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KOMATSU PC290LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:15001 & UP) – PDF Download
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- KOMATSU PC290LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- SERIAL NUMBER:15001 & UP
- PUBLICATION NUMBER:SEN05644-02
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Description
KOMATSU PC290LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:15001 & UP)
KOMATSU PC290LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:15001 & UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC290LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:15001 & UP)
• This shop manual describes the technical information required for the services performed in a workshop. The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of “Structure and function” serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for the standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or component and the special tools for the works as well as precautions for doing them safely. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the criterion values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams
TABLE OF CONTENTS:
KOMATSU PC290LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:15001 & UP)
COVER .................................................................................................................................... 1 00 Index and foreword..................................................................................................................... 3 Index................................................................................................................................. 4 Foreword, safety and general information.............................................................................................. 15 Important safety notice........................................................................................................... 15 How to read the shop manual....................................................................................................... 20 Explanation of terms for maintenance standard..................................................................................... 22 Handling of fuel system devices................................................................................................... 24 Handling of intake system parts................................................................................................... 25 Handling of hydraulic equipment................................................................................................... 26 Method of disconnecting and connecting push-pull type coupler..................................................................... 28 Handling of electrical equipment.................................................................................................. 31 How to read electric wire code.................................................................................................... 39 Precautions when performing operation............................................................................................. 42 Standard tightening torque table.................................................................................................. 45 List of abbreviation.............................................................................................................. 49 Conversion table.................................................................................................................. 53 01 Specification.......................................................................................................................... 59 Specifications........................................................................................................................ 61 Specification drawings............................................................................................................ 61 Working range drawings............................................................................................................ 62 Specifications.................................................................................................................... 63 Weight table...................................................................................................................... 66 Table of fuel, coolant and lubricants............................................................................................. 67 10 Structure and function................................................................................................................. 69 Engine and cooling system............................................................................................................. 71 Engine related parts.............................................................................................................. 71 Cooling system.................................................................................................................... 73 Power train system.................................................................................................................... 75 Power train....................................................................................................................... 75 Swing circle...................................................................................................................... 77 Swing machinery................................................................................................................... 78 Final drive....................................................................................................................... 80 Undercarriage and frame............................................................................................................... 82 Track frame and idler cushion..................................................................................................... 82 Hydraulic system...................................................................................................................... 84 Hydraulic equipment layout drawing................................................................................................ 84 Valve control..................................................................................................................... 86 Hydraulic tank.................................................................................................................... 88 CLSS.............................................................................................................................. 90 Main pump......................................................................................................................... 95 Control valve..................................................................................................................... 119 Swing motor....................................................................................................................... 172 Travel motor...................................................................................................................... 183 PPC valve......................................................................................................................... 197 Solenoid valve.................................................................................................................... 218 Attachment circuit selector valve (for high pressure circuit)..................................................................... 221 Attachment circuit selector valve (for low pressure circuit)...................................................................... 223 Center swivel joint............................................................................................................... 226 Accumulator....................................................................................................................... 228 Work equipment........................................................................................................................ 229 Work equipment.................................................................................................................... 229 Work equipment shim............................................................................................................... 230 Bucket play adjustment shim....................................................................................................... 231 Cab and its attachments............................................................................................................... 232 Cab mount and cab tipping stopper................................................................................................. 232 ROPS cab.......................................................................................................................... 233 Electrical system..................................................................................................................... 234 Electrical control system......................................................................................................... 234 Machine monitor system............................................................................................................ 277 KOMTRAX system.................................................................................................................... 296 Sensors........................................................................................................................... 298 20 Standard value tablePC290LC-........................................................................................................... 315 Standard service value table.......................................................................................................... 317 Standard value table for engine related parts..................................................................................... 317 Standard value table for chassis related parts.................................................................................... 319 30 Testing Adjusting...................................................................................................................... 333 General information on testing and adjusting.......................................................................................... 335 Tools for testing and adjusting................................................................................................... 335 Sketch of tools for testing and adjusting......................................................................................... 