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KOMATSU PC490LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:80001 and up) – PDF Download
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- KOMATSU PC490LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL
- SERIAL NUMBER:80001 and up
- PUBLICATION NUMBER:SEN05622-02
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Description
KOMATSU PC490LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:80001 and up)
KOMATSU PC490LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:80001 AND UP) – PDF DOWNLOAD:
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DESCRIPTION:
KOMATSU PC490LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:80001 and 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 PC490LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SN:80001 and up)
Cover.................................................................................................................................... 1 00 Index and foreword ................................................................................................................... 3 Index ............................................................................................................................... 4 Foreword, safety and general information ............................................................................................ 16 Important safety notice ......................................................................................................... 16 How to read the shop manual ..................................................................................................... 21 Explanation of terms for maintenance standard ................................................................................... 23 Handling equipment of fuel system devices ....................................................................................... 25 Handling of intake system parts ................................................................................................. 26 Handling of hydraulic equipment ................................................................................................. 27 Method of disconnecting and connecting of push-pull type coupler ................................................................ 29 Handling of electrical equipment ................................................................................................ 32 How to read electric wire code .................................................................................................. 40 Precautions when performing operation ........................................................................................... 43 Standard tightening torque table ................................................................................................ 48 List of abbreviation ............................................................................................................ 54 Conversion table ................................................................................................................ 59 01 Specification ........................................................................................................................ 65 Table of contents ................................................................................................................... 66 Specifications ...................................................................................................................... 67 Specification drawing ........................................................................................................... 67 Working range drawing ........................................................................................................... 68 Specification ................................................................................................................... 69 Table of weight ................................................................................................................. 72 Table of fuel, coolant and lubricants ........................................................................................... 73 10 Structure and function ............................................................................................................... 75 Table of contents ................................................................................................................... 76 Engine and cooling system ........................................................................................................... 77 Engine-related parts ............................................................................................................ 77 Cooling system .................................................................................................................. 79 Cooling fan pump ................................................................................................................ 82 Cooling fan motor ............................................................................................................... 92 Power train ......................................................................................................................... 100 Power train ..................................................................................................................... 100 Swing circle .................................................................................................................... 102 Swing machinery ................................................................................................................. 103 Final drive ..................................................................................................................... 105 Undercarriage and frame ............................................................................................................. 107 Track frame and idler cushion ................................................................................................... 107 Hydraulic system .................................................................................................................... 109 Hydraulic component layout ...................................................................................................... 109 Valve control ................................................................................................................... 111 Hydraulic tank .................................................................................................................. 113 CLSS ............................................................................................................................ 116 Main pump ....................................................................................................................... 121 Control valve ................................................................................................................... 144 Swing motor ..................................................................................................................... 199 Travel motor .................................................................................................................... 210 PPC valve ....................................................................................................................... 225 Solenoid valve .................................................................................................................. 244 Attachment circuit selector valve ............................................................................................... 247 Center swivel joint ............................................................................................................. 250 Accumulator ..................................................................................................................... 252 Work equipment ...................................................................................................................... 253 Work equipment .................................................................................................................. 253 Work equipment shims ............................................................................................................ 254 Bucket play adjustment shim ..................................................................................................... 255 Cab and its attachments ............................................................................................................. 256 Cab mount and cab tipping stopper ............................................................................................... 256 ROPS cab ........................................................................................................................ 257 Electrical system ................................................................................................................... 258 Electrical control system ....................................................................................................... 258 Machine monitor system .......................................................................................................... 307 KOMTRAX system .................................................................................................................. 325 Sensor .......................................................................................................................... 327 20 Standard value tables ................................................................................................................ 345 Table of contents ................................................................................................................... 346 Standard service value table ........................................................................................................ 347 Standard value table for engine ................................................................................................. 347 Standard value table for machine ................................................................................................ 349 30 Testing and adjusting ................................................................................................................ 363 Table of contents ................................................................................................................... 364 Related information on testing and adjusting ........................................................................................ 365 Tools for testing and adjusting ................................................................................................. 365 Sketch of tools for testing and adjusting ....................................................................................... 368 Engine and cooling system ........................................................................................................... 