Temp Sens High Error............................................................................ 864 Failure Code [CA2376] EGR Orifice Temp Sens Low Error............................................................................. 866 Failure Code [CA2381] KVGT Pos Sens High Error.................................................................................... 868 Failure Code [CA2382] KVGT Pos Sens Low Error..................................................................................... 870 Failure Code [CA2383] KVGT Solenoid Open Error.................................................................................... 874 Failure Code [CA2386] KVGT Solenoid Short Error................................................................................... 876 Failure Code [CA2387] KVGT Servo Error............................................................................................ 878 Failure Code [CA2554] Exh Manifold Press Sens In Range Error...................................................................... 879 Failure Code [CA2555] Grid Htr Relay Volt Low Error............................................................................... 880 Failure Code [CA2556] Grid Htr Relay Volt High Error.............................................................................. 884 Failure Code [CA2637] KDOC Face Plugging.......................................................................................... 888 Failure Code [CA2639] Manual Stationary Regeneration Request...................................................................... 890 Failure Code [CA2961] EGR Orifice Temp High Error 1............................................................................... 892 Failure Code [CA2973] Chg Air Press Sensor In Range Error......................................................................... 893 Failure Code [CA3133] KDPF Outlet Press Sens High Error........................................................................... 894 Failure Code [CA3134] KDPF Outlet Press Sens Low Error............................................................................ 896 Failure Code [CA3135] KDPF Outlet Press Sens In Range Error....................................................................... 900 Failure Code [CA3251] KDOC Inlet Temp High Error.................................................................................. 904 Failure Code [CA3253] KDOC Temp Error - Non Regeneration.......................................................................... 908 Failure Code [CA3254] KDOC Outlet Temp High Error 1............................................................................... 910 Failure Code [CA3255] KDPF Temp Error - Non Regeneration.......................................................................... 913 Failure Code [CA3256] KDPF Outlet Temp High Error 1............................................................................... 914 Failure Code [CA3311] KDOC Outlet Temp High Error 2............................................................................... 915 Failure Code [CA3312] KDPF Outlet Temp High Error 2............................................................................... 916 Failure Code [CA3313] KDOC Inlet Temp Sensor Low Error............................................................................ 920 Failure Code [CA3314] KDOC Inlet Temp Sens High Error............................................................................. 924 Failure Code [CA3315] KDOC Inlet Temp Sens In Range Error......................................................................... 928 Failure Code [CA3316] KDOC Outlet Temp Sens Low Error............................................................................. 932 Failure Code [CA3317] KDOC Outlet Temp Sens High Error............................................................................ 936 Failure Code [CA3318] KDOC Outlet Temp Sens In Range Error........................................................................ 940 Failure Code [CA3319] KDPF Outlet Temp Sens High Error............................................................................ 944 Failure Code [CA3321] KDPF Outlet Temp Sens Low Error............................................................................. 948 Failure Code [CA3322] KDPF Outlet Temp Sens In Range Error........................................................................ 952 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error.................................................................... 956 Failure Code [CA3421] Mass Air Flow Sensor Sup Volt Low Error..................................................................... 958 Failure Code [CA3741] Rail Press Valve Trip Error................................................................................. 960 Failure Code [D110KB] Battery Relay Output Voltage................................................................................ 962 Failure Code [D19JKZ] Personal Code Relay Abnormality............................................................................. 964 Failure Code [D811MC] KOMTRAX Error............................................................................................... 967 Failure Code [D862KA] GPS Antenna Open Circuit.................................................................................... 967 Failure Code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)....................................................................... 968 Failure Code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)...................................................................... 970 Failure Code [D8AQKR] CAN2 Discon (KOMTRAX)....................................................................................... 972 Failure Code [DA20MC] Pump Controller............................................................................................. 973 Failure Code [DA22KK] Pump Solenoid Power Low Error............................................................................... 974 Failure Code [DA25KP] 5V Sensor 1 Power Abnormality............................................................................... 976 Failure Code [DA29KQ] Model Selection Abnormality................................................................................. 980 Failure Code [DA2LKA] Operating Lamp Open Circuit (Pump Con)...................................................................... 982 Failure Code [DA2LKB] Operating Lamp Short Circuit (Pump Con)..................................................................... 984 Failure Code [DA2QKR] CAN2 Discon (Pump Con)...................................................................................... 986 Failure Code [DA2QKR] CAN1 Discon (Pump Con)...................................................................................... 989 Failure Code [DAF0MB] Monitor ROM Abnormality..................................................................................... 990 Failure Code [DAF0MC] Monitor Error............................................................................................... 991 Failure Code [DAF8KB] Camera Power Supply Short Circuit........................................................................... 992 Failure Code [DAF9KQ] Model Selection Abnormality................................................................................. 994 Failure Code [DAFGMC] GPS Module Error............................................................................................ 995 Failure Code [DAFLKA] Operating Lamp Open Circuit (Monitor)....................................................................... 996 Failure Code [DAFLKB] Operating Lamp Short Circuit (Monitor)...................................................................... 998 Failure Code [DAFQKR] CAN2 Discon (Monitor).......................................................................................1000 Failure Code [DAZ9KQ] A/C Model Selection Abnormality.............................................................................1001 Failure Code [DAZQKR] CAN2 Discon (Aircon ECU)....................................................................................1002 Failure Code [DB2QKR] CAN2 Discon (Engine Con)....................................................................................1006 Failure Code [DB2RKR] CAN1 Discon (Engine Con)....................................................................................1012 Failure Code [DGH2KB] Hyd Oil Sensor Short Circuit................................................................................1016 Failure Code [DHA4KA] Air Cleaner Clog Sensor Open Circuit........................................................................1018 Failure Code [DHPAMA] F Pump Press Sensor Abnormality.............................................................................1020 Failure Code [DHPBMA] R Pump Press Sensor Abnormality.............................................................................1024 Failure Code [DHS3MA] Arm Curl PPC Press Sensor Abnormality.......................................................................1028 Failure Code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality....................................................................1032 Failure Code [DHS8MA] Boom Raise PPC Press Sensor Abnormality.....................................................................1036 Failure Code [DHS9MA] Boom Lower PPC Press Sensor Abnormality.....................................................................1040 