339 Engine and cooling system............................................................................................................. 341 Checking engine speed............................................................................................................. 341 Measuring boost pressure.......................................................................................................... 342 Measuring exhaust gas color....................................................................................................... 343 Measuring and adjusting valve clearance........................................................................................... 345 Measuring compression pressure.................................................................................................... 348 Measuring blowby pressure......................................................................................................... 352 Measuring engine oil pressure..................................................................................................... 353 Measuring EGR valve and KVGT oil pressure......................................................................................... 354 Measuring fuel pressure........................................................................................................... 355 Measuring fuel delivery, return and leakage....................................................................................... 361 Bleeding air from fuel system..................................................................................................... 366 Checking fuel circuit for leakage................................................................................................. 368 Handling cylinder cutout mode operation........................................................................................... 369 Handling no injection cranking operation.......................................................................................... 370 Checking and adjusting air conditioner compressor belt tension.................................................................... 371 Replacing fan belt................................................................................................................ 372 Power train........................................................................................................................... 373 Testing swing circle bearing clearance............................................................................................ 373 Undercarriage and frame............................................................................................................... 374 Testing and adjusting track shoe tension.......................................................................................... 374 Hydraulic system...................................................................................................................... 375 Releasing remaining pressure from hydraulic circuit............................................................................... 375 Measuring and adjusting of oil pressure in work equipment, swing, and travel circuits............................................. 376 Measuring oil pressure in control circuit......................................................................................... 380 Measuring and adjusting oil pressure in pump PC control circuit................................................................... 381 Measuring and adjusting oil pressure in pump LS control circuit................................................................... 384 Measuring solenoid valve output pressure.......................................................................................... 389 Measuring PPC valve output pressure............................................................................................... 392 Adjusting play of work equipment and swing PPC valves............................................................................. 394 Testing pump swash plate sensor................................................................................................... 395 Isolating the parts causing hydraulic drift in work equipment..................................................................... 396 Measuring oil leakage............................................................................................................. 397 Bleeding air from hydraulic circuit............................................................................................... 400 Cab and its attachments............................................................................................................... 402 Checking cab tipping stopper...................................................................................................... 402 Adjusting mirrors................................................................................................................. 403 Electrical system..................................................................................................................... 405 Special functions of machine monitor.............................................................................................. 405 Angle adjustment of rear view camera.............................................................................................. 475 Handling voltage circuit of engine controller..................................................................................... 477 Handling battery disconnect switch................................................................................................ 478 Testing diodes.................................................................................................................... 479 Pm clinic............................................................................................................................. 480 Pm clinic service................................................................................................................. 480 40 Troubleshooting........................................................................................................................ 491 General information on troubleshooting................................................................................................ 499 Instruction on troubleshooting.................................................................................................... 499 How to proceed troubleshooting.................................................................................................... 501 Testing before troubleshooting.................................................................................................... 502 Testing procedure before troubleshooting.......................................................................................... 504 Preparation work for troubleshooting of electrical system......................................................................... 532 Classification and procedure for troubleshooting.................................................................................. 536 Symptom of probable failure and troubleshooting No................................................................................ 539 Information mentioned in troubleshooting table.................................................................................... 542 Diagnostic procedure for wiring harness open curcuit of pressure sensor system.................................................... 545 Connector list and layout......................................................................................................... 547 Connector contact identification.................................................................................................. 558 T-branch box and T-branch adapter table........................................................................................... 595 Fuse list and location............................................................................................................ 601 Precautions for cleaning and replacing KDPF (KCSF, KDOC).......................................................................... 603 Failure codes table............................................................................................................... 605 Troubleshooting by failure code (Display of code)..................................................................................... 614 Failure code [879AKA] A/C Inner Sensor Open Circuit............................................................................... 614 Failure code [879AKB] A/C Inner Sensor Short Circuit.............................................................................. 615 Failure code [879BKA] A/C Outer Sensor Open Circuit............................................................................... 616 Failure code [879BKB] A/C Outer Sensor Short Circuit.............................................................................. 617 Failure code [879CKA] Ventilating Sensor Open Circuit............................................................................. 618 Failure code [879CKB] Ventilating Sensor Short Circuit............................................................................ 619 Failure code [879DKZ] Sunlight Sensor Open or Short Circuit....................................................................... 620 Failure code [879EMC] Ventilation Damper Abnormality.............................................................................. 621 Failure code [879FMC] Air Mix Damper Abnormality.................................................................................. 622 Failure code [879GKX] Refrigerant Abnormality..................................................................................... 623 Failure code [989L00] Engine Controller Lock Caution1............................................................................. 624 Failure code [989M00] Engine Controller Lock Caution2............................................................................. 625 Failure code [989N00] Engine Controller Lock Caution3............................................................................. 626 Failure code [A1U0N3] HC desorb request1.......................................................................................... 627 Failure code [A1U0N4] HC desorb request2.......................................................................................... 629 Failure code [AA10NX] Air Cleaner Clogging........................................................................................ 