370 Testing engine speed ............................................................................................................ 370 Testing boost pressure .......................................................................................................... 371 Testing exhaust gas color ....................................................................................................... 373 Testing and adjusting valve clearance ........................................................................................... 375 Testing compression pressure .................................................................................................... 378 Testing blowby pressure ......................................................................................................... 380 Testing engine oil pressure ..................................................................................................... 381 Testing EGR valve and KVGT oil pressure ......................................................................................... 382 Testing fuel pressure ........................................................................................................... 383 Testing fuel leakage and return ................................................................................................. 385 Bleeding air from fuel system ................................................................................................... 388 Testing fuel circuit for leakage ................................................................................................ 390 Handling cylinder cutout mode operation ......................................................................................... 391 Handling no-injection cranking operation ........................................................................................ 392 Checking and adjusting air conditioner compressor belt tension .................................................................. 393 Replacing alternator belt ....................................................................................................... 394 Fuel doser cleaning procedure ................................................................................................... 395 Writing compensation values at replacement of injector and engine controller .................................................... 398 Power train ......................................................................................................................... 402 Testing swing circle bearing clearance .......................................................................................... 402 Undercarriage and frame ............................................................................................................. 403 Testing and adjusting track tension ............................................................................................. 403 Hydraulic system .................................................................................................................... 404 Releasing remaining pressure from hydraulic circuit ............................................................................. 404 Testing and adjusting oil pressure in work equipment, swing and travel circuits ................................................. 405 Testing oil pressure in control circuit ......................................................................................... 410 Testing and adjusting oil pressure in pump PC control circuit ................................................................... 411 Testing and adjusting oil pressure in pump LS control circuit ................................................................... 414 Testing output pressure of solenoid valve ....................................................................................... 419 Testing PPC valve output pressure ............................................................................................... 423 Adjusting play of work equipment and swing PPC valves ........................................................................... 425 Testing pump swash plate sensor ................................................................................................. 426 Testing fan speed ............................................................................................................... 427 Testing fan pump circuit oil pressure ........................................................................................... 428 Checking fan pump EPC current ................................................................................................... 429 Testing fan pump EPC solenoid valve output pressure ............................................................................. 430 Isolating the parts causing hydraulic drift in work equipment ................................................................... 431 Testing oil leakage ............................................................................................................. 433 Bleeding air from hydraulic circuit ............................................................................................. 436 Cab and its attachments ............................................................................................................. 439 Checking cab tipping stopper .................................................................................................... 439 Adjusting mirrors ............................................................................................................... 440 Electrical system ................................................................................................................... 443 Special functions of machine monitor ............................................................................................ 443 Adjusting rearview camera angle ................................................................................................. 512 Handling voltage circuit of engine controller ................................................................................... 514 Handling battery disconnect switch .............................................................................................. 515 Testing diodes .................................................................................................................. 516 Pm clinic ........................................................................................................................... 517 Check sheet ..................................................................................................................... 521 40 Troubleshooting ...................................................................................................................... 527 Table of contents ................................................................................................................... 528 Related information on troubleshooting .............................................................................................. 535 Troubleshooting points .......................................................................................................... 535 Sequence of events in troubleshooting ........................................................................................... 537 Checks before troubleshooting ................................................................................................... 539 Inspection procedure before troubleshooting ..................................................................................... 541 Preparation for troubleshooting of electrical system ............................................................................ 558 Classification and procedure for troubleshooting ................................................................................ 564 Symptom and troubleshooting numbers ............................................................................................. 567 Information in troubleshooting table ............................................................................................ 570 Connector list and layout ....................................................................................................... 572 Connector contact identification ................................................................................................ 583 T-branch box and T-branch adapter table ......................................................................................... 621 Connection table of fuse box .................................................................................................... 626 Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ................................................................... 628 Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) ................................................. 631 Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) ..................................... 632 Failure codes table ............................................................................................................. 633 Troubleshooting by failure code (Display of code) ................................................................................... 642 Failure code [879AKA] A/C Inner Sensor Open Circuit ............................................................................. 642 Failure code [879AKB] A/C Inner Sensor Short Circuit ............................................................................ 643 Failure code [879BKA] A/C Outer Sensor Open Circuit ............................................................................. 644 Failure code [879BKB] A/C Outer Sensor Short Circuit ............................................................................ 645 Failure code [879CKA] Ventilating Sensor Open Circuit ........................................................................... 646 Failure code [879CKB] Ventilating Sensor Short Circuit .......................................................................... 647 Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit ..................................................................... 648 Failure code [879EMC] Ventilation Damper Abnormality ............................................................................ 649 Failure code [879FMC] Air Mix Damper Abnormality ................................................................................ 650 Failure code [879GKX] Refrigerant Abnormality ................................................................................... 651 Failure code [989L00] Engine Controller Lock Caution 1 .......................................................................... 652 Failure code [989M00] Engine Controller Lock Caution 2 .......................................................................... 653 Failure code [989N00] Engine Controller Lock Caution 3 .......................................................................... 