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Komatsu PC490LC-10 Hydraulic Excavator Shop Manual – PDF DOWNLOAD
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Komatsu PC490LC-10 Hydraulic Excavator Shop Manual
SERIAL NUMBERS : PC490LC-10 A40001 and up
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Description
Komatsu PC490LC-10 Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC490LC-10 Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC490LC-10
Serial Number: A40001 and up
Book Code: CEBM025303
Language: English
Pages: 1815
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC490LC-10 Hydraulic Excavator Shop Manual
1 GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following sections. These sections are further divided into each main group of components.
01 GENERAL:
This section lists the general machine dimensions, performance specifications, component weights, and fuel, coolant and lubricant specification charts.
10 STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
20 STANDARD VALUE TABLE:
This section explains the standard values for new machine and judgement criteria for testing, adjusting and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30 TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs.
40 TROUBLESHOOTING:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the
50 DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
60 MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.
80 AIR CONDITIONING
This section explains the air conditioning system, structure and function, troubleshooting, disassembly, and assembly.
90 DIAGRAMS AND DRAWINGS
This section has the foldout drawings for the machine.
TABLE OF CONTENTS:
Komatsu PC490LC-10 Hydraulic Excavator Shop Manual
CEBM025303................................................................................................................................ 1 CONTENTS.................................................................................................................................. 2 SAFETY.................................................................................................................................... 17 Safety Notice......................................................................................................................... 17 Important Safety Notice........................................................................................................... 17 General Precautions............................................................................................................... 17 Preparations For Work............................................................................................................. 19 Precautions During Work........................................................................................................... 19 GENERAL................................................................................................................................... 22 HOW TO READ THE SHOP MANUAL........................................................................................................... 24 Volumes........................................................................................................................... 24 Distribution And Updating......................................................................................................... 24 Filing Method..................................................................................................................... 24 Revised Edition Mark.............................................................................................................. 24 Revisions......................................................................................................................... 24 Symbols........................................................................................................................... 24 HOISTING INSTRUCTIONS................................................................................................................. 25 Hoisting.......................................................................................................................... 25 Making Signs...................................................................................................................... 25 Precautions....................................................................................................................... 25 Precautions for Sling Work.................................................................................................... 25 Precautions for Using Mobile Crane............................................................................................ 26 Precautions for Using Overhead Hoist Crane.................................................................................... 26 Selecting Wire Ropes.............................................................................................................. 27 HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS.................................................................................. 28 Points to Remember When Handling Electric Equipment............................................................................... 28 Points to Remember When Handling Hydraulic Equipment.............................................................................. 39 PUSH PULL COUPLER..................................................................................................................... 41 Type 1............................................................................................................................ 41 Disconnection................................................................................................................. 41 Connection.................................................................................................................... 41 Type 2............................................................................................................................ 42 Disconnection................................................................................................................. 42 Connection.................................................................................................................... 42 Type 3............................................................................................................................ 43 Disconnection................................................................................................................. 43 Connection.................................................................................................................... 43 EXPLANATION OF MAINTENANCE STANDARD TERMS............................................................................................. 44 HANDLING OF FUEL SYSTEM DEVICES....................................................................................................... 45 HANDLING OF INTAKE SYSTEM PARTS....................................................................................................... 46 STANDARD TIGHTENING TORQUE............................................................................................................ 47 Bolts And Nuts.................................................................................................................... 47 Tightening Torque Of Hose Nuts.................................................................................................... 48 Tightening Torque Of Split Flange Bolts........................................................................................... 48 Tightening Torque For Flared Nuts................................................................................................. 48 Tightening Torques for Split Flanged Bolts........................................................................................ 49 Tightening Torques For O-ring Boss Piping Joints.................................................................................. 49 Table Of Tightening Torques For O-ring Boss Plugs................................................................................. 49 Tightening Torque For Hoses (Taper Seal Type And Face Seal Type).................................................................. 50 Tightening Torque For Face Seal Joints........................................................................................ 50 ELECTRIC WIRE CODE.................................................................................................................... 51 Classification By Thickness....................................................................................................... 51 Classification By Color And Code.................................................................................................. 51 How To Read Electric Wire Code.................................................................................................... 52 PRECAUTIONS FOR OPERATIONS............................................................................................................ 55 Precautions when Carrying Out Removal Work........................................................................................ 55 Precautions when Carrying Out Installation Work................................................................................... 56 Precautions when Completing the Operation......................................................................................... 57 CONVERSION TABLES..................................................................................................................... 58 Method Of Using The Conversion Table.............................................................................................. 58 COATING MATERIALS..................................................................................................................... 64 LIST OF ABBREVIATIONS................................................................................................................. 66 List of Abbreviations Used in the Shop Manual..................................................................................... 66 List of Abbreviations Used in the Circuit Diagrams................................................................................ 70 01 GENERAL................................................................................................................................ 71 SPECIFICATION DIMENSION DRAWINGS...................................................................................................... 72 Dimensions........................................................................................................................ 72 Working Ranges.................................................................................................................... 73 SPECIFICATIONS........................................................................................................................ 74 WEIGHT TABLE.......................................................................................................................... 78 FUEL, COOLANT AND LUBRICANTS.......................................................................................................... 80 10 STRUCTURE, FUNCTION & MAINTENANCE STD.................................................................................................. 83 ENGINE AND COOLING SYSTEM............................................................................................................. 86 Engine Related Parts.............................................................................................................. 86 Radiator, Oil Cooler and Aftercooler.............................................................................................. 88 Cooling Fan Pump.................................................................................................................. 90 Operation of Pump............................................................................................................. 93 Control of Delivery........................................................................................................... 96 Servo Valve................................................................................................................... 97 Cooling Fan Motor............................................................................................................. 99 Hydraulic Motor................................................................................................................... 101 Suction Valve................................................................................................................. 102 Reversible Valve.............................................................................................................. 104 Safety Valve.................................................................................................................. 106 POWER TRAIN SYSTEM.................................................................................................................... 108 Power Train....................................................................................................................... 108 Swing Circle...................................................................................................................... 110 Swing machinery................................................................................................................... 112 Final Drive....................................................................................................................... 114 UNDERCARRIAGE AND FRAME............................................................................................................... 116 Track Frame and Idler Cushion..................................................................................................... 116 HYDRAULIC SYSTEM...................................................................................................................... 118 Hydraulic Component Layout........................................................................................................ 118 Valve Control..................................................................................................................... 120 Hydraulic Tank.................................................................................................................... 121 Oil Filler Port Cap........................................................................................................... 122 CLSS.............................................................................................................................. 124 Structure of CLSS............................................................................................................. 124 Basic Principle............................................................................................................... 125 Main Pump......................................................................................................................... 130 LS valve...................................................................................................................... 135 Operation..................................................................................................................... 136 PC Valve.......................................................................................................................... 140 Operation..................................................................................................................... 142 LS(PC)-EPC Valve.............................................................................................................. 148 Operation..................................................................................................................... 149 Control Valve..................................................................................................................... 