631 Failure code [AB00KE] Charge Voltage Low.......................................................................................... 633 Failure code [B@BAZG] Engine Oil Pressure Low..................................................................................... 635 Failure code [B@BAZK] Eng Oil Level Low........................................................................................... 636 Failure code [B@BCNS] Engine Coolant Overheat..................................................................................... 637 Failure code [B@BCZK] Radiator Coolant Level Low.................................................................................. 638 Failure code [B@HANS] Hyd Oil Overheat............................................................................................ 640 Failure code [CA115] Eng Ne and Bkup Speed Sens Error............................................................................. 641 Failure code [CA122] Chg Air Press Sensor High Error.............................................................................. 642 Failure code [CA123] Chg Air Press Sensor Low Error............................................................................... 644 Failure code [CA131] Throttle Sensor High Error................................................................................... 646 Failure code [CA132] Throttle Sensor Low Error.................................................................................... 648 Failure code [CA144] Coolant Temp Sens High Error................................................................................. 650 Failure code [CA145] Coolant Temp Sens Low Error.................................................................................. 652 Failure code [CA153] Chg Air Temp Sensor High Error............................................................................... 654 Failure code [CA154] Chg Air Temp Sensor Low Error................................................................................ 656 Failure code [CA187] Sensor 2 Supply Volt Low Error............................................................................... 658 Failure code [CA221] Ambient Press Sensor High Error.............................................................................. 660 Failure code [CA222] Ambient Press Sensor Low Error............................................................................... 662 Failure code [CA227] Sensor 2 Supply Volt High Error.............................................................................. 664 Failure code [CA234] Eng Overspeed................................................................................................ 665 Failure code [CA238] Ne Speed Sensor Supply Volt Error............................................................................ 666 Failure code [CA239] Ne Speed Sens Supply Volt High Error......................................................................... 667 Failure code [CA271] IMV/PCV1 Short Error......................................................................................... 668 Failure code [CA272] IMV/PCV1 Open Error.......................................................................................... 670 Failure code [CA295] Ambient Press Sens In Range Error............................................................................ 671 Failure code [CA322] Inj #1(L#1) Open/Short Error................................................................................. 672 Failure code [CA323] Inj #5(L#5) Open/Short Error................................................................................. 674 Failure code [CA324] Inj #3(L#3) Open/Short Error................................................................................. 676 Failure code [CA325] Inj #6(L#6) Open/Short Error................................................................................. 678 Failure code [CA331] Inj #2(L#2) Open/Short Error................................................................................. 680 Failure code [CA332] Inj #4(L#4) Open/Short Error................................................................................. 682 Failure code [CA343] ECM Critical Internal Failure................................................................................ 684 Failure code [CA351] Injectors Drive Circuit Error................................................................................ 685 Failure code [CA352] Sensor 1 Supply Volt Low Error............................................................................... 686 Failure code [CA356] Mass Air Flow Sensor High Error.............................................................................. 688 Failure code [CA357] Mass Air Flow Sensor Low Error............................................................................... 690 Failure code [CA386] Sensor 1 Supply Volt High Error.............................................................................. 692 Failure code [CA428] Water in Fuel Sensor High Error.............................................................................. 693 Failure code [CA429] Water in Fuel Sensor Low Error............................................................................... 695 Failure code [CA435] Eng Oil Press Sw Error....................................................................................... 697 Failure code [CA441] Battery Voltage Low Error.................................................................................... 698 Failure code [CA442] Battery Voltage High Error................................................................................... 700 Failure code [CA449] Rail Press Very High Error................................................................................... 701 Failure code [CA451] Rail Press Sensor High Error................................................................................. 702 Failure code [CA452] Rail Press Sensor Low Error.................................................................................. 704 Failure code [CA488] Chg Air Temp High Torque Derate.............................................................................. 705 Failure code [CA515] Rail Press Sens Sup Volt High Error.......................................................................... 706 Failure code [CA516] Rail Press Sens Sup Volt Low Error........................................................................... 708 Failure code [CA553] Rail Press High Error........................................................................................ 710 Failure code [CA555] Crankcase Press High Error 1................................................................................. 711 Failure code [CA556] Crankcase Press High Error 2................................................................................. 712 Failure code [CA559] Rail Press Low Error......................................................................................... 713 Failure code [CA595] Turbo Speed High Error 2..................................................................................... 715 Failure code [CA687] Turbo Speed Low Error........................................................................................ 716 Failure code [CA689] Eng Ne Speed Sensor Error.................................................................................... 718 Failure code [CA691] Intake Air Temp Sens High Error.............................................................................. 720 Failure code [CA692] Intake Air Temp Sens Low Error............................................................................... 722 Failure code [CA697] ECM Int Temp Sensor High Error............................................................................... 724 Failure code [CA698] ECM Int Temp Sensor Low Error................................................................................ 725 Failure code [CA731] Eng Bkup Speed Sens Phase Error.............................................................................. 726 Failure code [CA778] Eng Bkup Speed Sensor Error.................................................................................. 727 Failure code [CA1117] Persistent Data Lost Error.................................................................................. 731 Failure code [CA1664] KDOC Malfunction............................................................................................ 732 Failure code [CA1691] Regeneration Ineffective.................................................................................... 734 Failure code [CA1695] Sensor 5 Supply Volt Low Error.............................................................................. 736 Failure code [CA1696] Sensor 5 Supply Volt High Error............................................................................. 738 Failure code [CA1843] Crankcase Press Sens High Error............................................................................. 740 Failure code [CA1844] Crankcase Press Sens Low Error.............................................................................. 742 Failure code [CA1879] KDPF Delta P Sensor High Error.............................................................................. 744 Failure code [CA1881] KDPF Delta P Sensor Low Error............................................................................... 746 Failure code [CA1883] KDPF Delta P Sens In Range Error............................................................................ 748 Failure code [CA1921] KDPF Soot Load High Error 1................................................................................. 751 Failure code [CA1922] KDPF Soot Load High Error 2................................................................................. 753 Failure code [CA1942] Crankcase Press Sens In Range Error......................................................................... 757 Failure code [CA1993] KDPF Delta Pressure Low Error............................................................................... 758 Failure code [CA2185] Throt Sensor Sup Volt High Error............................................................................ 759 Failure code [CA2186] Throt Sensor Sup Volt Low Error............................................................................. 760 Failure code [CA2249] Rail Press Very Low Error................................................................................... 761 Failure code [CA2271] EGR Valve Pos Sens High Error............................................................................... 762 Failure code [CA2272] EGR Valve Pos Sens Low Error................................................................................ 