Failure Code [DHSAMA] Swing RH PPC Press Sensor Abnormality.......................................................................1044 Failure Code [DHSBMA] Swing LH PPC Press Sensor Abnormality.......................................................................1048 Failure Code [DHSCMA] Arm Dump PPC Press Sensor Abnormality.......................................................................1052 Failure Code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality....................................................................1056 Failure Code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality..................................................................1060 Failure Code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality..................................................................1064 Failure Code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality..................................................................1068 Failure Code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality..................................................................1072 Failure Code [DKR0MA] F Pump Swash Plate Sensor Abnormality.......................................................................1076 Failure Code [DKR1MA] R Pump Swash Plate Sensor Abnormality.......................................................................1080 Failure Code [DR21KX] Camera 2 Picture Rev. Drive Abnormality.....................................................................1084 Failure Code [DR31KX] Camera 3 Picture Rev. Drive Abnormality.....................................................................1086 Failure Code [DV20KB] Travel Alarm Short Circuit..................................................................................1088 Failure Code [DW43KA] Travel Speed Sol Open Circuit...............................................................................1090 Failure Code [DW43KB] Travel Speed Sol Short Circuit..............................................................................1092 Failure Code [DW45KA] Swing Brake Sol Open Circuit................................................................................1094 Failure Code [DW45KB] Swing Brake Sol Short Circuit...............................................................................1098 Failure Code [DW91KA] Travel Junction Sol Open Circuit............................................................................1102 Failure Code [DW91KB] Travel Junction Sol Short Circuit...........................................................................1104 Failure Code [DWA2KA] Attachment Sol Open Circuit.................................................................................1106 Failure Code [DWA2KB] Attachment Sol Short Circuit................................................................................1108 Failure Code [DWK0KA] 2-Stage Relief Sol Open Circuit.............................................................................1110 Failure Code [DWK0KB] 2-Stage Relief Sol Short Circuit............................................................................1112 Failure Code [DWK2KA] Variable Back Press Sol Open Circuit........................................................................1114 Failure Code [DWK2KB] Variable Back Press Sol Short Circuit.......................................................................1116 Failure Code [DWK8KA] Swing Press C/O Sol Open Circuit............................................................................1118 Failure Code [DWK8KB] Swing Press C/O Sol Short Circuit...........................................................................1120 Failure Code [DXA8KA] PC-EPC (F) Sol Open Circuit.................................................................................1122 Failure Code [DXA8KB] PC-EPC (F) Sol Short Circuit................................................................................1126 Failure Code [DXA9KA] PC-EPC (R) Sol Open Circuit.................................................................................1128 Failure Code [DXA9KB] PC-EPC (R) Sol Short Circuit................................................................................1132 Failure Code [DXE0KA] LS-EPC Sol Open Circuit.....................................................................................1134 Failure Code [DXE0KB] LS-EPC Sol Short Circuit....................................................................................1136 Failure Code [DXE4KA] Attachment Flow EPC Open Circuit............................................................................1138 Failure Code [DXE4KB] Attachment Flow EPC Short Circuit...........................................................................1140 Failure Code [DXE5KA] Merge-divide Main Sol Open Circuit..........................................................................1142 Failure Code [DXE5KB] Merge-divide Main Sol Short Circuit.........................................................................1144 Failure Code [DXE6KA] Merge-divide LS Sol Open Circuit............................................................................1146 Failure Code [DXE6KB] Merge-divide LS Sol Short Circuit...........................................................................1148 Failure Code [DY20KA] Wiper Working Abnormality...................................................................................1150 Failure Code [DY20MA] Wiper Parking Abnormality...................................................................................1154 Failure Code [DY2CKB] Washer Drive Short Circuit..................................................................................1158 Failure Code [DY2DKB] Wiper Drive (Fwd) Short Circuit.............................................................................1160 Failure Code [DY2EKB] Wiper Drive (Rev) Short Circuit.............................................................................1162 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).........................................................................................1164 E-1 Engine Does Not Start (Engine Does Not Rotate)................................................................................1164 E-2 Manual Pre-Heating System Does Not Work.......................................................................................1172 E-3 Automatic Pre-Heating System Does Not Work....................................................................................1176 E-4 Pre-Heating Monitor Does Not Light Up When Pre-Heater is Operated.............................................................1178 E-5 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing...............................................1180 E-6 When Starting Switch is Turned to ON Position (Before Starting Engine), Engine Oil Level Monitor Lights Up in Yellow..........1183 E-7 When Starting Switch is Turned to ON Position (Before Starting Engine), Radiator Coolant Level Monitor Lights Up in Yellow....1183 E-8 Coolant Temperature Monitor Lights Up in White While Engine is Running........................................................1184 E-9 Hydraulic Oil Temperature Monitor Lights Up in White While Engine is Running..................................................1184 E-10 Charge Level Monitor Lights Up While Engine is Running.......................................................................1185 E-11 Fuel Level Monitor Lights Up in Red While Engine is Running..................................................................1185 E-12 Air Cleaner Clogging Monitor Lights Up in Yellow While Engine is Running.....................................................1185 E-13 Water Separator Monitor Lights Up While Engine is Running....................................................................1186 E-14 Coolant Temperature Monitor Lights Up in Red While Engine is Running.........................................................1186 E-15 Hydraulic Oil Temperature Monitor Lights Up in Red While Engine is Running...................................................1187 E-16 Engine Oil Pressure Monitor Lights Up in Red While Engine is Running.........................................................1187 E-17 Fuel Gauge Indicates Either Full or Empty and Does Not Move..................................................................1188 E-18 Fuel Gauge Indicates Incorrect Amount (Indicates Neither Full Nor Empty).....................................................1190 E-19 Coolant Temperature Gauge Indicates Either Min or Max and Does Not Move......................................................1191 E-20 Coolant Temperature Gauge Indicates Incorrect Temperature (Indicates Neither Min Nor Max)....................................1192 E-21 Hydraulic Oil Temperature Gauge Indicates Either Min or Max and Does Not Move................................................1194 E-22 Hydraulic Oil Temperature Gauge Indicates Incorrect Temperature (Indicates Neither Min nor Max)..............................1196 E-23 Content of Display on Machine Monitor is Different From That of Actual Machine...............................................1197 E-24 Machine Monitor Does Not Display Some Items..................................................................................1197 E-25 Function Switch Does Not Work................................................................................................1197 E-26 Automatic Pre-Heating System Does Not Work (In Cold