152 Functions and Operation by Valve.............................................................................................. 164 Unload Valve.................................................................................................................. 168 LS Bypass Valve............................................................................................................... 170 Pressure Compensation Valve................................................................................................... 171 Pressure Compensation Valve Inner Shuttle Valve............................................................................... 174 Boom Regeneration Circuit..................................................................................................... 176 Arm Regeneration Circuit...................................................................................................... 178 Merge-Divider Valve........................................................................................................... 180 LS Select Valve............................................................................................................... 183 Self Pressure Reducing Valve.................................................................................................. 184 Travel Junction Valve......................................................................................................... 187 Travel PPC Shuttle Valve...................................................................................................... 190 Boom Hydraulic Drift Preventive Valve......................................................................................... 192 Arm Drift Preventive Valve.................................................................................................... 195 Suction Safety Valve For Drift Prevention Valve............................................................................... 198 Arm Quick Return Valve........................................................................................................ 199 Variable Back Pressure Valve.................................................................................................. 201 Main Relief Valve............................................................................................................. 202 2-Stage Safety-Suction Valve.................................................................................................. 204 Swing Motor................................................................................................................... 206 Swing Holding Brake........................................................................................................... 208 Swing 2-Stage Relief Valve.................................................................................................... 211 Swing Motor Reverse Prevention Valve.......................................................................................... 212 Travel Motor...................................................................................................................... 215 Operation of Motor............................................................................................................ 218 Operation of Parking Brake.................................................................................................... 220 Brake Valve................................................................................................................... 222 Safety Valve (Bidirectional 2-Stage Set Safety Valve)......................................................................... 223 PPC Valve......................................................................................................................... 227 Work Equipment and Swing PPC Valve............................................................................................ 227 Travel PPC valve.................................................................................................................. 233 1st-line Attachment PPC Valve (with EPC valve).................................................................................... 237 EPC valve..................................................................................................................... 238 Solenoid Valve.................................................................................................................... 242 Attachment Circuit Selector Valve................................................................................................. 244 Center Swivel Joint............................................................................................................... 246 PPC Accumulator............................................................................................................... 247 WORK EQUIPMENT........................................................................................................................ 248 Work Equipment.................................................................................................................... 248 Work Equipment Shims.......................................................................................................... 249 CAB AND ITS ATTACHMENTS............................................................................................................... 250 Cab Mount and Cab Tipping Stopper................................................................................................. 250 ROPS Cab.......................................................................................................................... 251 ELECTRICAL SYSTEM..................................................................................................................... 252 Engine Control.................................................................................................................... 252 Engine Controller Function.................................................................................................... 255 Engine And Pump Combined Control Function..................................................................................... 258 Pump and Valve Control Function................................................................................................... 264 One-touch Power Maximizing Function........................................................................................... 266 Machine Push-up Function...................................................................................................... 268 Auto-Deceleration Function.................................................................................................... 270 Engine Automatic Warm-up Function............................................................................................. 272 Overheat Prevention Function.................................................................................................. 274 Turbocharger Protection Function.............................................................................................. 275 Swing Control Function........................................................................................................ 276 Quick Warm-Up Function........................................................................................................ 278 Swing 2-Stage Relief Function................................................................................................. 278 Travel Control Function....................................................................................................... 280 PPC Lock Function............................................................................................................. 282 Oil Flow Adjuster Function For Attachment..................................................................................... 284 Hydraulic Fan Control Function.................................................................................................... 286 Fan Rotation Control.......................................................................................................... 286 Engine Output Control......................................................................................................... 287 Fan Reverse Rotation Function................................................................................................. 288 System Component Part......................................................................................................... 290 Pump Controller............................................................................................................... 294 Resistor for PC-EPC valve..................................................................................................... 299 CAN Terminating Resistor...................................................................................................... 300 MACHINE MONITOR SYSTEM................................................................................................................ 301 Machine Monitor................................................................................................................... 302 Input and Output Signals...................................................................................................... 303 Display....................................................................................................................... 306 Gauges........................................................................................................................ 308 Caution Monitor............................................................................................................... 310 Pilot Monitor................................................................................................................. 314 Switches.......................................................................................................................... 316 Guidance ICON and Function Switch............................................................................................. 318 Operator Mode Function........................................................................................................ 322 Service Mode Function......................................................................................................... 324 KOMTRAX SYSTEM........................................................................................................................ 326 KOMTRAX Terminal.................................................................................................................. 327 Input and Output Signals.......................................................................................................... 328 SENSORS............................................................................................................................... 330 Ambient Pressure Sensor........................................................................................................... 330 Engine Oil Pressure Sensor........................................................................................................ 331 Charge Pressure Sensor............................................................................................................ 331 Charge Temperature Sensor......................................................................................................... 332 Coolant Temperature Sensor........................................................................................................ 332 Ne (Crankshaft) Speed Sensor...................................................................................................... 333 Bkup (Camshaft) Speed Sensor...................................................................................................... 333 Common Rail Pressure Sensor....................................................................................................... 334 EGR Valve Lift Sensor............................................................................................................. 335 KVGT Speed Sensor................................................................................................................. 336 KVGT Position Sensor.............................................................................................................. 336 Mass Air Flow and Temperature Sensor.............................................................................................. 337 Dosing Fuel Pressure Sensor....................................................................................................... 338 KDPF Differential Pressure and Outlet Pressure Sensor............................................................................. 338 KDOC Inlet Temperature Sensor..................................................................................................... 339 KDOC Outlet Temperature Sensor.................................................................................................... 339 KDPF Outlet Temperature Sensor.................................................................................................... 340 Crankcase Pressure Sensor......................................................................................................... 340 Engine Oil Level Sensor........................................................................................................... 341 Fuel Level Sensor................................................................................................................. 342 Coolant Level Sensor.............................................................................................................. 343 Hydraulic Oil Temperature Sensor.................................................................................................. 343 Front Pump Oil Pressure Sensor.................................................................................................... 344 Rear Pump Oil Pressure Sensor..................................................................................................... 345 PPC Oil Pressure Sensor........................................................................................................... 346 Air Cleaner Clogging Sensor....................................................................................................... 347 Front Pump Swash Plate Sensor..................................................................................................... 348 Rear Pump Swash Plate Sensor...................................................................................................... 349 Cooling Fan Speed Sensor.......................................................................................................... 350 20 STD VALUE TABLES....................................................................................................................... 351 STANDARD SERVICE VALUE TABLES......................................................................................................... 352 Standard Value Table for Engine................................................................................................... 352 Standard Value Table for Machine.................................................................................................. 354 Engine Speed.................................................................................................................. 354 Travel of Control Valve Spool................................................................................................. 354 Travel of Control Lever....................................................................................................... 355 Operating Effort of Control Lever and Pedal................................................................................... 355 Hydraulic Oil Pressure........................................................................................................ 