764 Failure code [CA2288] Turbo Speed High Error 1.................................................................................... 767 Failure code [CA2311] IMV Solenoid Error.......................................................................................... 768 Failure code [CA2349] EGR Valve Solenoid Open Error............................................................................... 769 Failure code [CA2353] EGR Valve Solenoid Short Error.............................................................................. 771 Failure code [CA2357] EGR Differential Pressure................................................................................... 773 Failure code [CA2373] Exh Manifold Press. Sens Volt............................................................................... 774 Failure code [CA2374] Exhaust Manifold Press Sens Low Error....................................................................... 776 Failure code [CA2375] EGR Orifice Temp Sens High Error............................................................................ 778 Failure code [CA2376] EGR Orifice Temp Sens Low Error............................................................................. 780 Failure code [CA2381] KVGT Pos Sens High Error.................................................................................... 782 Failure code [CA2382] KVGT Pos Sens Low Error..................................................................................... 784 Failure code [CA2383] KVGT Solenoid Open Error.................................................................................... 786 Failure code [CA2386] KVGT Solenoid Short Error................................................................................... 788 Failure code [CA2387] KVGT Servo Error............................................................................................ 790 Failure code [CA2554] Exh Manifold Press Sens In Range Error...................................................................... 791 Failure code [CA2555] Grid Htr Relay Volt Low Error............................................................................... 792 Failure code [CA2556] Grid Htr Relay Volt High Error.............................................................................. 794 Failure code [CA2637] KDOC Face Plugging.......................................................................................... 796 Failure code [CA2639] Manual Stationary Regeneration Request...................................................................... 798 Failure code [CA2961] EGR Orifice Temp High Error 1............................................................................... 800 Failure code [CA2973] Chg Air Press Sensor In Range Error......................................................................... 801 Failure code [CA3133] KDPF Outlet Press Sens High Error........................................................................... 802 Failure code [CA3134] KDPF Outlet Press Sens Low Error............................................................................ 804 Failure code [CA3135] KDPF Outlet Press Sens In Range Error....................................................................... 806 Failure code [CA3251] DOC Inlet Temp High Error................................................................................... 809 Failure code [CA3253] KDOC Temp Error - Non Regeneration.......................................................................... 812 Failure code [CA3254] KDOC Outlet Temp High Error 1............................................................................... 813 Failure code [CA3255] KDPF Temp Error - Non Regeneration.......................................................................... 816 Failure code [CA3256] KDPF Outlet Temp High Error 1............................................................................... 817 Failure code [CA3311] KDOC Outlet Temp High Error 2............................................................................... 818 Failure code [CA3312] KDPF Outlet Temp High Error 2............................................................................... 819 Failure code [CA3313] KDOC Inlet Temp Sensor Low Error............................................................................ 821 Failure code [CA3314] KDOC Inlet Temp Sens High Error............................................................................. 824 Failure code [CA3315] KDOC Inlet Temp Sens In Range Error......................................................................... 828 Failure code [CA3316] KDOC Outlet Temp Sens Low Error............................................................................. 832 Failure code [CA3317] KDOC Outlet Temp Sens High Error............................................................................ 835 Failure code [CA3318] KDOC Inlet Temp Sens In Range Error......................................................................... 839 Failure code [CA3319] KDPF Outlet Temp Sens High Error............................................................................ 843 Failure code [CA3321] KDPF Outlet Temp Sens Low Error............................................................................. 847 Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................................................ 850 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error.................................................................... 854 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error..................................................................... 855 Failure code [CA3741] Rail Press Valve Trip Error................................................................................. 857 Failure code [D110KB] Battery Relay Output Voltage................................................................................ 858 Failure code [D19JKZ] Personal Code Relay Abnormality............................................................................. 860 Failure code [D811MC] KOMTRAX Error............................................................................................... 863 Failure code [D862KA] GPS Antenna Open Circuit.................................................................................... 864 Failure code [D8ALKA] Operating Lamp Open Circuit(KOMTRAX)........................................................................ 865 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)...................................................................... 867 Failure code [D8AQKR] CAN2 Discon (KOMTRAX)....................................................................................... 868 Failure code [DA20MC] Pump Controller............................................................................................. 869 Failure code [DA22KK] Pump Solenoid Power Low Error............................................................................... 870 Failure code [DA25KP] 5V Sensor 1 Power Abnormality............................................................................... 872 Failure code [DA29KQ] Model Selection Abnormality................................................................................. 875 Failure code [DA2LKA] Operating Lamp Open Circuit(Pump Con)....................................................................... 877 Failure code [DA2LKB] Operating Lamp Short Circuit(Pump Con)...................................................................... 879 Failure code [DA2QKR] CAN2 Discon (Pump Con)...................................................................................... 880 Failure code [DA2QKR] CAN1 Discon (Pump Con)...................................................................................... 882 Failure code [DAF0MB] Monitor ROM Abnormality..................................................................................... 883 Failure code [DAF0MC] Monitor Error............................................................................................... 884 Failure code [DAF8KB] Camera Power Supply Short Circuit........................................................................... 885 Failure code [DAF9KQ] Model Selection Abnormality................................................................................. 887 Failure code [DAFGMC] GPS Module Error............................................................................................ 888 Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor)........................................................................ 889 Failure code [DAFLKB] Operating Lamp Short Circuit(Monitor)....................................................................... 891 Failure code [DAFQKR] CAN2 Discon (Monitor)....................................................................................... 892 Failure code [DAZ9KQ] A/C Model Selection Abnormality............................................................................. 893 Failure code [DAZQKR] CAN2 Discon (Aircon ECU).................................................................................... 894 Failure code [DB2QKR] CAN2 Discon (Engine Con).................................................................................... 898 Failure code [DB2RKR] CAN1 Discon (Engine Con).................................................................................... 903 Failure code [DGH2KB] Hyd Oil Sensor Short Circuit................................................................................ 907 Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit........................................................................ 909 Failure code [DHPAMA] F Pump Press Sensor Abnormality............................................................................. 910 Failure code [DHPBMA] R Pump Press Sensor Abnormality............................................................................. 913 Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality....................................................................... 916 Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality.................................................................... 918 Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality..................................................................... 921 Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality..................................................................... 924 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality....................................................................... 927 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality....................................................................... 