Season)..................................................................1198 E-27 Auto-Deceleration Monitor Does Not Light Up or Does Not Go Out When Auto-Deceleration Switch is Operated.....................1199 E-28 Auto-Deceleration is Not Actuated or Canceled When Lever is Operated.........................................................1200 E-29 Working Mode Selector Screen Selection Screen is Not Displayed When Working Mode Switch is Operated..........................1201 E-30 Engine or Hydraulic Pump Setting Does Not Change When Working Mode is Changed................................................1201 E-31 Travel Speed Monitor Does Not Change When Travel Speed Switch is Operated....................................................1202 E-32 Travel Speed Does Not Change When Travel Speed is Shifted....................................................................1203 E-33 Alarm Buzzer Does Not Stop Sounding..........................................................................................1204 E-34 When Starting Switch is Turned to OFF Position, Service Meter is Not Displayed...............................................1204 E-35 Service Mode Cannot be Selected..............................................................................................1205 E-36 Any of Work Equipment, Swing and Travel Does Not Work........................................................................1206 E-37 Any of Work Equipment, Swing and Travel Can Not be Locked....................................................................1208 E-38 Machine Can Not Swing While Swing Brake Cancel Switch is Canceled............................................................1210 E-39 Swing Brake Does Not Operate While Swing Brake Cancel Switch is Locked.......................................................1214 E-40 One-Touch Power Maximizing Function Does Not Work Or Monitor is Not Displayed................................................1216 E-41 One-Touch Power Maximizing Function Cannot be Released.......................................................................1218 E-42 Travel Alarm Does Not Sound When Machine Travels.............................................................................1219 E-43 Travel Alarm Does Not Stop Sounding When Machine Stops.......................................................................1220 E-44 Horn Does Not Sound..........................................................................................................1222 E-45 Horn Does Not Stop Sounding..................................................................................................1224 E-46 Wiper Monitor Does Not Light Up or Go Out When Wiper Switch is Operated......................................................1225 E-47 Wiper Does Not Operate When Wiper Switch is Operated.........................................................................1226 E-48 Window Washer Does Not Operate When Window Washer Switch is Operated.........................................................1228 E-49 BOOM LOWER Indication is Not Displayed Properly With Monitoring Function.....................................................1230 E-50 ARM DUMP Indication is Not Displayed Properly With Monitoring Function.......................................................1230 E-51 ARM IN Indication is Not Displayed Properly With Monitoring Function.........................................................1230 E-52 BOOM RAISE Indication is Not Displayed Properly With Monitoring Function.....................................................1230 E-53 BUCKET CURL Indication is Not Displayed Properly With Monitoring Function....................................................1231 E-54 BUCKET DUMP Indication is Not Displayed Properly With Monitoring Function....................................................1231 E-55 SWING Indication is Not Displayed Properly With Monitoring Function..........................................................1231 E-56 TRAVEL Indication is Not Displayed Properly With Monitoring Function.........................................................1231 E-57 Service is Not Displayed Properly With Monitoring Function...................................................................1232 E-58 Attachment Hydraulic Circuit Cannot be Changed...............................................................................1235 E-59 KOMTRAX System Does Not Work Properly........................................................................................1236 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...........................................................................1238 Information Mentioned in Troubleshooting Table (H Mode)...........................................................................1238 Failure Mode and Cause Table......................................................................................................1242 H-1 All of Work Equipment, Swing and Travel Operation Lacks Speed or Power........................................................1250 H-2 Engine Speed Lowers Significantly or Engine Stalls............................................................................1254 H-3 Any of Work Equipment, Swing and Travel Does Not Work.........................................................................1256 H-4 Unusual Sound is Heard from Around Hydraulic Pump.............................................................................1256 H-5 Fine Control Performance or Response is Poor..................................................................................1257 H-6 Boom Operation Lacks Speed or Power...........................................................................................1258 H-7 Arm Operation Lacks Speed or Power............................................................................................1260 H-8 Bucket Operation Lacks Speed or Power.........................................................................................1262 H-9 Work Equipment Does Not Move in Single Operation..............................................................................1263 H-10 Hydraulic Drift of Boom is Large.............................................................................................1263 H-11 Hydraulic Drift of Arm is Large..............................................................................................1264 H-12 Hydraulic Drift of Bucket is Large...........................................................................................1264 H-13 Time Lag of Work Equipment is Large..........................................................................................1265 H-14 When Part of Work Equipment is Relieved Singly, Other Parts of Work Equipment Move...........................................1266 H-15 One-Touch Power Maximizing Function Does Not Work............................................................................1266 H-16 In Combined Operation of Work Equipment, Equipment Having Heavier Load Moves Slower..........................................1267 H-17 In Combined Operations of Swing and Boom RAISE, Boom Rising Speed is Low.....................................................1268 H-18 In Combined Operations of Swing and Travel, Travel Speed Drops Largely.......................................................1269 H-19 Machine Does Not Travel Straight.............................................................................................1270 H-20 Travel Speed is Too Low......................................................................................................1272 H-21 Machine ishard to Steer or Travel Power is Low...............................................................................1274 H-22 Travel Speed Does Not Change, or Travel Speed is Too Low or High.............................................................1276 H-23 One of Tracks Dose Not Run...................................................................................................1277 H-24 Upper Structure Does Not Swing to the Right or Left..........................................................................1278 H-25 Upper Structure Swing Only to the Right or Left..............................................................................1279 H-26 Swing Acceleration is Poor or Swing Speed is Low (Both Right and Left).......................................................1280 H-27 Swing Aceleration is Poor or Swing Speed is Low (Either Right or Left).......................................................1281 H-28 Upper Structure Overruns Excessively When it Stops Swinging (Both Right and Left)............................................1282 H-29 Upper Structure Overruns Excessively When it Stops Swinging (Either Right or Left)...........................................1283 H-30 Shock is Large When Upper Structure Stops Swinging...........................................................................1284 H-31 Large Unusual Noise is Heard When Upper Structure Stops Swinging.............................................................1284 H-32 Swing Drift on a Slope is Large While Swing Holding Brake is Applied.........................................................1285 H-33 Swing Drift On a Slope is Large While Swing Holding Brake is Released........................................................1285 H-34 Attachment Circuit Cannot be Changed While Attachment is Installed...........................................................1286 H-35 Oil Flow in Attachment Circuit Cannot be