356 Swing......................................................................................................................... 357 Travel........................................................................................................................ 358 Work Equipment................................................................................................................ 360 Performance in Combined Operation............................................................................................. 362 Pump Swash Plate Sensor....................................................................................................... 362 Characteristics of PC Flow Control............................................................................................ 362 Fan........................................................................................................................... 363 Main Pump..................................................................................................................... 363 Posture of Machine for Measuring Performance and Measurement Procedure............................................................ 365 Control Valve: Spool Travel................................................................................................... 365 Swing 1: Overrun When Stopping Swing, Time Taken to Start Swing, Time Taken to Swing.......................................... 365 Swing 2: Amount of Hydraulic Drift of Swing................................................................................... 365 Travel 1: Travel Speed, Idle Running (Without Load)........................................................................... 365 Travel 2: Travel Speed (Actual Run), Travel Deviation......................................................................... 366 Travel 3: Travel Deviation.................................................................................................... 366 Travel 4: Hydraulic Drift of Travel........................................................................................... 366 Work Equipment 1: Hydraulic Drift of Work Equipment........................................................................... 366 Work Equipment 2: Boom Speed.................................................................................................. 367 Work Equipment 3: Arm Speed................................................................................................... 367 Work Equipment 4: Bucket Speed................................................................................................ 367 Work Equipment 5: Boom Time Lag............................................................................................... 367 Work Equipment 6: Arm Time Lag................................................................................................ 368 Work Equipment 7: Bucket Time Lag............................................................................................. 368 Work Equipment 8: PC Flow Characteristics Control............................................................................. 368 30 TESTING & ADJUSTING.................................................................................................................... 369 GENERAL INFORMATION................................................................................................................... 372 Tools for Testing, Adjusting, and Troubleshooting................................................................................. 372 Sketch of Tools for Testing and Adjusting......................................................................................... 378 ENGINE AND COOLING SYSTEM............................................................................................................. 382 Checking Engine Speed............................................................................................................. 382 Measuring Boost Pressure.......................................................................................................... 384 Measuring Exhaust Gas Temperature................................................................................................. 386 Measuring Exhaust Gas Color....................................................................................................... 388 Measuring and Adjusting Valve Clearance........................................................................................... 390 Testing....................................................................................................................... 390 Adjusting..................................................................................................................... 393 Measuring Compression Pressure.................................................................................................... 394 Measuring Engine Oil Pressure..................................................................................................... 399 Measuring EGR Valve and KVGT Oil Pressure......................................................................................... 401 Measuring Fuel Pressure........................................................................................................... 403 Measuring Fuel Leakage and Return................................................................................................. 405 Testing....................................................................................................................... 405 Measuring return rate from injector........................................................................................... 407 Bleeding Air from Fuel System..................................................................................................... 409 Bleeding Air.................................................................................................................. 410 Checking Fuel Circuit for Leakage................................................................................................. 413 Handling Cylinder Cut-Out Mode Operation.......................................................................................... 414 Handling No-Injection Cranking Operation.......................................................................................... 414 Checking and Adjusting Air Conditioner Compressor Belt Tension.................................................................... 415 Checking...................................................................................................................... 415 Adjusting..................................................................................................................... 416 Replacing Fan Belt................................................................................................................ 417 Replacing..................................................................................................................... 417 Fuel Doser Cleaning Procedure..................................................................................................... 419 Removal....................................................................................................................... 419 Cleaning...................................................................................................................... 420 Installation.................................................................................................................. 422 Writing Compensation Values at Replacement of Injector and Engine Controller...................................................... 423 Connection of PC.............................................................................................................. 423 Starting INSITE............................................................................................................... 424 POWER TRAIN........................................................................................................................... 429 Testing Swing Circle Bearing Clearance............................................................................................ 429 Testing....................................................................................................................... 429 UNDERCARRIAGE AND FRAME............................................................................................................... 431 Testing and Adjusting Track Shoe Tension.......................................................................................... 431 Testing....................................................................................................................... 431 Adjusting..................................................................................................................... 431 HYDRAULIC SYSTEM...................................................................................................................... 433 Releasing Remaining Pressure from Hydraulic Circuit............................................................................... 433 Measuring and Adjusting of Oil Pressure in Work Equipment, Swing, and Travel Circuits............................................. 435 Testing....................................................................................................................... 435 Adjusting..................................................................................................................... 437 Measuring Oil Pressure in Control Circuit......................................................................................... 441 Measuring and Adjusting Oil Pressure in Pump PC Control Circuit................................................................... 443 Testing....................................................................................................................... 443 Adjusting..................................................................................................................... 445 Measuring and Adjusting Oil Pressure in Pump LS Control Circuit................................................................... 447 Testing....................................................................................................................... 447 Checking Oil Pressure with Sensor Adapter (Special Tool)...................................................................... 451 Adjusting..................................................................................................................... 452 Measuring Solenoid Valve Output Pressure.......................................................................................... 453 Testing....................................................................................................................... 453 Operating Condition........................................................................................................... 455 Measuring PPC Valve Output Pressure............................................................................................... 457 Adjusting Play of Work Equipment and Swing PPC Valves............................................................................. 459 Testing Pump Swash Plate Sensor................................................................................................... 460 Measuring Fan Pump Circuit Oil Pressure........................................................................................... 461 Checking Fan Pump EPC Current..................................................................................................... 462 Measuring Fan Pump EPC Solenoid Valve Output Pressure............................................................................. 463 Isolating the Parts Causing Hydraulic Drift in Work Equipment..................................................................... 465 Measuring Oil Leakage............................................................................................................. 467 Bleeding Air From Hydraulic Circuit............................................................................................... 471 Bleeding Air.................................................................................................................. 472 CAB AND ITS ATTACHMENTS............................................................................................................... 475 Checking Cab Tipping Stopper...................................................................................................... 475 Adjusting Mirrors................................................................................................................. 476 ELECTRICAL SYSTEM..................................................................................................................... 479 Special Functions of Machine Monitor.............................................................................................. 479 Upper Part Of Machine Monitor (Display Portion)............................................................................... 480 Upper Part of Machine Monitor (Switch Portion)................................................................................ 480 Lower Part of Machine Monitor (Switch Portion)................................................................................ 480 Ordinary Functions and Special Functions of Machine Monitor....................................................................... 480 Operator Mode (Outline)....................................................................................................... 483 Service Mode.................................................................................................................. 502 Angle Adjustment of Rear View Camera.............................................................................................. 566 Handling Voltage Circuit of Engine Controller..................................................................................... 568 Handling Battery Disconnect Switch................................................................................................ 569 Testing Diodes.................................................................................................................... 570 PM CLINIC............................................................................................................................. 571 PM Clinic Service................................................................................................................. 571 Check Items Related to Engine................................................................................................. 573 Check Items Related to Oil Pressure........................................................................................... 574 Check Sheet....................................................................................................................... 575 1. Engine..................................................................................................................... 575 2. Work equipment speed....................................................................................................... 576 3. Hydraulic drift of work equipment.......................................................................................... 576 4. Hydraulic circuit.......................................................................................................... 577 Visual Check of Welded Structures............................................................................................. 580 Undercarriage Inspection Report................................................................................................... 581 40 TROUBLESHOOTING........................................................................................................................ 583 GENERAL INFORMATION ON TROUBLESHOOTING................................................................................................ 591 Points to Remember When Troubleshooting........................................................................................... 