930 Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality....................................................................... 933 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality.................................................................... 936 Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality.................................................................. 939 Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality.................................................................. 942 Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality.................................................................. 945 Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality.................................................................. 948 Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality....................................................................... 951 Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality....................................................................... 954 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality..................................................................... 957 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality..................................................................... 959 Failure code [DV20KB] Travel Alarm Short Circuit.................................................................................. 961 Failure code [DW43KA] Travel Speed Sol Open Circuit............................................................................... 963 Failure code [DW43KB] Travel Speed Sol Short Circuit.............................................................................. 965 Failure code [DW45KA] Swing Brake Sol Open Circuit................................................................................ 967 Failure code [DW45KB] Swing Brake Sol Short Circuit............................................................................... 969 Failure code [DW91KA] Travel Junction Sol Open Circuit............................................................................ 972 Failure code [DW91KB] Travel Junction Sol Short Circuit........................................................................... 974 Failure code [DWA2KA] Attachment Sol Open Circuit................................................................................. 976 Failure code [DWA2KB] Attachment Sol Short Circuit................................................................................ 978 Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit............................................................................. 980 Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit............................................................................ 982 Failure code [DWK2KA] Variable Back Press Sol Open Circuit........................................................................ 984 Failure code [DWK2KB] Variable Back Press Sol Short Circuit....................................................................... 986 Failure code [DWK8KA] Swing Press C/O Sol Open Circuit............................................................................ 988 Failure code [DWK8KB] Swing Press C/O Sol Short Circuit........................................................................... 990 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit................................................................................. 992 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit................................................................................ 994 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit................................................................................. 996 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit................................................................................ 998 Failure code [DXE0KA] LS-EPC Sol Open Circuit.....................................................................................1000 Failure code [DXE0KB] LS-EPC Sol Short Circuit....................................................................................1002 Failure code [DXE4KA] Attachment Flow EPC Open Circuit............................................................................1004 Failure code [DXE4KB] Attachment Flow EPC Short Circuit...........................................................................1006 Failure code [DXE5KA] Merge-divide Main Sol Open Circuit..........................................................................1008 Failure code [DXE5KB] Merge-divide Main Sol Short Circuit.........................................................................1010 Failure code [DXE6KA] Merge-divide LS Sol Open Circuit............................................................................1012 Failure code [DXE6KB] Merge-divide LS Sol Short Circuit...........................................................................1014 Failure code [DY20KA] Wiper Working Abnormality...................................................................................1016 Failure code [DY20MA] Wiper Parking Abnormality...................................................................................1018 Failure code [DY2CKB] Washer Drive Short Circuit..................................................................................1020 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit.............................................................................1022 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit.............................................................................1024 Troubleshooting of electrical system (E-mode).........................................................................................1026 E-1 Engine does not start (Engine does not rotate)................................................................................1026 E-2 Manual preheating system does not work........................................................................................1032 E-3 Automatic preheating system does not work.....................................................................................1035 E-4 Preheating monitor does not light up when preheater is operated...............................................................1037 E-5 When starting switch is turned to ON position, machine monitor displays nothing...............................................1039 E-6 When starting switch is turned to ON position (before starting engine), engine oil level monitor lights up in yellow..........1042 E-7 When starting switch is turned to ON position (before starting engine), radiator coolant level monitor lights up in yellow....1043 E-8 Coolant temperature monitor lights up in white while engine is running........................................................1044 E-9 Hydraulic oil temperature monitor lights up in white while engine is running..................................................1045 E-10 Charge level monitor lights up while engine is running.......................................................................1046 E-11 Fuel level monitor lights up in red while engine is running..................................................................1047 E-12 Air cleaner clogging monitor lights up in yellow while engine is running.....................................................1048 E-13 Water separator monitor lights up while engine is running....................................................................1049 E-14 Coolant temperature monitor lights up in red while engine is running.........................................................1050 E-15 Hydraulic oil temperature monitor lights up in red while engine is running...................................................1051 E-16 Engine oil pressure monitor lights up in red while engine is running.........................................................1052 E-17 Fuel gauge indicate either full or empty and does not move...................................................................1053 E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty).....................................................1054 E-19 Coolant temperature gauge indicate either Min or Max and does not move.......................................................1055 E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min nor Max)....................................1056 E-21 Hydraulic oil temperature gauge indicate either Min or Max and does not move.................................................1057 E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min nor Max)..............................1059 E-23 Content of display on machine monitor is different from that of actual machine...............................................1060 E-24 Machine monitor does not display some items..................................................................................1061 E-25 Function switch does not work................................................................................................1062 E-26 Automatic preheating system does not work (In cold season)...................................................................1063 E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration switch is operated.....................1064 E-28 Auto-deceleration is not actuated or canceled when lever is operated.........................................................1065 E-29 Working mode selector screen selection screen is not diplayed when working mode switch is operated...........................1067 E-30 Engine or hydraulic pump setting does not change when working mode is changed................................................1068 E-31 Travel speed monitor does not change when travel speed switch is operated....................................................1069 E-32 Travel speed does not change when travel speed is shifted....................................................................1070 E-33 Alarm buzzer does not stop sounding..........................................................................................1071 E-34 When starting switch is turned to OFF position, service meter is notdis played...............................................1072 E-35 Service mode cannot be selected..............................................................................................1073 E-36 Any of work equipment, swing and travel does not work........................................................................1074 E-37 Any of work equipment, swing and travel can not be locked....................................................................1076 E-38 Machine can not swing while swing brake cancel switch is canceled............................................................1077 