Controlled..........................................................................1286 TROUBLESHOOTING OF ENGINE (S-MODE)....................................................................................................1287 Information Mentioned in Troubleshooting Table (S-Mode)...........................................................................1287 S-1 When Starting Switch is Turned to START Position, Engine Does Not Crank.......................................................1288 S-2 When Engine Cranks, Smoke Does Not Come Out...................................................................................1289 S-3 Engine Does Not Start While Fuel is Injected (Incomplete Combustion)..........................................................1290 S-4 Startability is Poor..........................................................................................................1292 S-5 Engine Does Not Pick Up Smoothly..............................................................................................1294 S-6 Engine Stops During Operation.................................................................................................1296 S-7 Engine Runs Rough or is Unstable..............................................................................................1298 S-8 Engine Lacks Power............................................................................................................1300 S-9 Exhaust Smoke is Black (KDPF Clogs Up Early)..................................................................................1304 S-10 Engine Oil Consumption is Too Much...........................................................................................1306 S-11 Oil Becomes Contaminated Early...............................................................................................1307 S-12 Fuel Consumption is Excessive................................................................................................1308 S-13 Oil is in Coolant (or Coolant Spurts or Coolant Level Goes Down).............................................................1309 S-14 Engine Oil Pressure Drops....................................................................................................1310 S-15 Fuel is Contaminated in Engine Oil...........................................................................................1312 S-16 Coolant is Contaminated in Engine Oil (Oil Becomes Cloudy White).............................................................1313 S-17 Coolant Temperature Rises Too High (Overheating).............................................................................1314 S-18 Unusual Noise is Heard.......................................................................................................1315 S-19 Vibration is Excessive.......................................................................................................1316 S-20 Automatic Regeneration is Operated Frequently................................................................................1317 S-21 Active Regeneration is Operated for Long.....................................................................................1318 S-22 White Smoke Comes Out in the Process of Active Regeneration..................................................................1319 50 DISASSEMBLY AND ASSEMBLY...............................................................................................................1321 HOW TO READ THIS SECTION..............................................................................................................1326 Removal And Installation Of Assemblies............................................................................................1326 Special Tools.................................................................................................................1326 Removal.......................................................................................................................1326 Installation..................................................................................................................1326 Disassembly And Assembly Of Assemblies............................................................................................1327 Special Tools.................................................................................................................1327 Disassembly...................................................................................................................1327 Assembly......................................................................................................................1328 Coating Materials List............................................................................................................1329 SKETCHES OF SPECIAL TOOLS.............................................................................................................1337 CONNECTOR REPAIR PROCEDURES...........................................................................................................1340 Stripping Insulation..............................................................................................................1340 Wire Inspection...................................................................................................................1340 Contact Terminal Removal (HD30 Type)..............................................................................................1341 Crimping Contact Terminal (HD30 Type).............................................................................................1342 Insertion Of Contact Terminal (HD30 Type).........................................................................................1343 Contact Terminal Removal (DT Type)................................................................................................1344 Crimping Contact Terminal (DT Type)...............................................................................................1345 Insertion Of Contact Terminal (DT Type)...........................................................................................1346 ENGINE AND COOLING SYSTEM.............................................................................................................1348 Removal and Installation of Supply Pump Assembly..................................................................................1348 Special Tools.................................................................................................................1348 Removal.......................................................................................................................1348 Installation..................................................................................................................1351 Fuel Injector Assembly............................................................................................................1354 Special Tools.................................................................................................................1354 Removal.......................................................................................................................1354 Installation..................................................................................................................1358 Removal and Installation of Cylinder Head Assembly................................................................................1366 Special Tools.................................................................................................................1366 Removal.......................................................................................................................1366 Installation..................................................................................................................1377 Removal and Installation of Radiator Assembly.....................................................................................1394 Removal.......................................................................................................................1394 Installation..................................................................................................................1396 Removal and Installation of Hydraulic Oil Cooler Assembly.........................................................................1398 Removal.......................................................................................................................1398 Installation..................................................................................................................1401 Removal and Installation of Aftercooler Assembly..................................................................................1402 Removal.......................................................................................................................1402 Installation..................................................................................................................1403 Removal and Installation Engine And Main Pump Assembly............................................................................1404 Special Tools.....................................................................................................................1404 Removal.......................................................................................................................1404 Installation..................................................................................................................1416 