591 Sequence of Events in Troubleshooting............................................................................................. 593 Checks Before Troubleshooting..................................................................................................... 595 Testing Procedure Before Troubleshooting.......................................................................................... 597 Walk-Around Check............................................................................................................. 597 Checking in Accordance with Checking Procedure................................................................................ 599 Preparation Work for Troubleshooting of Electrical System......................................................................... 605 Preparation Work.............................................................................................................. 605 Classification and Procedure for Troubleshooting.................................................................................. 610 Classification of Troubleshooting............................................................................................. 610 Procedure for Troubleshooting................................................................................................. 610 Symptom of Probable Failure and Troubleshooting No................................................................................ 614 Information Mentioned in Troubleshooting Table.................................................................................... 618 DIAGNOSTIC PROCEDURE FOR WIRING HARNESS............................................................................................... 620 Open Circuit Of Pressure Sensor System............................................................................................ 620 Connector list.................................................................................................................... 623 Layout of connectors.............................................................................................................. 628 Connection Table for Connector Pin Numbers........................................................................................ 634 T-Branch Box and T-Branch Adapter Table........................................................................................... 669 Fuse List and Location............................................................................................................ 673 Connection Table of Fuse Box.................................................................................................. 673 Locations of Fusible Links.................................................................................................... 674 Location of Fuse Box and Fuse Numbers......................................................................................... 674 Precautions for Cleaning and Replacing KDPF (KCSF, KDOC).......................................................................... 675 FAILURE CODE (DISPLAY OF CODE)........................................................................................................ 678 Failure Codes Table............................................................................................................... 678 879AKA - Air Conditioner Inner Sensor Disconnection............................................................................... 685 879AKB - Air Conditioner Inner Sensor Disconnection............................................................................... 685 879BKA - A/C Outer Sensor Open Circuit............................................................................................ 685 879BKB - A/C Outer Sensor Short Circuit........................................................................................... 685 879CKA - Ventilating Sensor Open Circuit.......................................................................................... 685 879CKB - Ventilating Sensor Short Circuit......................................................................................... 685 879DKZ - Sunlight Sensor Open or Short Circuit.................................................................................... 685 879EMC - Ventilation Damper Abnormality........................................................................................... 686 879FMC - Air Mix Damper Abnormality............................................................................................... 686 879GKX - Refrigerant Abnormality.................................................................................................. 686 989L00 - Engine Controller Lock Caution 1......................................................................................... 687 989M00 - Engine Controller Lock Caution 2......................................................................................... 687 989N00 - Engine Controller Lock Caution 3......................................................................................... 688 A1U0N3 - KDPF Dry Request (HC Release) 1.......................................................................................... 689 A1U0N4 - KDPF Dry Request (HC Release) 2.......................................................................................... 691 AA10NX - Air Cleaner Clogging..................................................................................................... 694 AB00KE - Charge Voltage Low....................................................................................................... 696 B@BAZG - Engine Oil Pressure Low.................................................................................................. 698 B@BAZK - Eng Oil Level Low........................................................................................................ 700 B@BCNS - Engine Coolant Overheat.................................................................................................. 702 B@BCZK - Radiator Coolant Level Low............................................................................................... 704 B@HANS - Hyd Oil Overheat......................................................................................................... 706 CA115 - Eng Ne and Bkup Speed Sens Error.......................................................................................... 707 CA122 - Chg Air Press Sensor High Error........................................................................................... 708 CA123 - Chg Air Press Sensor Low Error............................................................................................ 710 CA131 - Throttle Sensor High Error................................................................................................ 712 CA132 - Throttle Sensor Low Error................................................................................................. 714 CA135 - Eng Oil Press Sensor High Error........................................................................................... 716 CA141 - Eng Oil Press Sensor Low Error............................................................................................ 718 CA144 - Coolant Temp Sens High Error.............................................................................................. 720 CA145 - Coolant Temp Sens Low Error............................................................................................... 722 CA153 - Chg Air Temp Sensor High Error............................................................................................ 724 CA154 - Chg Air Temp Sensor Low Error............................................................................................. 726 CA187 - Sensor 2 Supply Volt Low Error............................................................................................ 728 CA221 - Ambient Press Sensor High Error........................................................................................... 730 CA222 - Ambient Press Sensor Low Error............................................................................................ 732 CA227 - Sensor 2 Supply Volt High Error........................................................................................... 734 CA234 - Eng Overspeed............................................................................................................. 735 CA238 - Ne Speed Sensor Supply Volt Error......................................................................................... 736 CA239 - Ne Speed Sens Supply Volt High Error...................................................................................... 738 CA271 - IMV/PCV1 Short Error...................................................................................................... 740 CA272 - IMV/PCV1 Open Error....................................................................................................... 742 CA273 - PCV2 Short Error.......................................................................................................... 744 CA274 - PCV2 Open Error........................................................................................................... 746 CA322 - Inj #1 (L#1) Open/Short Error............................................................................................. 748 CA323 - Inj #5 (L#5) Open/Short Error............................................................................................. 750 CA324 - Inj #3 (L#3) Open/Short Error............................................................................................. 752 CA325 - Inj #6 (L#6) Open/Short Error............................................................................................. 754 CA331 - Inj #2 (L#2) Open/Short Error............................................................................................. 756 CA332 - Inj #4 (L#4) Open/Short Error............................................................................................. 758 CA343 - ECM Critical Internal Failure............................................................................................. 760 CA351 - Injectors Drive Circuit Error............................................................................................. 761 CA352 - Sensor 1 Supply Volt Low Error............................................................................................ 762 CA356 - Mass Air Flow Sensor High Error........................................................................................... 764 CA357 - Mass Air Flow Sensor Low Error............................................................................................ 766 CA386 - Sensor 1 Supply Volt High Error........................................................................................... 768 CA441 - Battery Voltage Low Error................................................................................................. 770 CA442 - Battery Voltage High Error................................................................................................ 772 CA449 - Rail Press Very High Error................................................................................................ 773 CA451 - Rail Press Sensor High Error.............................................................................................. 774 CA452 - Rail Press Sensor Low Error............................................................................................... 776 CA515 - Rail Press Sens Sup Volt Low Error........................................................................................ 778 CA516 - Rail Press Sens Sup Volt High Error....................................................................................... 780 CA553 - Rail Press High Error..................................................................................................... 782 CA555 - Crankcase Press High Error 1.............................................................................................. 783 CA556 - Crankcase Press High Error 2.............................................................................................. 784 CA559 - Supply Pump Press Low Error 1............................................................................................. 785 CA595 - Turbo Speed High Error 2.................................................................................................. 789 CA687 - Turbo Speed Low Error..................................................................................................... 790 CA689 - Eng Ne Speed Sensor Error................................................................................................. 792 CA691 - Intake Air Temp Sens High Error........................................................................................... 794 CA692 - Intake Air Temp Sens Low Error............................................................................................ 796 CA697 - ECM Internal Temp Sensor High Error....................................................................................... 798 CA698 - ECM Internal Temp Sensor Low Error........................................................................................ 799 CA731 - Eng Bkup Speed Sens Phase Error........................................................................................... 800 CA778 - Eng Bkup Speed Sensor Error............................................................................................... 801 CA1117 - Partial Data Lost Error.................................................................................................. 804 CA1664 - KDOC Malfunction......................................................................................................... 806 CA1691 - Regeneration Ineffective................................................................................................. 808 CA1695 - Sensor 5 Supply Volt High Error.......................................................................................... 812 CA1696 - Sensor 5 Supply Volt Low Error........................................................................................... 814 CA1843 - Crankcase Press Sens High Error.......................................................................................... 816 CA1844 - Crankcase Press Sens Low Error........................................................................................... 818 CA1879 - KDPF Differential P Sensor High Error.................................................................................... 821 CA1881 - KDPF Differential P Sensor Low Error..................................................................................... 823 CA1883 - KDPF Differential Pressure Sensor In Range Error......................................................................... 825 CA1921 - KDPF Soot Load High Error 1.............................................................................................. 829 CA1922 - KDPF Soot Load High Error 2.............................................................................................. 831 CA1923 - Doser Solenoid Valve 1 High Error........................................................................................ 836 CA1924 - Fuel Doser Sol Valve 1 Low Error......................................................................................... 838 CA1925 - Doser Solenoid Valve 1 In Range Error.................................................................................... 841 CA1927 - Doser Fuel Pressure Sensor High Error.................................................................................... 844 CA1928 - Doser Fuel Pressure Sensor Low Error..................................................................................... 846 CA1942 - Crankcase Press Sens In Range Error...................................................................................... 