654 Failure code [A1U0N3] HC Desorb Request 1 ....................................................................................... 655 Failure code [A1U0N4] HC Desorb Request 2 ....................................................................................... 657 Failure code [AA10NX] Air Cleaner Clogging ...................................................................................... 659 Failure code [AB00KE] Charge Voltage Low ........................................................................................ 661 Failure code [B@BAZG] Eng Oil Press Low ......................................................................................... 663 Failure code [B@BAZK] Eng Oil Level Low ......................................................................................... 664 Failure code [B@BCNS] Eng Water Overheat ........................................................................................ 665 Failure code [B@BCZK] Eng Water Level Low ....................................................................................... 666 Failure code [B@HANS] Hyd Oil Overheat .......................................................................................... 668 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................................... 669 Failure code [CA122] Chg Air Press Sensor High Error ............................................................................ 670 Failure code [CA123] Chg Air Press Sensor Low Error ............................................................................. 672 Failure code [CA131] Throttle Sensor High Error ................................................................................. 674 Failure code [CA132] Throttle Sensor Low Error .................................................................................. 676 Failure code [CA135] Eng Oil Press Sensor High Error ............................................................................ 678 Failure code [CA141] Eng Oil Press Sensor Low Error ............................................................................. 680 Failure code [CA144] Coolant Temp Sens High Error ............................................................................... 682 Failure code [CA145] Coolant Temp Sens Low Error ................................................................................ 684 Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................. 686 Failure code [CA154] Chg Air Temp Sensor Low Error .............................................................................. 688 Failure code [CA187] Sensor 2 Supply Volt Low Error ............................................................................. 690 Failure code [CA221] Ambient Press Sensor High Error ............................................................................ 692 Failure code [CA222] Ambient Press Sensor Low Error ............................................................................. 694 Failure code [CA227] Sensor 2 Supply Volt High Error ............................................................................ 696 Failure code [CA234] Eng Overspeed .............................................................................................. 697 Failure code [CA238] Ne Speed Sensor Supply Volt Error .......................................................................... 698 Failure code [CA239] Ne Speed Sens Supply Volt High Error ....................................................................... 699 Failure code [CA271] IMV/PCV1 Short Error ....................................................................................... 700 Failure code [CA272] IMV/PCV1 Open Error ........................................................................................ 701 Failure code [CA273] PCV2 Short Error ........................................................................................... 702 Failure code [CA274] PCV2 Open Error ............................................................................................ 703 Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................................... 704 Failure code [CA323] Inj #5(L#5) Open/Short Error ............................................................................... 706 Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................................... 708 Failure code [CA325] Inj #6(L#6) Open/Short Error ............................................................................... 710 Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................................... 712 Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................................... 714 Failure code [CA343] ECM Critical Internal Failure .............................................................................. 716 Failure code [CA351] Injectors Drive Circuit Error .............................................................................. 717 Failure code [CA352] Sensor 1 Supply Volt Low Error ............................................................................. 718 Failure code [CA356] Mass Air Flow Sensor High Error ............................................................................ 720 Failure code [CA357] Mass Air Flow Sensor Low Error ............................................................................. 722 Failure code [CA386] Sensor 1 Supply Volt High Error ............................................................................ 724 Failure code [CA441] Battery Voltage Low Error .................................................................................. 725 Failure code [CA442] Battery Voltage High Error ................................................................................. 727 Failure code [CA449] Rail Press Very High Error ................................................................................. 728 Failure code [CA451] Rail Press Sensor High Error ............................................................................... 729 Failure code [CA452] Rail Press Sensor Low Error ................................................................................ 731 Failure code [CA515] Rail Press Sens Sup Volt High Error ........................................................................ 733 Failure code [CA516] Rail Press Sens Sup Volt Low Error ......................................................................... 735 Failure code [CA553] Rail Press High Error ...................................................................................... 737 Failure code [CA555] Crankcase Press High Error 1 ............................................................................... 738 Failure code [CA556] Crankcase Press High Error 2 ............................................................................... 739 Failure code [CA559] Rail Press Low Error ....................................................................................... 740 Failure code [CA595] Turbo Speed High Error 2 ................................................................................... 744 Failure code [CA687] Turbo Speed Low Error ...................................................................................... 745 Failure code [CA689] Eng Ne Speed Sensor Error .................................................................................. 747 Failure code [CA691] Intake Temperature Sensor High Error ....................................................................... 749 Failure code [CA692] Intake Temperature Sensor Low Error ........................................................................ 751 Failure code [CA697] ECM Internal Temp Sensor High Error ........................................................................ 753 Failure code [CA698] ECM Int Temp Sensor Low Error .............................................................................. 754 Failure code [CA731] Eng Bkup Speed Sens Phase Error ............................................................................ 755 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................ 756 Failure code [CA1117] Persistent Data Lost Error ................................................................................ 758 Failure code [CA1664] KDOC Malfunction .......................................................................................... 759 Failure code [CA1691] Regeneration Ineffective .................................................................................. 762 Failure code [CA1695] Sens supply 5 volt high error ............................................................................. 765 Failure code [CA1696] Sens supply 5 volt low error .............................................................................. 766 Failure code [CA1843] Crankcase Pressure Sensor High Error ...................................................................... 768 Failure code [CA1844] Crankcase Press Sensor Low Error .......................................................................... 770 Failure code [CA1879] KDPF Delta Pressure Sensor High Error ..................................................................... 772 Failure code [CA1881] KDPF Delta Pressure Sensor Low Error ...................................................................... 774 Failure code [CA1883] KDPF Delta Pressure Sensor In Range Error ................................................................. 776 Failure code [CA1921] KDPF Soot Load High Error 1 ............................................................................... 779 Failure code [CA1922] KDPF Soot Load High Error 2 ............................................................................... 782 Failure code [CA1923] Dosing Fuel Valve 1 High Error ............................................................................ 787 Failure code [CA1924] Dosing Fuel Valve 1 Low Error ............................................................................. 789 Failure code [CA1925] Dosing Fuel Valve 1 In Range Error ........................................................................ 791 Failure code [CA1927] Dosing Fuel Press Sens High Error ......................................................................... 793 Failure code [CA1928] Dosing Fuel Press Sens Low Error .......................................................................... 795 Failure code [CA1942] Crankcase Press Sens In Range Error ....................................................................... 797 Failure code [CA1963] Dosing Fuel Valve 1 Servo Error ........................................................................... 798 Failure code [CA1977] Fuel Doser Open/Short Error ............................................................................... 800 Failure code [CA1993] KDPF Delta Pressure Low Error ............................................................................. 802 Failure code [CA2185] Throt Sensor Sup Volt High Error .......................................................................... 