Removal and Installation of Engine Front Oil Seal.................................................................................1422 Removal.......................................................................................................................1422 Installation..................................................................................................................1425 Removal and Installation of Engine Rear Oil Seal..................................................................................1428 Removal.......................................................................................................................1428 Installation..................................................................................................................1429 Removal and Installation of Fuel Cooler Assembly..................................................................................1432 Removal.......................................................................................................................1432 Installation..................................................................................................................1432 Removal and Installation of Fuel Tank Assembly....................................................................................1433 Removal.......................................................................................................................1433 Installation..................................................................................................................1436 Removal and Installation of Engine Hood Assembly..................................................................................1437 Removal.......................................................................................................................1437 Installation..................................................................................................................1438 Removal and Installation of KDPF Assembly.........................................................................................1442 Removal.......................................................................................................................1442 Installation..................................................................................................................1445 Disassembly and Assembly of KDPF..................................................................................................1454 Disassembly...................................................................................................................1454 Assembly......................................................................................................................1459 Removal and Installation of KCCV Assembly.........................................................................................1464 Removal.......................................................................................................................1464 Installation..................................................................................................................1466 Removal and Installation of Air Cleaner Assembly..................................................................................1468 Removal.......................................................................................................................1468 Installation..................................................................................................................1470 POWER TRAIN...........................................................................................................................1472 Removal and Installation of Travel Motor and Final Drive Assembly.................................................................1472 Removal.......................................................................................................................1472 Installation..................................................................................................................1473 Disassembly and Assembly of Final Drive...........................................................................................1474 Disassembly...................................................................................................................1474 Assembly......................................................................................................................1478 Removal and Installation of Swing Motor and Swing Machinery Assembly..............................................................1484 Installation..................................................................................................................1487 Disassembly and Assembly of Swing Machinery.......................................................................................1488 Disassembly...................................................................................................................1488 Assembly......................................................................................................................1492 Removal and Installation of Swing Circle Assembly.................................................................................1498 Removal.......................................................................................................................1498 Installation..................................................................................................................1498 UNDERCARRIAGE AND FRAME...............................................................................................................1499 Separation and Connection of Track Shoe Assembly..................................................................................1499 Separating Track..............................................................................................................1499 Connecting Track..............................................................................................................1500 Removal and Installation of Sprocket..............................................................................................1502 Removal.......................................................................................................................1502 Installation..................................................................................................................1502 Removal and Installation of Idler and Idler Cushion Assembly......................................................................1503 Removal.......................................................................................................................1503 Installation..................................................................................................................1503 Disassembly and Assembly of Idler.................................................................................................1504 Disassembly...................................................................................................................1504 Assembly......................................................................................................................1505 Disassembly and Assembly of Idler Cushion.........................................................................................1508 Disassembly...................................................................................................................1508 Assembly......................................................................................................................1509 Disassembly and Assembly of Track Roller..........................................................................................1512 Disassembly...................................................................................................................1512 Assembly......................................................................................................................1513 Disassembly and Assembly of Carrier Roller........................................................................................1515 Disassembly...................................................................................................................1515 Assembly......................................................................................................................1516 Removal and Installation of Revolving Frame Assembly..............................................................................1520 Removal.......................................................................................................................1520 Installation..................................................................................................................1522 Removal and Installation of Counterweight Assembly................................................................................1524 Removal.......................................................................................................................1524 Installation..................................................................................................................1527 HYDRAULIC SYSTEM......................................................................................................................1528 Center Swivel Joint...............................................................................................................1528 