848 CA1963 - Doser Solenoid Valve 1 Servo Error....................................................................................... 850 CA1977 - Doser Open Short Circuit Error........................................................................................... 852 CA1993 - KDPF Differential Pressure Low Error..................................................................................... 854 CA2185 - Throt Sensor Sup Volt High Error......................................................................................... 856 CA2186 - Throt Sensor Sup Volt Low Error.......................................................................................... 858 CA2249 - Rail Press Very Low Error................................................................................................ 860 CA2265 - Fuel Feed Pump Open Error................................................................................................ 862 CA2266 - Fuel Feed Pump Short Error............................................................................................... 864 CA2271 - EGR Valve Pos Sens High Error............................................................................................ 866 CA2272 - EGR Valve Pos Sens Low Error............................................................................................. 868 CA2349 - EGR Valve Solenoid Low Error............................................................................................. 870 CA2353 - EGR Valve Solenoid current High Error.................................................................................... 872 CA2357 - EGR Valve Servo Error.................................................................................................... 874 CA2373 - Exhaust Manifold Press Sens High Error................................................................................... 876 CA2374 - Exhaust Manifold Press Sens Low Error.................................................................................... 878 CA2375 - EGR Orifice Temp Sens High Error......................................................................................... 880 CA2376 - EGR Orifice Temp Sens Low Error.......................................................................................... 882 CA2381 - KVGT Pos Sens High Error................................................................................................. 884 CA2382 - KVGT Pos Sens Low Error.................................................................................................. 886 CA2383 - KVGT Solenoid Open Error................................................................................................. 890 CA2386 - KVGT Solenoid Short Error................................................................................................ 892 CA2387 - KVGT Valve Servo Error................................................................................................... 894 CA2554 - Exh Manifold Press Sens In Range Error................................................................................... 895 CA2555 - Grid Htr Relay Open Circuit Error........................................................................................ 896 CA2556 - Grid Htr Relay Volt High Error........................................................................................... 898 CA2637 - KDOC Blocked............................................................................................................. 900 CA2639 - Manual Stationary Regeneration Request................................................................................... 902 CA2732 - Dozer Solenoid Valve 2 High Error........................................................................................ 904 CA2733 - Doser Solenoid Valve 2 Low Error......................................................................................... 906 CA2741 - Dozer Solenoid Valve 1 Connection Error.................................................................................. 908 CA2765 - Injector Trim Data Mismatch.............................................................................................. 910 CA2878 - Doser Solenoid Valve 2 Servo Error....................................................................................... 912 CA2973 - Chg Air Press Sensor In Range Error...................................................................................... 919 CA3133 - KDPF Outlet Press Sens High Error........................................................................................ 920 CA3134 - KDPF Outlet Press Sens Low Error......................................................................................... 922 CA3135 - KDPF Outlet Press Sens In Range Error.................................................................................... 924 CA3251 - KDOC Inlet Temp High Error............................................................................................... 928 CA3253 - KDOC Temp Error - Non Regeneration....................................................................................... 931 CA3254 - KDOC Outlet Temp High Error 1............................................................................................ 933 CA3255 - KDPF Temp Error - Non Regeneration....................................................................................... 936 CA3256 - KDPF Outlet Temp High Error 1............................................................................................ 937 CA3311 - KDOC Outlet Temp High Error 2............................................................................................ 938 CA3312 - KDPF Outlet Temp High Error 2............................................................................................ 939 CA3313 - KDOC Inlet Temp Sensor Low Error......................................................................................... 942 CA3314 - KDOC Inlet Temp Sens High Error.......................................................................................... 946 CA3315 - KDOC Inlet Temp Sens In Range Error...................................................................................... 950 CA3316 - KDOC Outlet Temp Sens Low Error.......................................................................................... 954 CA3317 - KDOC Outlet Temp Sens High Error......................................................................................... 958 CA3318 - KDOC Outlet Temp Sens In Range Error..................................................................................... 962 CA3319 - KDPF Outlet Temp Sens High Error......................................................................................... 966 CA3321 - KDPF Outlet Temp Sens Low Error.......................................................................................... 970 CA3322 - KDPF Outlet Temp Sens In Range Error..................................................................................... 974 CA3419 - Mass Air Flow (MAF) Sensor Sup Volt High Error........................................................................... 978 CA3421 - Mass Air Flow (MAF) Sensor Sup Volt Low Error............................................................................ 980 D110KB - Battery Relay Output Voltage............................................................................................. 982 D19JKZ - Personal Code Relay Abnormality.......................................................................................... 984 D811MC - KOMTRAX Error............................................................................................................ 987 D862KA - GPS Antenna Open Circuit................................................................................................. 987 D8AQKR - CAN2 Discon (KOMTRAX).................................................................................................... 992 DA20MC - Pump Controller.......................................................................................................... 993 DA22KK - Pump Solenoid Power Low Error............................................................................................ 994 DA25KP - 5 V Sensor 1 Power Abnormality........................................................................................... 996 DA29KQ - Model Selection Abnormality..............................................................................................1000 DA2QKR - CAN2 Discon (Pump Con)...................................................................................................1008 DA2RKR - CAN1 Discon (Pump Con)...................................................................................................1011 DAF0MB - Monitor Memory Error.....................................................................................................1012 DAF0MC - Monitor Error............................................................................................................1013 DAF8KB - Camera Power Supply Short Circuit........................................................................................1014 DAF9KQ - Model Selection Abnormality..............................................................................................1016 DAFGMC - GPS Module Error.........................................................................................................1017 DAFQKR - CAN2 Discon..............................................................................................................1022 DAZ9KQ - A/C Model Selection Abnormality..........................................................................................1023 DAZQKR - CAN2 Discon (AC).........................................................................................................1024 DB2QKR - CAN2 Discon (Engine Con).................................................................................................1030 DB2RKR - CAN1 Discon (Engine Con).................................................................................................1036 DGH2KA - Hyd Oil Temp Sensor Open.................................................................................................1042 DGH2KB - Hyd Oil Temp Sensor Short Circuit........................................................................................1044 DHA4KA - Air Cleaner Clog Sensor Open Circuit.....................................................................................1046 DHPAMA - F Pump Press Sensor Abnormality..........................................................................................1047 DHPBMA - R Pump Press Sensor Abnormality..........................................................................................1050 DHS3MA - Arm In PPC Press Sensor Abnormality......................................................................................1053 DHS4MA - Bucket Curl PPC Press Sensor Abnormality.................................................................................1056 DHS8MA - Boom Raise PPC Press Sensor Abnormality..................................................................................1060 DHS9MA - Boom Lower PPC Press Sensor Abnormality..................................................................................1064 DHSAMA - Swing RH PPC Press Sensor Abnormality....................................................................................1068 DHSBMA - Swing LH PPC Press Sensor Abnormality....................................................................................1072 DHSCMA - Arm Out PPC Press Sensor Abnormality.....................................................................................1076 DHSDMA - Bucket Dump PPC Press Sensor Abnormality.................................................................................1080 DHSFMA - Travel Fwd LH PPC Press Sensor Abnormality...............................................................................1084 DHSGMA - Travel Fwd RH PPC Press Sensor Abnormality...............................................................................1088 DHSHMA - Travel Rev LH PPC Press Sensor Abnormality...............................................................................1092 DHSJMA - Travel Rev RH PPC Press Sensor Abnormality...............................................................................1096 DKR0MA - F Pump Swash Plate Sensor Abnormality....................................................................................1100 DKR1MA - R Pump Swash Plate Sensor Abnormality....................................................................................1104 DLM3KB - Fan Speed Sensor: Short circuit..........................................................................................1110 DV20KB - Travel Alarm Short Circuit...............................................................................................1112 DW43KA - Travel Speed Sol Open Circuit............................................................................................1114 DW43KB - Travel Speed Sol Short Circuit...........................................................................................1116 DW45KA - Swing Brake Sol Open Circuit.............................................................................................1118 DW45KB - Swing Brake Sol Short Circuit............................................................................................1122 DW91KA - Travel Junction Sol Open Circuit.........................................................................................1130 DW91KB - Travel Junction Sol Short Circuit........................................................................................1132 DWA2KA - Attachment Sol Open Circuit..............................................................................................1134 DWA2KB - Attachment Sol Short Circuit.............................................................................................1136 DWK0KA - 2-Stage Relief Sol Open Circuit..........................................................................................1138 DWK0KB - 2-Stage Relief Sol Short Circuit.........................................................................................1140 DWK2KA - Variable Back Press Sol Open Circuit.....................................................................................1142 DWK2KB - Variable Back Press Sol Short Circuit....................................................................................1144 DWK8KA - Swing Press Cut-Off Sol Open Circuit.....................................................................................1146 DWK8KB - Swing Press Cut-Off Sol Short Circuit....................................................................................1148 DXA8KA - PC-EPC (F) Sol Open Circuit..............................................................................................1154 DXA8KB - PC-EPC (F) Sol Short Circuit.............................................................................................1156 DXA9KA - PC-EPC (R) Sol Open Circuit..............................................................................................1158 DXA9KB - PC-EPC (R) Sol Short Circuit.............................................................................................1162 DXE0KA - LS-EPC Sol Open Circuit..................................................................................................1164 DXE0KB - LS-EPC Sol Short Circuit.................................................................................................1166 DXE4KA - Attachment Flow EPC Open Circuit.........................................................................................1168 DXE4KB - Attachment Flow EPC Short Circuit........................................................................................1170 DXE5KA - Merge-divide Main Sol Open Circuit.......................................................................................1172 DXE5KB - Merge-divide Main Sol Short Circuit......................................................................................1174 DXE6KA - Merge-divide LS Sol Open Circuit.........................................................................................1176 DXE6KB - Merge-divide LS Sol Short Circuit........................................................................................1178 DY20KA - Wiper Working Abnormality................................................................................................1180 DY20MA - Wiper Parking Abnormality................................................................................................1184 DY2EKB - Wiper Drive (Rev) Short Circuit..........................................................................................1188 ELECTRICAL SYSTEM (E-MODE)............................................................................................................1190 E-1 Engine Does Not Start (Engine Does Not Rotate)................................................................................1190 E-2 Manual Pre-Heating System Does Not Work.......................................................................................1198 E-3 Automatic Pre-Heating System Does Not Work....................................................................................1202 E-4 Pre-Heating Monitor Does Not Light Up When Pre-Heater is Operated.............................................................1204 E-5 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing...............................................1206 E-6 When Starting Switch is Turned to ON Position (Before Starting Engine), Engine Oil Level Monitor Lights Up in Yellow..........1209 E-7 When Starting Switch is Turned to ON Position (Before Starting Engine), Radiator Coolant Level Monitor Lights Up in Yellow....1209 E-8 Coolant Temperature Monitor Lights Up in White While Engine is Running........................................................1210 E-9 Hydraulic Oil Temperature Monitor Lights Up in White While Engine is Running..................................................1210 E-10 Charge Level Monitor Lights Up While Engine is Running.......................................................................1211 E-11 Fuel Level Monitor Lights Up in Red While Engine is Running..................................................................1211 E-12 Air Cleaner Clogging Monitor Lights Up in Yellow While Engine is Running.....................................................1211 E-13 Engine Coolant Temperature Monitor Lights Up in Red While Engine is Running..................................................1212 E-14 Hydraulic Oil Temperature Monitor Lights Up in Red While Engine is Running...................................................1212 E-15 Engine Oil Pressure Monitor Lights Up in Red While Engine is Running.........................................................1213 E-16 Fuel Gauge Display Does Not Move from Minimum or Maximum.....................................................................1214 E-17 Display of Fuel Gauge Differs from Actual Fuel Level.........................................................................1216 E-18 Coolant Temperature Gauge Indicate Either Min or Max and Does Not Move.......................................................1217 E-20 Hydraulic Oil Temperature Gauge Indicate Either Min or Max and Does Not Move.................................................1220 E-21 Hydraulic Oil Temperature Gauge Differs from Actual oil Temperature..........................................................1222 E-22 Machine Monitor Does Not Display Partially...................................................................................1223 E-23 Function Switch Does Not Work................................................................................................1223 E-24 Automatic Pre-Heating System Does Not Work (In Cold Weather).................................................................1224 E-25 Auto-Deceleration Monitor Does Not Light Up or Does Not Go Out When Auto-Deceleration Switch is Operated.....................1225 E-26 Auto-Deceleration is Not Actuated or Canceled When Lever is Operated.........................................................1226 E-27 Working Mode Selector Screen Selection Screen is Not Displayed When Working Mode Switch is Operated..........................1227 E-28 Engine or Hydraulic Pump Setting Does Not Change When Working Mode is Changed................................................1227 E-29 Travel Speed Monitor Does Not Change When Travel Speed Switch is Operated....................................................1227 E-30 Travel Speed Does Not Change When Travel Speed is Shifted....................................................................1228 E-31 Alarm Buzzer Does Not Stop Sounding..........................................................................................1229 E-32 When Starting Switch is Turned OFF, Service Meter is Not Displayed...........................................................1229 E-33 Machine Monitor Service Mode Cannot be Selected..............................................................................1230 E-34 All of Work Equipment, Swing and Travel Does Not Work........................................................................1232 E-35 All of Work Equipment, Swing and Travel Can Not be Locked....................................................................1234 E-36 Machine Can Not Swing While Swing Brake Cancel Switch is Canceled............................................................1236 E-37 Swing Brake Does Not Operate While Swing Brake Cancel Switch is set to NORMAL position.......................................1238 E-38 One-Touch Power Maximizing Function Does Not Work Or Pilot Monitor is Not Displayed..........................................1240 E-39 One-Touch Power Maximizing Function Cannot be Released.......................................................................1243 E-40 Travel Alarm Does Not Sound When Machine Travels.............................................................................1244 E-41 Travel Alarm Does Not Stop Sounding When Machine Stops.......................................................................1246 E-42 Horn Does Not Sound..........................................................................................................1248 E-43 Horn Does Not Stop Sounding..................................................................................................1250 E-44 Wiper Monitor Does Not Light Up or Go Out When Wiper Switch is Operated......................................................1251 E-45 Wiper Does Not Operate When Wiper Switch is Operated.........................................................................1252 E-46 Window Washer Does Not Operate When Window Washer Switch is Operated.........................................................1254 E-47 Boom LOWER Indication is Not Displayed Properly With Monitoring Function.....................................................1254 E-48 Arm DUMP Indication is Not Displayed Properly With Monitoring Function.......................................................1254 E-49 Arm IN Indication is Not Displayed Properly With Monitoring Function.........................................................1254 E-50 Boom RAISE Indication is Not Displayed Properly With Monitoring Function.....................................................1255 E-51 Bucket CURL Indication is Not Displayed Properly With Monitoring Function....................................................1255 E-52 Bucket DUMP Indication is Not Displayed Properly With Monitoring Function....................................................1255 E-53 Swing Indication is Not Displayed Properly With Monitoring Function..........................................................1255 E-54 Travel Indication is Not Displayed Properly With Monitoring Function.........................................................1256 E-55 Attachment is Not Displayed Properly With Monitoring Function................................................................1257 E-56 Attachment Hydraulic Circuit Cannot be Changed...............................................................................1260 E-57 KOMTRAX System Does Not Work Properly........................................................................................1262 E-58 Machine Push-up Function is Not Canceled.....................................................................................1264 HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)..............................................................................................1268 Information Mentioned in Troubleshooting Table (H Mode)...........................................................................1268 Failure Mode and Cause Table......................................................................................................1270 H-1 All of Work Equipment, Swing and Travel Operation Lacks Speed or Power........................................................1276 H-2 Engine Speed Lowers Significantly or Engine Stalls............................................................................1278 H-3 All of Work Equipment, Swing and Travel Does Not Work.........................................................................1280 H-4 Unusual Sound is Heard from Around Hydraulic Pump.............................................................................1280 H-5 Fine Control Performance or Response is Poor..................................................................................1281 H-6 Boom Operation Lacks Speed or Power...........................................................................................1282 H-7 Arm Operation Lacks Speed or Power............................................................................................1286 H-8 Bucket Operation Lacks Speed or Power.........................................................................................1290 H-9 Work Equipment Does Not Move in Single Operation..............................................................................1293 H-10 Hydraulic Drift of Boom is Large.............................................................................................1294 H-11 Time Lag of Work Equipment is Large..........................................................................................1298 H-13 One-Touch Power Maximizing Function Does Not Work............................................................................1300 H-14 Machine Push Up Function Does Not Work.......................................................................................1301 H-15 In Combined Operation of Work Equipment, Equipment Having Heavier Load Moves Slower..........................................1302 H-16 In Combined Operations of Swing and Boom RAISE, Boom Rising Speed is Low.....................................................1303 H-17 Travel Speed Drops Largely In Combined Operations of Swing and Travel........................................................1303 H-18 Machine Does Not Travel Straight.............................................................................................1304 H-19 Travel Speed is Too Low......................................................................................................1306 H-20 Machine is Hard to Steer or Travel Power is Low..............................................................................1308 H-21 Travel Speed Does Not Change, or Travel Speed is Too Low or High.............................................................1311 H-22 One of Tracks Does Not Run...................................................................................................1312 H-23 Upper Structure Does Not Swing to the Right or Left..........................................................................1313 H-24 Swing Acceleration is Poor or Swing Speed is Low.............................................................................1315 H-25 Upper Structure Overruns Excessively When it Stops Swinging..................................................................1317 H-26 Shock is Large When Upper Structure Stops Swinging...........................................................................1319 H-27 Large Unusual Noise is Heard When Upper Structure Stops Swinging.............................................................1320 H-28 Swing Drift On a Slope is Large..............................................................................................1321 H-29 Attachment circuit cannot be Changed.........................................................................................1323 H-30 Oil Flow in Attachment Circuit Cannot be Controlled..........................................................................1324 ENGINE (S-MODE).......................................................................................................................1328 Information Mentioned in Troubleshooting Table (S-Mode)...........................................................................1328 S-1 When Starting Switch is Turned to START Position, Engine Does Not Crank.......................................................1329 S-2 When Engine Cranks, Exhaust Smoke Does Not Come Out...........................................................................1330 S-3 Fuel is Being Injected But Engine Does Not Start (Incomplete Combustion: Engine Cranks but Does Not Start)....................1331 S-4 Start ability is Poor.........................................................................................................1333 S-5 Engine Does Not Pick Up Smoothly..............................................................................................1335 S-6 Engine Stops During Operation.................................................................................................1337 S-7 Engine Runs Rough or is Unstable..............................................................................................1339 S-8 Engine Lacks Power............................................................................................................1340 S-9 Exhaust Smoke is Black (KDPF Gets Clogged in a Short Time)....................................................................1342 S-10 Engine Oil Consumption is Excessive..........................................................................................1344 S-11 Oil Becomes Contaminated Early...............................................................................................1345 S-12 Fuel Consumption is Excessive................................................................................................1346 S-13 Oil is in Coolant (or Coolant Spurts or Coolant Level Goes Down).............................................................1347 S-14 Oil Pressure Drops...........................................................................................................1348 S-15 Fuel is Contaminated in Engine Oil...........................................................................................1350 S-16 Coolant Mixes in Engine Oil (Oil Becomes Cloudy White).......................................................................1351 S-17 Coolant Temperature Rises Too High (Overheating).............................................................................1352 S-18 Unusual Noise is Heard.......................................................................................................1353 S-19 Vibration is Excessive.......................................................................................................1354 S-20 Air Cannot be Bled from Fuel Circuit.........................................................................................1355 S-21 Automatic Regeneration is Operated Frequently................................................................................1356 S-22 Active Regeneration is Operated for Long.....................................................................................1357 S-23 White Smoke Comes Out in the Process of Active Regeneration..................................................................1358 