804 Failure code [CA2186] Throt Sensor Sup Volt Low Error ........................................................................... 806 Failure code [CA2249] Rail Press Very Low Error ................................................................................. 808 Failure code [CA2265] Fuel feed pump open circuit error ......................................................................... 809 Failure code [CA2266] Fuel feed pump short circuit error ........................................................................ 811 Failure code [CA2271] EGR Valve Pos Sens High Error ............................................................................. 813 Failure code [CA2272] EGR Valve Pos Sens Low Error .............................................................................. 815 Failure code [CA2349] EGR Valve Solenoid Open Error ............................................................................. 817 Failure code [CA2353] EGR Valve Solenoid Short Error ............................................................................ 819 Failure code [CA2357] EGR Valve Servo Error ..................................................................................... 821 Failure code [CA2381] KVGT Pos Sens High Error .................................................................................. 822 Failure code [CA2382] KVGT Pos Sens Low Error ................................................................................... 824 Failure code [CA2383] KVGT Solenoid Open Error .................................................................................. 826 Failure code [CA2386] KVGT Solenoid Short Error ................................................................................. 828 Failure code [CA2387] KVGT Servo Error .......................................................................................... 830 Failure code [CA2555] Grid Htr Relay Open Circuit Error ......................................................................... 831 Failure code [CA2556] Grid Htr Relay Short Circuit Error ........................................................................ 833 Failure code [CA2637] KDOC Face Plugging ........................................................................................ 835 Failure code [CA2639] Manual Stationary Regeneration Request .................................................................... 837 Failure code [CA2732] Dosing Fuel Valve 2 High Error ............................................................................ 840 Failure code [CA2733] Dosing Fuel Valve 2 Low Error ............................................................................. 842 Failure code [CA2741] Dosing Fuel Valve Swap Error .............................................................................. 844 Failure code [CA2765] Inj Trim Data Error ....................................................................................... 846 Failure code [CA2878] Dosing Fuel Valve 2 Servo Error ........................................................................... 847 Failure code [CA2881] Dosing Fuel Pressure Low Error 1 .......................................................................... 850 Failure code [CA3133] KDPF Outlet Pressure Sensor High Error .................................................................... 855 Failure code [CA3134] KDPF Outlet Pressure Sensor Low Error ..................................................................... 857 Failure code [CA3135] KDPF Outlet Pressure Sensor In Range Error ................................................................ 859 Failure code [CA3167] Fuel Doser Degradation .................................................................................... 863 Failure code [CA3251] KDOC Inlet Temperature High Error ......................................................................... 866 Failure code [CA3253] KDOC Temp Error - Non Regeneration ........................................................................ 869 Failure code [CA3254] KDOC Outlet Temp High Error 1 ............................................................................. 872 Failure code [CA3255] KDPF Temp Error - Non Regeneration ........................................................................ 875 Failure code [CA3256] KDPF Outlet Temp High Error 1 ............................................................................. 879 Failure code [CA3311] KDOC Outlet Temp High Error 2 ............................................................................. 882 Failure code [CA3312] KDPF Outlet Temp High Error 2 ............................................................................. 885 Failure code [CA3313] KDOC Inlet Temperature Sensor Low Error ................................................................... 888 Failure code [CA3314] KDOC Inlet Temperature Sensor High Error .................................................................. 891 Failure code [CA3315] KDOC Intlet Temperature Sensor In Range Error ............................................................. 895 Failure code [CA3316] KDOC Outlet Temperature Sensor Low Error .................................................................. 900 Failure code [CA3317] KDOC Outlet Temperature Sensor High Error ................................................................. 903 Failure code [CA3318] KDOC Outlet Temp Sensor In Range Error .................................................................... 907 Failure code [CA3319] KDPF Outlet Temperature Sensor High Error ................................................................. 912 Failure code [CA3321] KDPF Outlet Temperature Sensor Low Error .................................................................. 916 Failure code [CA3322] KDPF Outlet Temp Sensor In Range Error .................................................................... 919 Failure code [CA3419] Mass Air Flow Sensor Power Supply High Error .............................................................. 924 Failure code [CA3421] Mass Air Flow Sensor Power Supply Low Error ............................................................... 926 Failure code [D110KB] Battery Relay Drive S/C ................................................................................... 928 Failure code [D19JKZ] Personal Code Relay Abnormality ........................................................................... 930 Failure code [D811MC] KOMTRAX Error ............................................................................................. 933 Failure code [D862KA] GPS Antenna Open Circuit .................................................................................. 934 Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) ..................................................................... 935 Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) .................................................................... 937 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ..................................................................................... 938 Failure code [DA20MC] Pump Controller Malfunction ............................................................................... 939 Failure code [DA22KK] Pump Solenoid Power Low Error ............................................................................. 940 Failure code [DA25KP] 5V Sensor1 Power Abnormality .............................................................................. 942 Failure code [DA29KQ] Model Selection Abnormality ............................................................................... 944 Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) .................................................................... 947 Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) ................................................................... 949 Failure code [DA2QKR] CAN2 Discon (Pump Con) .................................................................................... 950 Failure code [DA2RKR] CAN1 Discon ( Pump Con) ................................................................................... 953 Failure code [DAF0MB] Monitor ROM Abnormality ................................................................................... 954 Failure code [DAF0MC] Monitor Error ............................................................................................. 955 Failure code [DAF8KB] Camera Power Supply Short Circuit ......................................................................... 956 Failure code [DAF9KQ] Model Selection Abnormality ............................................................................... 958 Failure code [DAFGMC] GPS Module Error .......................................................................................... 959 Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) ..................................................................... 960 Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) .................................................................... 962 Failure code [DAFQKR] CAN2 Discon (Monitor) ..................................................................................... 963 Failure code [DAZ9KQ] AC Model Selection Abnormality ............................................................................ 964 Failure code [DAZQKR] CAN2 Discon (AC) .......................................................................................... 965 Failure code [DB2QKR] CAN2 Discon (Engine Con) .................................................................................. 970 Failure code [DB2RKR] CAN1 Discon (Engine Con) .................................................................................. 975 Failure code [DGH2KA] Hyd Oil Temp Sensor Open .................................................................................. 980 Failure code [DGH2KB] Hyd Oil Sensor Short Circuit .............................................................................. 982 Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit .................................................................. 984 Failure code [DHPAMA] Pump Press Sensor Abnormality ............................................................................. 986 Failure code [DHPBMA] R Pump Press Sensor Abnormality ........................................................................... 989 Failure code [DHS3MA] Arm IN PPC Sen. Abnormality ............................................................................... 992 Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality .................................................................. 994 Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality ................................................................... 