Removal.......................................................................................................................1528 Installation..................................................................................................................1530 Disassembly and Assembly of Swivel Joint..........................................................................................1532 Disassembly...................................................................................................................1532 Assembly......................................................................................................................1533 Removal and Installation of Hydraulic Tank Assembly...............................................................................1534 Removal.......................................................................................................................1534 Installation..................................................................................................................1539 Removal and Installation of Main Pump Assembly....................................................................................1540 Removal.......................................................................................................................1540 Installation..................................................................................................................1544 Removal and Installation of Control Valve.........................................................................................1546 Removal.......................................................................................................................1546 Installation..................................................................................................................1553 Disassembly and Assembly of Control Valve.........................................................................................1556 Procedures for Replacing Pressure Compensation Valve Seal.....................................................................1556 Assembly of Control Valve Assembly............................................................................................1558 Disassembly and Assembly of Work Equipment PPC Valve..............................................................................1564 Disassembly...................................................................................................................1564 Assembly......................................................................................................................1564 Disassembly and Assembly of Travel PPC Valve......................................................................................1566 Disassembly...................................................................................................................1567 Assembly......................................................................................................................1567 WORK EQUIPMENT........................................................................................................................1570 Removal and Installation of Work Equipment Assembly...............................................................................1570 Special Tools.................................................................................................................1570 Removal.......................................................................................................................1570 Installation..................................................................................................................1572 Disassembly and Assembly of Work Equipment Cylinder...........................................................................1574 Disassembly...................................................................................................................1574 Assembly......................................................................................................................1577 CAB AND ITS ATTACHMENTS...............................................................................................................1582 Removal and Installation of Operator's Cab Assembly...............................................................................1582 Removal.......................................................................................................................1582 Removal.......................................................................................................................1582 Installation..................................................................................................................1587 Removal and Installation of Operator Cab Glass (Fixed Glass)......................................................................1588 Removal.......................................................................................................................1589 Installation..................................................................................................................1590 Removal and Installation of Front Window Assembly.................................................................................1600 Removal.......................................................................................................................1600 Installation..................................................................................................................1603 Removal and Installation of Floor Frame Assembly..................................................................................1608 Removal.......................................................................................................................1608 Installation..................................................................................................................1615 Removal and Installation of Air Conditioner Unit Assembly.........................................................................1616 Removal.......................................................................................................................1616 Installation..................................................................................................................1621 Removal and Installation of Operator’s Seat.......................................................................................1622 Removal.......................................................................................................................1622 Installation..................................................................................................................1623 Removal and Installation of Seat Belt.............................................................................................1626 Removal.......................................................................................................................1626 Installation..................................................................................................................1627 Removal and Installation of Front Wiper Assembly..................................................................................1628 Removal.......................................................................................................................1628 Installation..................................................................................................................1633 ELECTRICAL SYSTEM.....................................................................................................................1640 Removal and Installation of Air Conditioner Compressor Assembly...................................................................1640 Removal.......................................................................................................................1640 Installation..................................................................................................................1642 Removal and Installation of Air Conditioner Condenser Assembly....................................................................1644 Removal.......................................................................................................................1644 Installation..................................................................................................................1645 Removal and Installation of Engine Controller Assembly............................................................................1646 Removal.......................................................................................................................1646 Installation..................................................................................................................1647 Removal and Installation of Pump Controller Assembly..............................................................................1650 Removal.......................................................................................................................1650 Installation..................................................................................................................1652 Removal and Installation of Machine Monitor Assembly..............................................................................1654 Removal.......................................................................................................................1654 