50 DISASSEMBLY & ASSEMBLY.................................................................................................................1359 HOW TO READ THIS SECTION..............................................................................................................1364 Removal and Installation of Assemblies............................................................................................1364 Special Tools.................................................................................................................1364 Removal.......................................................................................................................1364 Installation..................................................................................................................1364 Disassembly and Assembly of Assemblies............................................................................................1365 Special Tools.................................................................................................................1365 Disassembly...................................................................................................................1365 Assembly......................................................................................................................1366 Coating Materials List............................................................................................................1367 SPECIAL TOOLS LIST....................................................................................................................1372 Sketches of Special Tools.........................................................................................................1376 CONNECTOR REPAIR PROCEDURES...........................................................................................................1382 Stripping Insulation..............................................................................................................1382 Wire Inspection...................................................................................................................1382 Contact Terminal Removal (HD30 Type)..............................................................................................1383 Crimping Contact Terminal (HD30 Type).............................................................................................1384 Insertion of Contact Terminal (HD30 Type).........................................................................................1385 Contact Terminal Removal (DT Type)................................................................................................1386 Crimping Contact Terminal (DT Type)...............................................................................................1387 Insertion of Contact Terminal (DT Type)...........................................................................................1388 ENGINE AND COOLING SYSTEM.............................................................................................................1389 Supply Pump Assembly..............................................................................................................1389 Removal.......................................................................................................................1389 Installation..................................................................................................................1394 Fuel Injector Assembly............................................................................................................1398 Removal.......................................................................................................................1398 Installation..................................................................................................................1402 Cylinder Head Assembly............................................................................................................1408 Removal.......................................................................................................................1408 Installation..................................................................................................................1416 Radiator Assembly.................................................................................................................1422 Removal.......................................................................................................................1422 Installation..................................................................................................................1424 Hydraulic Oil Cooler Assembly.....................................................................................................1426 Removal.......................................................................................................................1426 Installation..................................................................................................................1428 Aftercooler Assembly..............................................................................................................1430 Removal.......................................................................................................................1430 Installation..................................................................................................................1432 Cooling Fan and Fan Motor Assembly................................................................................................1434 Removal.......................................................................................................................1434 Installation..................................................................................................................1438 Engine and Main Pump Assembly.....................................................................................................1440 Removal.......................................................................................................................1440 Installation..................................................................................................................1450 Engine Front Oil Seal.........................................................................................................1454 Removal.......................................................................................................................1454 Installation..................................................................................................................1456 Engine Rear Oil Seal..............................................................................................................1460 Removal.......................................................................................................................1460 Installation..................................................................................................................1462 Engine Hood Assembly..............................................................................................................1466 Removal.......................................................................................................................1466 Installation..................................................................................................................1466 KDPF Assembly.....................................................................................................................1467 Removal.......................................................................................................................1467 Installation..................................................................................................................1469 KCCV Assembly.....................................................................................................................1470 Removal.......................................................................................................................1470 Installation..................................................................................................................1470 Air Cleaner Assembly..............................................................................................................1472 Removal.......................................................................................................................1472 Installation..................................................................................................................1473 POWER TRAIN...........................................................................................................................1474 Travel Motor and Final Drive Assembly.............................................................................................1474 Removal.......................................................................................................................1474 Installation..................................................................................................................1475 Final Drive.......................................................................................................................1476 Disassembly...................................................................................................................1476 Assembly......................................................................................................................1480 Swing Motor and Swing Machinery...................................................................................................1486 Removal.......................................................................................................................1486 Installation..................................................................................................................1487 Swing Machinery...................................................................................................................1488 Disassembly...................................................................................................................1488 Assembly......................................................................................................................1492 Swing Circle Assembly.............................................................................................................1497 Removal.......................................................................................................................1497 Installation..................................................................................................................1497 UNDERCARRIAGE AND FRAME...............................................................................................................1498 Separation and Connection of Track Shoe Assembly..................................................................................1498 Separation Track..............................................................................................................1498 Connecting Track..............................................................................................................1499 Sprocket..........................................................................................................................1501 Removal.......................................................................................................................1501 Installation..................................................................................................................1501 Idler and Idler Cushion Assembly..................................................................................................1502 Removal.......................................................................................................................1502 Installation..................................................................................................................1502 Idler.............................................................................................................................1503 Disassembly...................................................................................................................1503 Assembly......................................................................................................................1504 Idler Cushion.....................................................................................................................1507 Disassembly...................................................................................................................1507 Assembly......................................................................................................................1508 Track Roller......................................................................................................................1510 Assembly......................................................................................................................1510 Carrier Roller....................................................................................................................1511 Assembly......................................................................................................................1511 Revolving Frame Assembly..........................................................................................................1513 Removal.......................................................................................................................1513 Installation..................................................................................................................1515 Counterweight Assembly............................................................................................................1517 Removal.......................................................................................................................1517 Installation..................................................................................................................1519 HYDRAULIC SYSTEM......................................................................................................................1520 Center Swivel Joint Assembly......................................................................................................1520 Removal.......................................................................................................................1520 Installation..................................................................................................................1521 Center Swivel Joint...............................................................................................................1522 Disassembly...................................................................................................................1522 Assembly......................................................................................................................1523 Hydraulic Tank Assembly...........................................................................................................1524 Removal.......................................................................................................................1524 Installation..................................................................................................................1527 Main Pump Assembly................................................................................................................1530 Removal.......................................................................................................................1530 Installation..................................................................................................................1533 Control Valve Assembly............................................................................................................1536 