E-39 Swing brake does not operate while swing brake cancel switch is locked.......................................................1079 E-40 One-touch power maximizing function does not work or monitor is not displayed................................................1081 E-41 One-touch power maximizing function cannot be released.......................................................................1083 E-42 Travel alarm does not sound when machine travels.............................................................................1084 E-43 Travel alarm does not stop sounding when machine stops.......................................................................1085 E-44 Horn does not sound..........................................................................................................1086 E-45 Horn does not stop sounding..................................................................................................1088 E-46 Wiper monitor does not light up or go out when wipper switch is operated.....................................................1089 E-47 Wiper does not operate when wipper switch is operated........................................................................1090 E-48 Window washer does not operate when window washer switch is operated.........................................................1092 E-49 BOOM LOWER indication is not displayed properly with monitoring function.....................................................1093 E-50 ARM DUMP indication is not displayed properly with monitoring function.......................................................1094 E-51 ARM IN indication is not displayed properly with monitoring function.........................................................1095 E-52 BOOM RAISE indication is not displayed properly with monitoring function.....................................................1096 E-53 BUCKET CURL indication is not displayed properly with monitoring function....................................................1097 E-54 BUCKET DUMP indication is not displayed properly with monitoring function....................................................1098 E-55 SWING indication is not displayed properly with monitoring function..........................................................1099 E-56 TRAVEL indication is not displayed properly with monitoring function.........................................................1100 E-57 Service is not displayed properly with monitoring function...................................................................1101 E-58 Attachment hydraulic circuit cannot be changed...............................................................................1104 E-59 KOMTRAX system does not work properly........................................................................................1105 Troubleshooting of hydraulic and mechanical system (H-mode)...........................................................................1106 Information mentioned in troubleshooting table (H mode)...........................................................................1106 System chart for hydraulic system.................................................................................................1107 Failure mode and cause table......................................................................................................1109 H-1 All of work equipment, swing and travel operation lacks speed or power........................................................1117 H-2 Engine speed lowers significantly or engine stalls............................................................................1120 H-3 Any of work equipment, swing and travel does not work.........................................................................1122 H-4 Unusual sound is heard from around hydraulic pump.............................................................................1123 H-5 Fine control performance or response is poor..................................................................................1124 H-6 Boom operation lacks speed or power...........................................................................................1125 H-7 Arm operation lacks speed or power............................................................................................1127 H-8 Bucket operation lacks speed or power.........................................................................................1129 H-9 Work equipment does not move in single operation..............................................................................1130 H-10 Hydraulic drift of boom is large.............................................................................................1131 H-11 Hydraulic drift of arm is large..............................................................................................1132 H-12 Hydraulic drift of bucket is large...........................................................................................1133 H-13 Time lag of work equipment is large..........................................................................................1134 H-14 When part of work equipment is relieved singly, other parts of work equipment move...........................................1136 E-15 One-touch power maximizing function does not work............................................................................1137 H-16 In combined operation of work equipment, equipment having heavier load moves slower..........................................1138 H-17 In combined operations of swing and boom RAISE, boom rising speed is low.....................................................1139 H-18 In combined operations of swing and travel, travel speed drops largely.......................................................1140 H-19 Machine does not travel straight.............................................................................................1141 H-20 Travel speed is too low......................................................................................................1142 H-21 Machine is hard to steer or travel power is low..............................................................................1144 H-22 Travel speed does not change, or travel speed is too low or high.............................................................1146 H-23 One of tracks dose not run...................................................................................................1147 H-24 Upper structure does not swing to the right or left..........................................................................1148 H-25 Upper structure swing only to the right or left..............................................................................1149 H-26 Swing acceleration is poor or swing speed is low (both right and left).......................................................1150 H-27 Swing acceleration is poor or swing speed is low (either right or left)......................................................1151 H-28 Upper structure overruns excessively when it stops swinging (both right and left)............................................1152 H-29 Upper structure overruns excessively when it stops swinging (either right or left)...........................................1153 H-30 Shock is large when upper structure stops swinging...........................................................................1154 H-31 Large unusual noise is heard when upper structure stops swinging.............................................................1155 H-32 Swing drift on a slope is large while swing holding brake is applied.........................................................1156 H-33 Swing drift on a slope is large while swing holding brake is released........................................................1157 H-34 Attachment circuit cannot be changed while attachment is installed...........................................................1158 H-35 Oil flow in attachment circuit cannot be controlled..........................................................................1159 Troubleshooting of engine (S-mode)....................................................................................................1160 Information mentioned in troubleshooting table (S mode)...........................................................................1160 S-1 When starting switch is turned to START position, engine does not crank.......................................................1161 S-2 When engine cranks, smoke does not come out...................................................................................1162 S-3 Engine does not start while fuel is injected (Incomplete combustion)..........................................................1163 S-4 Startability is poor..........................................................................................................1164 S-5 Engine does not pick up smoothly..............................................................................................1166 S-6 Engine stops during operation.................................................................................................1167 S-7 Engine runs rough or is unstable..............................................................................................1169 S-8 Engine lacks power............................................................................................................1170 S-9 Exhaust smoke is black (KDPF clogs up early)..................................................................................1172 S-10 Engine oil consumption is too much...........................................................................................1174 S-11 Oil becomes contaminated early...............................................................................................1175 S-12 Fuel consumption is excessive................................................................................................1176 S-13 Oil is in coolant (or coolant spurts or coolant level goes down).............................................................1177 S-14 Engine oil pressure drops....................................................................................................1178 S-15 Fuel is contaminated in engine oil...........................................................................................1179 S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white).............................................................1180 S-17 Coolant temperature rises too high (Overheating).............................................................................1181 S-18 Unusual noise is heard.......................................................................................................1182 