Installation..................................................................................................................1656 Removal and Installation of Pump Swash Plate Sensor...............................................................................1657 Removal.......................................................................................................................1657 Installation..................................................................................................................1657 Removal and Installation of Mass Air Flow and Temperature Sensor..................................................................1658 Removal.......................................................................................................................1658 Installation..................................................................................................................1658 Removal and Installation of KOMTRAX Terminal Assembly.............................................................................1660 Removal.......................................................................................................................1660 Installation..................................................................................................................1661 60 MAINTENANCE STANDARD...................................................................................................................1663 ENGINE AND COOLING SYSTEM.............................................................................................................1666 Engine Mounts.....................................................................................................................1666 Cooling System....................................................................................................................1668 POWER TRAIN...........................................................................................................................1670 Swing Circle......................................................................................................................1670 Swing Machinery...................................................................................................................1672 Final Drive.......................................................................................................................1674 Sprocket..........................................................................................................................1676 UNDERCARRIAGE AND FRAME...............................................................................................................1678 Track Frame and Idler Cushion.....................................................................................................1678 Idler.............................................................................................................................1680 Track Roller......................................................................................................................1682 Carrier Roller....................................................................................................................1684 Track Shoe........................................................................................................................1686 Triple Grouser Shoe...............................................................................................................1689 HYDRAULIC SYSTEM......................................................................................................................1690 Hydraulic Tank....................................................................................................................1690 Main Pump.........................................................................................................................1691 Control Valve.....................................................................................................................1692 General View..................................................................................................................1692 Sectional View (1/5)..........................................................................................................1694 Sectional View (2/5)..........................................................................................................1696 Sectional View (3/5)..........................................................................................................1698 Sectional View (4/5)..........................................................................................................1700 Sectional View (5/5)..........................................................................................................1702 Swing Motor.......................................................................................................................1703 Travel Motor......................................................................................................................1706 PPC VALVE.............................................................................................................................1709 Work Equipment and Swing PPC Valve................................................................................................1709 Travel PPC Valve..................................................................................................................1712 1st-Line Attachment PPC Valve (with EPC Valve)....................................................................................1716 EPC Valve.........................................................................................................................1718 2nd-Line Attachment PPC Valve.....................................................................................................1720 Solenoid Valve....................................................................................................................1722 Attachment Circuit Selector Valve.................................................................................................1724 For Low-Pressure Circuit......................................................................................................1724 For High-Pressure Circuit.....................................................................................................1725 Center Swivel Joint...............................................................................................................1726 WORK EQUIPMENT........................................................................................................................1727 Dimensions of Components..........................................................................................................1727 Dimensions of Arm.................................................................................................................1732 Boom Cylinder.....................................................................................................................1738 Standard......................................................................................................................1738 Large Diameter Piston.........................................................................................................1739 Arm Cylinder......................................................................................................................1740 Bucket Cylinder...................................................................................................................1741 80 AIR CONDITIONING.......................................................................................................................1743 AIR CONDITIONER.......................................................................................................................1746 Precautions for Refrigerant.......................................................................................................1746 Air Conditioner Component.........................................................................................................1748 Structure and Function of Refrigeration System....................................................................................1750 Overview of Refrigeration System..................................................................................................1751 Air Conditioner Unit..............................................................................................................1754 Function......................................................................................................................1755 Functions of Major Components.....................................................................................................1756 Evaporator....................................................................................................................1756 Heater core...................................................................................................................1756 Evaporator temperature sensor.................................................................................................1756 Servomotor....................................................................................................................1756 Expansion valve...............................................................................................................1758 Dual Pressure