997 Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality .......................................................................1000 Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality ......................................................................1003 Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality ......................................................................1006 Failure code [DHSCMA] Arm OUT PPC Press Sensor Abnormality ......................................................................1009 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ..................................................................1012 Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality ..................................................................1015 Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality ..................................................................1018 Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality ..................................................................1021 Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality ..................................................................1024 Failure code [DKR0MA] F pump S/P sensor Abnormality .............................................................................1027 Failure code [DKR1MA] R pump S/P sensor Abnormality .............................................................................1029 Failure code [DLM3KA] Fan speed sensor: Open circuit ............................................................................1031 Failure code [DLM3KB] Fan Speed Sensor Short Circuit ............................................................................1032 Failure code [DLM3MB] Fan Control Mismatch ......................................................................................1033 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ...................................................................1034 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ...................................................................1036 Failure code [DV20KB] Travel Alarm Short Circuit ................................................................................1038 Failure code [DW43KA] Travel Speed Sol Open Circuit .............................................................................1040 Failure code [DW43KB] Travel Speed Sol Short Circuit ............................................................................1042 Failure code [DW45KA] Swing Brake Sol Open Circuit ..............................................................................1044 Failure code [DW45KB] Swing Brake Sol Short Circuit .............................................................................1047 Failure code [DW7BKA] Fan Reverse Sol Open Circuit ..............................................................................1049 Failure code [DW7BKB] Fan Reverse Sol Short Circuit .............................................................................1051 Failure code [DW91KA] Travel Junction Sol Open Circuit ..........................................................................1053 Failure code [DW91KB] Travel Junction Sol Short Circuit .........................................................................1055 Failure code [DWA2KA] Attachment Sol Open Circuit ...............................................................................1057 Failure code [DWA2KB] Attachment Sol Short Circuit ..............................................................................1059 Failure code [DWK0KA] 2-stage Relief Sol Open Circuit ...........................................................................1061 Failure code [DWK0KB] 2-stage Relief Sol Short Circuit ..........................................................................1063 Failure code [DWK2KA] Variable Back Pressure Sol Open Circuit ...................................................................1065 Failure code [DWK2KB] Variable Back Pressure Sol Short Circuit ..................................................................1067 Failure code [DWK8KA] Swing C/O Solenoid Open Circuit ...........................................................................1069 Failure code [DWK8KB] Swing C/O Solenoid Short Circuit ..........................................................................1071 Failure code [DX16KA] Fan Pump EPC Sol Open Circuit .............................................................................1073 Failure code [DX16KB] Fan Pump EPC Sol Short Circuit ............................................................................1075 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit ...............................................................................1077 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit ..............................................................................1079 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ...............................................................................1081 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ..............................................................................1083 Failure code [DXE0KA] LS-EPC Sol Open Circuit ...................................................................................1085 Failure code [DXE0KB] LS-EPC Sol Short Circuit ..................................................................................1087 Failure code [DXE4KA] Service Current EPC Disc. .................................................................................1089 Failure code [DXE4KB] Service Current EPC S/C ...................................................................................1090 Failure code [DXE5KA] Merge-divider Main Sol Open Circuit .......................................................................1091 Failure code [DXE5KB] Merge-divider Main Sol Short Circuit ......................................................................1093 Failure code [DXE6KA] Merge-divider LS Sol Open Circuit .........................................................................1095 Failure code [DXE6KB] Merge-divider LS Sol Short Circuit ........................................................................1097 Failure code [DY20KA] Wiper Working Abnormality .................................................................................1099 Failure code [DY20MA] Wiper Parking Abnormality .................................................................................1101 Failure code [DY2CKB] Washer Drive Short Circuit ................................................................................1103 Failure code [DY2DKB] Wiper Drive (For) Short ...................................................................................1105 Failure code [DY2EKB] Wiper Drive (Rev) Short ...................................................................................1107 Troubleshooting of electrical system (E-mode) .......................................................................................1109 E-1 Engine does not start (Engine does not crank) ...............................................................................1109 E-2 Manual preheater does not operate ...........................................................................................1115 E-3 Automatic preheater does not operate ........................................................................................1118 E-4 While preheater is operating, engine preheating monitor does not light up ...................................................1120 E-5 While starting switch is turned ON, machine monitor displays nothing ........................................................1122 E-6 While starting switch is turned to ON position (with engine stopped), engine oil level monitor lights up in yellow ..........1125 E-7 While starting switch is turned to ON position (with engine stopped), radiator coolant level monitor lights up in yellow ....1126 E-8 Engine coolant temperature monitor lights up in white while engine is running ...............................................1127 E-9 Hydraulic oil temperature monitor lights up in white while engine is running ................................................1128 E-10 Charge level monitor lights up in red while engine is running ..............................................................1129 E-11 Fuel level monitor lights up in red while engine is running ................................................................1130 E-12 Air cleaner clogging monitor lights up in yellow while engine is running ...................................................1131 E-13 Engine coolant temperature monitor lights up in red while engine is running ................................................1132 E-14 Hydraulic oil temperature monitor lights up in red while engine is running .................................................1133 E-15 Engine oil pressure monitor lights up in red while engine is running .......................................................1134 E-16 Fuel gauge display does not move from minimum or maximum ...................................................................1135 E-17 Display of fuel gauge differs from actual fuel level .......................................................................1136 E-18 Engine coolant temperature gauge display does not move from minimum or maximum .............................................1137 E-19 Display of engine coolant temperature gauge differs from actual coolant temperature ........................................1138 E-20 Hydraulic oil temperature gauge display does not move from minimum or maximum ..............................................1139 E-21 Display of hydraulic oil temperature gauge differs from actual oil temperature .............................................1141 E-22 Machine monitor does not display partially .................................................................................1142 E-23 Function switch does not operate ...........................................................................................1143 E-24 Automatic warm-up system does not work (in cold weather) ...................................................................1144 E-25 When auto-decelerator switch is operated, auto-decelerator monitor does not light up or does not go off ....................1145 E-26 Auto-decelerator is not operated or canceled with lever ....................................................................1146 E-27 When working mode switch is operated, working mode selection screen is not displayed .......................................1147 E-28 When working mode is changed, setting of engine and hydraulic pump is not changed ..........................................1148 E-29 When travel speed switch is operated, travel speed monitor does not change .................................................1149 E-30 When travel speed selection is changed, actual travel speed does not change ................................................1150 E-31 Alarm buzzer cannot be canceled ............................................................................................1151 E-32 When starting switch is turned OFF, service