S-19 Vibration is excessive.......................................................................................................1183 S-20 Automatic regeneration is operated frequently................................................................................1184 S-21 Active regeneration is operated for long.....................................................................................1185 S-22 White smoke comes out in the process of active regeneration..................................................................1186 50 Disassembly and assembly...............................................................................................................1187 General information on disassembly and assembly.......................................................................................1190 How to read this manual...........................................................................................................1190 Coating materials list............................................................................................................1192 Special tools list................................................................................................................1196 Sketches of special tools.........................................................................................................1200 Engine and cooling system.............................................................................................................1203 Removal and installation of supply pump assembly..................................................................................1203 Removal and installation of injector assembly.....................................................................................1208 Removal and installation of cylinder head assembly................................................................................1217 Removal and installation of radiator assembly.....................................................................................1237 Removal and installation of hydraulic oil cooler assembly.........................................................................1239 Removal and installation of aftercooler assembly Removal..........................................................................1242 Removal and installation of engine and main pump assembly.........................................................................1244 Removal and installation of engine front oil seal.................................................................................1256 Removal and installation of engine rear oil seal..................................................................................1260 Removal and installation of fuel cooler assembly..................................................................................1263 Removal and installation of fuel tank assembly....................................................................................1264 Removal and installation of engine hood assembly..................................................................................1267 Removal and installation of KDPF assembly.........................................................................................1270 Disassembly and assembly of KDPF..................................................................................................1278 Removal and installation of KCCV assembly.........................................................................................1286 Removal and installation of air cleaner assembly..................................................................................1288 Power train system....................................................................................................................1291 Removal and installation of travel motor and final drive assembly.................................................................1291 Disassembly and assembly of final drive...........................................................................................1292 Removal and installation of swing motor and swing machinery assembly..............................................................1300 Disassembly and assembly of swing machinery.......................................................................................1303 Removal and installation of swing circle assembly.................................................................................1311 Undercarriage and frame...............................................................................................................1312 Separation and connection of track shoe assembly..................................................................................1312 Removal and installation of sprocket..............................................................................................1314 Removal and installation of idler and idler cushion assembly......................................................................1315 Disassembly and assembly of idler.................................................................................................1316 Disassembly and assembly of idler cushion.........................................................................................1319 Disassembly and assembly of track roller..........................................................................................1321 Disassembly and assembly of carrier roller........................................................................................1323 Removal and installation of revolving frame assembly..............................................................................1326 Removal and installation of counterweight assembly................................................................................1328 Hydraulic system......................................................................................................................1331 Removal and installation of center swivel joint assembly..........................................................................1331 Disassembly and assembly of center swivel joint...................................................................................1333 Removal and installation of hydraulic tank assembly...............................................................................1334 Removal and installation of main pump assembly....................................................................................1338 Removal and installation of control valve assembly................................................................................1342 Disassembly and assembly of control valve.........................................................................................1349 Disassembly and assembly of work equipment PPC valve..............................................................................1353 Disassembly and assembly of travel PPC valve......................................................................................1355 Work equipment........................................................................................................................1358 Removal and installation of work equipment assembly...............................................................................1358 Disassembly and assembly of work equipment cylinder...............................................................................1361 Cab and its attachments...............................................................................................................1367 Removal and installation of operator's cab assembly...............................................................................1367 Removal and installation of operator cab glass (adhered glass)....................................................................1372 Removal and installation of front window assembly.................................................................................1380 Removal and installation of floor frame assembly..................................................................................1386 Removal and installation of air conditioner unit assembly.........................................................................1392 Removal and installation of operator's seat.......................................................................................1396 Removal and installation of seat belt.............................................................................................1398 Removal and installation of front wiper assembly..................................................................................1400 Electric system.......................................................................................................................1406 Removal and installation of air conditioner compressor assembly...................................................................1406 Removal and installation of air conditioner condenser assembly....................................................................1409 Removal and installation of engine controller assembly............................................................................1411 Removal and installation of pump controller assembly..............................................................................1413 Removal and installation of machine monitor assembly..............................................................................1416 Removal and installation of pump swash plate sensor...............................................................................1418 Removal and installation of Mass air flow and temperature sensor..................................................................1419 Removal and installation of KOMTRAX terminal assembly.............................................................................1420 60 Maintenance standard...................................................................................................................1421 Engine and cooling system.............................................................................................................1423 Engine mount......................................................................................................................1423 Cooling system....................................................................................................................1424 Power train system....................................................................................................................1425 Swing circle......................................................................................................................1425 Swing