Switch..........................................................................................................1760 Air Conditioner Controller....................................................................................................1760 Air Conditioner Compressor....................................................................................................1761 Air Conditioner Condenser.....................................................................................................1762 Sunlight Sensor...............................................................................................................1763 Outside Air Temperature Sensor................................................................................................1763 Inspection and Troubleshooting Procedure of Air Conditioner.......................................................................1764 Basic Inspection and Troubleshooting Sequence.................................................................................1764 Air Conditioner Circuit Diagram and Arrangement of Connector Pins.................................................................1766 System Diagram....................................................................................................................1767 Air Conditioner Controller Input and Output Signals...............................................................................1768 Parts and Connectors Layout.......................................................................................................1770 Layout of Air Conditioner Related Parts and Connectors............................................................................1772 Testing Air Leakage (Duct)........................................................................................................1774 Testing with Self-Diagnosis Function..............................................................................................1776 How to Enter Air Conditioner “Electrical Systems” Screen in Service Mode of the Machine Monitor...................................1778 Testing Vent (Mode) Changeover....................................................................................................1780 Testing FRESH/RECIRC Air Changeover...............................................................................................1782 Testing Sunlight Sensor...........................................................................................................1783 Testing (Dual) Pressure Switch for Refrigerant....................................................................................1784 Testing Relay.....................................................................................................................1785 Troubleshooting Chart 1...........................................................................................................1786 Troubleshooting Chart 2...........................................................................................................1787 Information Mentioned in Troubleshooting Table....................................................................................1790 Information in Troubleshooting Table..........................................................................................1790 Failure Code List Related to Air Conditioner......................................................................................1792 Failure Code [879AKA] A/C Inner Sensor Open Circuit...............................................................................1793 Failure Code [879AKB] A/C Inner Sensor Short Circuit..............................................................................1793 Failure Code [879BKA] A/C Outer Sensor Open Circuit...............................................................................1794 Failure Code [879BKB] A/C Outer Sensor Short Circuit..............................................................................1796 Failure Code [879CKA] Ventilating Sensor Open Circuit.............................................................................1798 Failure Code [879CKB] Ventilating Sensor Short Circuit............................................................................1799 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit.......................................................................1800 Failure Code [879EMC] Ventilation Damper Abnormality..............................................................................1801 Failure Code [879FMC] Ventilation Damper Abnormality..............................................................................1802 Failure Code [879GKX] Refrigerant Abnormality.....................................................................................1802 A-1 Troubleshooting for Power Supply System (The Air Conditioner Does Not Operate)................................................1804 A-2 Troubleshooting of Compressor System (Air is Not Cooled)......................................................................1806 A-3 Troubleshooting of Blower Motor System (Air Does Not Come Out or Air Flow is Normal)..........................................1810 A-4 Troubleshooting for FRESH/RECIRC Air Changeover...............................................................................1812 Troubleshooting with Gauge Pressure...............................................................................................1814 [Measurement Condition for Pressure]..........................................................................................1814 Testing Refrigerant Pressure......................................................................................................1817 Check.........................................................................................................................1818 Troubleshooting Table with Gauge Pressure Indicated by Gauge Manifold.........................................................1820 Precautions for Disconnecting and Connecting Refrigerant Piping...................................................................1822 Disconnection.................................................................................................................1822 Connection....................................................................................................................1822 Tightening Torque for Joint Portion of Refrigerant Piping.........................................................................1823 Filling Compressor Oil............................................................................................................1824 Oil Level Control of Compressor...............................................................................................1824 Refilling of Compressor Oil...................................................................................................1824 Desiccant Replacement.............................................................................................................1826 90 DIAGRAMS AND SCHEMATICS................................................................................................................1829 HYDRAULIC SYSTEM......................................................................................................................1831 Symbols in Hydraulic Circuit Diagrams.............................................................................................1831 Hydraulic Circuit Diagram and Name of Valves......................................................................................1832 Hydraulic Circuit Diagram (1/2)...................................................................................................1833 Hydraulic Circuit Diagram (2/2)...................................................................................................1834 ELECTRICAL SYSTEM.....................................................................................................................1835 Air Conditioner Electrical Circuit................................................................................................1836 Electrical Control System Diagram.................................................................................................1837 Electrical Diagram (1/5)..........................................................................................................1838 Electrical Diagram (2/5)..........................................................................................................1839 Electrical Diagram (3/5)..........................................................................................................1840 Electrical Diagram (4/5)..........................................................................................................1841 Electrical Diagram (5/5)..........................................................................................................1842 Connector List and Stereogram.....................................................................................................1843 Chassis.......................................................................................................................1843 Operator's Compartment........................................................................................................1844 Engine Compartment............................................................................................................1845
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