meter is not displayed .........................................................1152 E-33 Machine monitor cannot be set in service mode ..............................................................................1153 E-34 All of work equipments, swing, and travel mechanism do not move ............................................................1154 E-35 All of work equipment, swing, and travel mechanism do not lock .............................................................1156 E-36 When swing brake cancel switch is set to CANCEL position, machine cannot swing .............................................1157 E-37 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position .............................1159 E-38 One-touch power maximizing function does not operate properly, or indicator not displayed on monitor .......................1161 E-39 One-touch power maximizing function is not cancelled .......................................................................1163 E-40 Alarm does not sound during travel .........................................................................................1164 E-41 Alarm does not stop sounding while machine is stopped ......................................................................1166 E-42 Horn does not sound ........................................................................................................1167 E-43 Horn does not stop sounding ................................................................................................1169 E-44 When wiper switch is operated, wiper monitor does not light up or go off ...................................................1170 E-45 When wiper switch is operated, windshield wiper does not operate ...........................................................1171 E-46 When window washer switch is operated, window washer does not operate ......................................................1173 E-47 Boom LOWER indicator is not displayed properly with monitoring function ....................................................1174 E-48 Arm OUT indicator is not displayed properly with monitoring function .......................................................1175 E-49 Arm IN indicator is not displayed properly with monitoring function ........................................................1176 E-50 Boom RAISE indicator is not displayed properly with monitoring function ....................................................1177 E-51 Bucket CURL indicator is not displayed properly with monitoring function ...................................................1178 E-52 Bucket DUMP indicator is not displayed properly with monitoring function ...................................................1179 E-53 Swing indicator is not displayed properly with monitoring function .........................................................1180 E-54 Travel indicator is not displayed properly with monitoring function ........................................................1181 E-55 Service indicator is not displayed properly with monitoring function .......................................................1182 E-56 Attachment hydraulic circuit cannot be changed .............................................................................1184 E-57 KOMTRAX system does not operate properly ...................................................................................1185 E-58 Machine push-up function cannot be canceled ................................................................................1187 E-59 Machine push-up function does not operate ..................................................................................1189 Troubleshooting of hydraulic and mechanical system (H-mode) .........................................................................1190 Information described in troubleshooting table (H-mode) .........................................................................1190 System diagram of hydraulic equipment system ....................................................................................1191 Failure mode and cause table ....................................................................................................1193 H-1 Speed or power of all work equipment, swing, and travel is low. .............................................................1199 H-2 Engine speed lowers significantly or engine stalls ..........................................................................1201 H-3 Any of work equipment, swing and travel does not work .......................................................................1203 H-4 Unusual sound is heard from around hydraulic pump ...........................................................................1204 H-5 Fine control performance or response is poor ................................................................................1205 H-6 Speed or power of boom is low ...............................................................................................1206 H-7 Speed or power of arm is low ................................................................................................1210 H-8 Speed or power of bucket is low .............................................................................................1214 H-9 Work equipment does not move in single operation ............................................................................1217 H-10 Hydraulic drift of work equipment is large .................................................................................1218 H-11 Time lag of work equipment is large ........................................................................................1222 H-12 Other work equipment moves when one of work equipment is relieved ..........................................................1223 H-13 One-touch power maximizing function does not work ..........................................................................1224 H-14 Machine push-up function does not work .....................................................................................1225 H-15 In combined operation of work equipment , equipment having heavier load moves slower. ......................................1226 H-16 In combined operation of swing and boom RAISE, boom rising speed is low ....................................................1227 H-17 Travel speed drops largely in combined operation of swing and trave ........................................................1228 H-18 Machine does not travel straight ...........................................................................................1229 H-19 Travel speed is low ........................................................................................................1231 H-20 Machine is hard to steer or travel power is low ............................................................................1233 H-21 Travel speed does not change, or travel speed is too low or high ...........................................................1235 H-22 One of tracks does not run .................................................................................................1236 H-23 Upper structure does not swing .............................................................................................1237 H-24 Swing acceleration is poor or swing speed is low ...........................................................................1239 H-25 Upper structure overruns excessively when it stops swinging ................................................................1241 H-26 Shock is large when upper structure stops swinging .........................................................................1243 H-27 Large unusual noise is heard when upper structure stops swinging ...........................................................1244 H-28 Swing drift on a slope is large ............................................................................................1245 H-29 Attachment circuit cannot be changed .......................................................................................1247 H-30 Oil flow in attachment circuit cannot be controlled ........................................................................1248 H-31 Fan speed is abnormal (high, low, or 0 rpm) ................................................................................1249 H-32 Unusual noise is heard from around fan .....................................................................................1250 Troubleshooting of engine (S-mode) ..................................................................................................1251 Information mentioned in troubleshooting table (S mode) .........................................................................1251 S-1 When starting switch is turned to START position, engine is not cranked .....................................................1252 S-2 The engine cranks but exhaust smoke does not come out .......................................................................1253 S-3 Fuel is injected but engine does not start (incomplete combustion, engine seems to start but does not) ......................1254 S-4 Engine startability is poor .................................................................................................1255 S-5 Engine does not pick-up smoothly ............................................................................................1257 S-6 Engine stops during operation ...............................................................................................1259 S-7 Engine runs rough or is unstable ............................................................................................1261 S-8 Engine lacks power ..........................................................................................................1262 S-9 KDPF gets clogged in a short time ...........................................................................................1264 S-10 Engine oil consumption is excessive ........................................................................................1266 S-11 Engine oil becomes contaminated early ......................................................................................1267 S-12 Fuel consumption is excessive ..............................................................................................1268 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ...........................................................1269 S-14 Oil pressure drops .........................................................................................................1270 S-15 Fuel mixes into engine oil .................................................................................................1271 S-16 Water mixes into engine oil (milky) ........................................................................................1272 S-17 Coolant temperature rises too high (overheating) ...........................................................................1273 S-18 Unusual noise is heard .....................................................................................................1274 S-19 Vibration is excessive .....................................................................................................1275 S-20 Air cannot be bled from fuel circuit .......................................................................................1276 S-21 Active regeneration is executed frequently .................................................................................1277 S-22 Active regeneration takes a long time ......................................................................................1278 S-23 White smoke is exhausted during active regeneration ........................................................................1279 50 Disassembly and assembly .............................................................................................................1281 Table of contents ...................................................................................................................1282 Related information on disassembly and assembly .....................................................................................1284 How to read this manual .........................................................................................................1284 Coating materials list ..........................................................................................................1286 Special tools list ..............................................................................................................1290 Sketches of special tools .......................................................................................................1294 Engine and cooling system ...........................................................................................................1299 Removal and installation of supply pump assembly ................................................................................1299 Removal and installation of injector assembly ...................................................................................1306 Removal and installation of cylinder head assembly ..............................................................................1313 Removal and installation of radiator assembly ...................................................................................1321 Removal and installation of hydraulic oil cooler assembly .......................................................................1324 Removal and installation of aftercooler assembly ................................................................................1326 Removal and installation of cooling fan and fan motor assembly ..................................................................1328 Removal and installation of engine and main pump assembly .......................................................................1332 Removal and installation of engine front seal ...................................................................................1342 Removal and installation of engine rear seal ....................................................................................1346 Removal and installation of engine hood assembly ................................................................................1351 Removal and installation of KDPF assembly .......................................................................................1352 Removal and installation of KCCV assembly .......................................................................................1354 Removal and installation of air cleaner assembly ................................................................................1355 Power train system ..................................................................................................................1357 Removal and installation of travel motor and final drive assembly ...............................................................1357 Disassembly and assembly of final drive .........................................................................................1358 Removal and installation of swing motor and swing machinery assembly ............................................................1366 Disassembly and assembly of swing machinery .....................................................................................1368 Removal and installation of swing circle assembly ...............................................................................1375 Undercarriage and frame .............................................................................................................1376 Separation and connection of track shoe assembly ................................................................................1376 Removal and installation of sprocket ............................................................................................1378 Removal and installation of idler and idler cushion assembly ....................................................................1379 Disassembly and assembly of idler ...............................................................................................1380 Disassembly and assembly of idler cushion .......................................................................................1383 Disassembly and assembly of track roller ........................................................................................1385 Disassembly and assembly of carrier roller ......................................................................................1386 Removal and installation of revolving frame assembly ............................................................................1388 Removal and installation of counterweight assembly ..............................................................................1390 Hydraulic system ....................................................................................................................1392 Removal and installation of center swivel joint assembly ........................................................................1392 Disassembly and assembly of center swivel joint .................................................................................1394 Removal and installation of hydraulic tank assembly .............................................................................1395 Removal and installation of main pump assembly ..................................................................................1399 Removal and installation of control valve assembly ..............................................................................1403 Disassembly and assembly of control valve .......................................................................................1407 Disassembly and assembly of work equipment PPC valve ............................................................................1412 Disassembly and assembly of travel PPC valve ....................................................................................1414 Work equipment ......................................................................................................................1416 Removal and installation of work equipment assembly .............................................................................1416 Disassembly and assembly of work equipment cylinder .............................................................................1419 Cab and its attachments .............................................................................................................1424 Removal and installation of operator's cab assembly .............................................................................1424 Removal and installation of operator's cab glass (adhered window glass) .........................................................1429 Removal and installation of front window assembly ...............................................................................1439 Removal and installation of floor frame assembly ................................................................................1445 Removal and installation of air conditioner unit assembly .......................................................................1451 Removal and installation of operator’s seat .....................................................................................1455 Removal and installation of seat belt ...........................................................................................1457 Removal and installation of front wiper assembly ................................................................................1458 Electrical system ...................................................................................................................1465 Removal and installation of air conditioner compressor assembly .................................................................1465 Removal and installation of air conditioner condenser assembly ..................................................................1468 Removal and installation of engine controller assembly ..........................................................................1470 Removal and installation of pump controller assembly ............................................................................1472 Removal and installation of machine monitor assembly ............................................................................1475 Removal and installation of pump swash plate sensor .............................................................................1477 Removal and installation of mass air flow and temperature sensor ................................................................1478 Removal and installation of KOMTRAX terminal assembly ...........................................................................1480 60 Maintenance standard .................................................................................................................1483 Table of contents ...................................................................................................................1484 Engine and cooling system ...........................................................................................................1485 Engine mount ....................................................................................................................1485 Cooling system ..................................................................................................................1486 Cooling fan pump ................................................................................................................1487 Cooling fan motor ...............................................................................................................1489 Power train system ..................................................................................................................1490 Swing circle ....................................................................................................................1490 Swing machinery .................................................................................................................1491 Final drive .....................................................................................................................1493 Undercarriage and frame .............................................................................................................1495 Sprocket ........................................................................................................................1495 Track frame and idler cushion ...................................................................................................1497 Idler ...........................................................................................................................1498 Track roller ....................................................................................................................1500 Carrier roller ..................................................................................................................1501 Track shoe ......................................................................................................................1502 Hydraulic system ....................................................................................................................1505 Main pump .......................................................................................................................1505 Control valve ...................................................................................................................1507 Swing motor .....................................................................................................................1518 Travel motor ....................................................................................................................1520 PPC valve .......................................................................................................................1523 Solenoid valve ..................................................................................................................1532 Attachment circuit selector valve ...............................................................................................1533 Center swivel joint .............................................................................................................1534 Work equipment ......................................................................................................................1535 Work equipment ..................................................................................................................1535 Work equipment cylinder .........................................................................................................1544 80 Appendix .............................................................................................................................1547 Table of contents ...................................................................................................................1548 Air conditioner components ..........................................................................................................1549 Precautions for refrigerant .....................................................................................................1549 Air conditioner component .......................................................................................................1550 Configuration and function of refrigeration cycle ...............................................................................1553 Outline of refrigeration cycle ..................................................................................................1554 Air conditioner unit ............................................................................................................1556 Dual pressure switch ............................................................................................................1563 Air conditioner controller ......................................................................................................1564 Compressor ......................................................................................................................1565 Condenser .......................................................................................................................1566 Receiver drier ..................................................................................................................1567 Sunlight sensor .................................................................................................................1568 Outer temperature sensor (outside air temperature sensor) .......................................................................1569 Procedure for testing and troubleshooting .......................................................................................1570 Circuit diagram and arrangement of connector pins ...............................................................................1572 System diagram ..................................................................................................................1574 Input and output signals of the air conditioner controller ......................................................................1575 Parts and connectors layout .....................................................................................................1577 Layout of air conditioner related parts and connectors ..........................................................................1578 Testing air leakage (duct) ......................................................................................................1581 Testing with self-diagnosis function ............................................................................................1584 How to open the electrical system abnormality record screen in service mode of the machine monitor ..............................1585 Testing vent (mode) changeover ..................................................................................................1587 Testing FRESH/RECIRC air changeover .............................................................................................1589 Testing sunlight sensor .........................................................................................................1590 Testing (dual) pressure switch for refrigerant ..................................................................................1591 Testing relays ..................................................................................................................1593 Troubleshooting chart 1 .........................................................................................................1594 Troubleshooting chart 2 .........................................................................................................1595 Information in troubleshooting table ............................................................................................1598 Failure code list related to air conditioner ....................................................................................1599 Failure code [879AKA] A/C Inner sensor Open Circuit .............................................................................1600 Failure code [879AKB] A/C Inner sensor Short Circuit ............................................................................1601 Failure code [879BKA] A/C Outer sensor Open Circuit .............................................................................1602 Failure code [879BKB] A/C Outer sensor Short Circuit ............................................................................1604 Failure code [879CKA] Ventilating sensor Open Circuit ...........................................................................1606 Failure code [879CKB] Ventilating sensor Short Circuit ..........................................................................1607 Failure code [879DKZ] Sunlight sensor Open or Short Circuit .....................................................................1608 Failure code [879EMC] Ventilating Damper Abnormality ............................................................................1610 Failure code [879FMC] Air Mix Damper Abnormality ................................................................................1611 Failure code [879GKX] Refrigerant Abnormality ...................................................................................1612 A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................................................1613 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ...................................................1615 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ..........................................1618 A-4 Troubleshooting for FRESH/RECIRC air changeover .............................................................................1620 Troubleshooting with gauge pressure .............................................................................................1622 Connection of service tool ......................................................................................................1625 Precautions for disconnecting and connecting air conditioner piping .............................................................1627 Handling of compressor oil ......................................................................................................1629 90 Diagrams and drawings ................................................................................................................1631 Table of contents ...................................................................................................................1632 Hydraulic circuit diagram ...........................................................................................................1633 Symbols in hydraulic circuit diagram ............................................................................................1633 Hydraulic circuit diagram .......................................................................................................1637 Electric circuit diagram ............................................................................................................1639 Symbols in electric circuit diagram .............................................................................................1639 Electrical circuit diagram ......................................................................................................1643 Electric circuit diagram for air conditioner unit ...............................................................................1648 INDEX....................................................................................................................................1649
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