machinery...................................................................................................................1426 Final drive.......................................................................................................................1428 Sprocket..........................................................................................................................1430 Undercarriage and frame...............................................................................................................1432 Truck frame and idler cushion.....................................................................................................1432 Idler.............................................................................................................................1434 Track roller......................................................................................................................1436 Carrier roller....................................................................................................................1438 Truck shoe........................................................................................................................1439 Hydraulic system......................................................................................................................1442 Hydraulic tank....................................................................................................................1442 Main pump.........................................................................................................................1443 Control valve ....................................................................................................................1444 Swing motor.......................................................................................................................1452 Travel motor......................................................................................................................1454 PPC valve.........................................................................................................................1457 Solenoid valve....................................................................................................................1466 Attachment circuit selector valve (for high-pressure circuit).....................................................................1467 Attachment circuit selector valve (for low-pressure circuit)......................................................................1468 Center swivel joint...............................................................................................................1469 Work equipment....................................................................................................................1470 80 Appendix...............................................................................................................................1481 Air conditioner.......................................................................................................................1483 Precautions for refrigerant.......................................................................................................1483 Air conditioner component.........................................................................................................1484 Configuration and function of refrigeration cycle.................................................................................1486 Outline of refrigeration cycle....................................................................................................1487 Air conditioner unit..............................................................................................................1489 Dual pressure switch..............................................................................................................1495 Air conditioner controller........................................................................................................1496 Air conditioner compressor........................................................................................................1497 Air conditioner condenser.........................................................................................................1498 Sunlight sensor...................................................................................................................1500 Outside air temperature sensor....................................................................................................1501 Procedure for testing and troubleshooting.........................................................................................1502 Circuit diagram and arrangement of connector pins.................................................................................1504 System diagram....................................................................................................................1506 Input and output signals of the air conditioner controller........................................................................1507 Parts and connectors layout.......................................................................................................1509 Layout of air conditioner related parts and connectors............................................................................1510 Testing air leakage (duct)........................................................................................................1513 Testing with self-diagnosis function..............................................................................................1516 How to enter air conditioner "Electrical Systems" screen in service mode of the machine monitor...................................1517 Testing vent (mode) changeover....................................................................................................1519 Testing FRESH/RECIRC air changeover...............................................................................................1521 Testing sunlight sensor...........................................................................................................1522 Testing (dual) pressure switch for refrigerant....................................................................................1523 Testing relays....................................................................................................................1525 Troubleshooting chart 1...........................................................................................................1526 Troubleshooting chart 2...........................................................................................................1527 Information mentioned in troubleshooting table....................................................................................1530 Failure code list related to air conditioner......................................................................................1531 Failure code [879AKA] A/C Inner sensor Open Circuit...............................................................................1532 Failure code [879AKB] A/C Inner sensor Short Circuit..............................................................................1533 Failure code [879BKA] A/C Outer sensor Open Circuit...............................................................................1534 Failure code [879BKB] A/C Outer sensor Short Circuit..............................................................................1536 Failure code [879CKA] Ventilating sensor Open Circuit.............................................................................1538 Failure code [879CKB] Ventilating sensor Short Circuit............................................................................1539 Failure code [879DKZ] Sunlight sensor Open or Short Circuit.......................................................................1540 Failure code [879EMC] Ventilating Damper Abnormality..............................................................................1542 Failure code [879FMC] Air Mix Damper Abnormality..................................................................................1543 Failure code [879GKX] Refrigerant Abnormality.....................................................................................1544 A-2 Troubleshooting of compressor system (Air is not cooled)......................................................................1547 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)............................................1550 A-4 Troubleshooting for FRESH/RECIRC air changeover...............................................................................1552 Troubleshooting with gauge pressure...............................................................................................1554 Testing refrigerant pressure......................................................................................................1557 Precautions for disconnecting and connecting air conditioner piping...............................................................1560 Handling of compressor oil........................................................................................................1562 Desiccant replacement.............................................................................................................1564 90 Diagrams and drawings..................................................................................................................1567 Hydraulic circuit diagram.............................................................................................................1569 Symbols in hydraulic circuit diagram..............................................................................................1569 Hydraulic circuit diagram.........................................................................................................1573 Electric circuit diagram..............................................................................................................1574 Symbols in electric circuit diagram...............................................................................................1574 Electrical circuit diagram........................................................................................................1577 Electrical circuit diagram for air conditioner unit...............................................................................1583 Index.....................................................................................................................................1585
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
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