Removal.......................................................................................................................1536 Installation..................................................................................................................1540 Procedures for Replacing Pressure Compensation Valve Seal Rings...............................................................1541 Assembly......................................................................................................................1543 Work Equipment PPC Valve..........................................................................................................1546 Disassembly...................................................................................................................1546 Assembly......................................................................................................................1546 Travel PPC Valve..................................................................................................................1548 Disassembly...................................................................................................................1548 Assembly......................................................................................................................1548 WORK EQUIPMENT........................................................................................................................1550 Work Equipment....................................................................................................................1550 Removal.......................................................................................................................1550 Installation..................................................................................................................1552 Work Equipment Cylinder...........................................................................................................1554 Disassembly...................................................................................................................1554 Assembly......................................................................................................................1557 CAB AND ITS ATTACHMENTS...............................................................................................................1560 Operator's Cab Assembly...........................................................................................................1560 Removal.......................................................................................................................1560 Installation..................................................................................................................1566 Operator Cab Glass (Fixed Glass)..................................................................................................1568 Removal.......................................................................................................................1569 Installation..................................................................................................................1570 Front Window Assembly.............................................................................................................1580 Removal.......................................................................................................................1580 Installation..................................................................................................................1583 Floor Frame Assembly..............................................................................................................1588 Removal.......................................................................................................................1588 Installation..................................................................................................................1595 Air Conditioner Unit Assembly.....................................................................................................1598 Removal.......................................................................................................................1598 Installation..................................................................................................................1603 Operator's Seat...................................................................................................................1604 Removal.......................................................................................................................1604 Installation..................................................................................................................1606 Seat Belt.........................................................................................................................1608 Removal.......................................................................................................................1608 Installation..................................................................................................................1609 Front Wiper Assembly..............................................................................................................1610 Removal.......................................................................................................................1610 Installation..................................................................................................................1616 ELECTRIC SYSTEM.......................................................................................................................1622 Air Conditioner Compressor Assembly...............................................................................................1622 Removal.......................................................................................................................1622 Installation..................................................................................................................1623 Air Conditioner Condenser Assembly................................................................................................1626 Removal.......................................................................................................................1626 Installation..................................................................................................................1626 Engine Controller Assembly........................................................................................................1628 Removal.......................................................................................................................1628 Installation..................................................................................................................1629 Pump Controller Assembly..........................................................................................................1630 Removal.......................................................................................................................1630 Installation..................................................................................................................1632 Machine Monitor Assembly..........................................................................................................1634 Removal.......................................................................................................................1634 Installation..................................................................................................................1636 Pump Swash Plate Sensor...........................................................................................................1638 Removal.......................................................................................................................1638 Installation..................................................................................................................1638 Mass Air Flow and Temperature Sensor..............................................................................................1640 Removal.......................................................................................................................1640 Installation..................................................................................................................1641 KOMTRAX Terminal Assembly.........................................................................................................1642 Removal.......................................................................................................................1642 Installation..................................................................................................................1643 60 MAINTENANCE STD........................................................................................................................1645 ENGINE AND COOLING SYSTEM.............................................................................................................1646 Engine Mounts.....................................................................................................................1646 Cooling System....................................................................................................................1648 Cooling Fan Pump..............................................................................................................1650 Servo Valve...................................................................................................................1651 Cooling Fan Motor.............................................................................................................1652 POWER TRAIN...........................................................................................................................1653 Swing Circle......................................................................................................................1653 Swing Machinery...................................................................................................................1654 Final Drive.......................................................................................................................1656 UNDERCARRIAGE AND FRAME...............................................................................................................1658 Sprocket..........................................................................................................................1658 Track Frame and Idler Cushion.....................................................................................................1660 Idler.............................................................................................................................1662 Track Roller......................................................................................................................1664 Carrier Roller....................................................................................................................1666 Track Shoe........................................................................................................................1668 Triple Grouser Shoe...............................................................................................................1671 HYDRAULIC SYSTEM......................................................................................................................1672 Main pump.........................................................................................................................1672 Control Valve.....................................................................................................................1675 General View..................................................................................................................1675 Swing Motor.......................................................................................................................1686 Travel Motor......................................................................................................................1689 PPC Valve.............................................................................................................................1692 Work Equipment and Swing PPC Valve................................................................................................1692 Travel PPC Valve..............................................................................................................1696 1st-Line Attachment PPC Valve (with EPC Valve)................................................................................1700 EPC Valve.....................................................................................................................1702 Solenoid Valve....................................................................................................................1704 Attachment Circuit Selector Valve.................................................................................................1705 For Low-Pressure Circuit......................................................................................................1705 Center Swivel Joint...............................................................................................................1706 WORK EQUIPMENT........................................................................................................................1707 Work equipment....................................................................................................................1707 Dimensions of Arm.................................................................................................................1712 Work Equipment Cylinder...........................................................................................................1718 Boom Cylinder.................................................................................................................1718 Arm Cylinder......................................................................................................................1719 Bucket Cylinder...................................................................................................................1720 80 AIR CONDITIONER........................................................................................................................1721 AIR CONDITIONER.......................................................................................................................1723 Precautions for Refrigerant.......................................................................................................1723 AIR CONDITIONER COMPONENT.............................................................................................................1724 STRUCTURE AND FUNCTION................................................................................................................1727 Overview..........................................................................................................................1728 Compression (Compressor)......................................................................................................1728 Condensation (Condenser)......................................................................................................1728 Expansion (Expansion valve)...................................................................................................1728 Evaporation (Evaporator)......................................................................................................1728 AIR CONDITIONER UNIT..................................................................................................................1730 Function..........................................................................................................................1731 Temperature Control...............................................................................................................1731 Over-cooling (Freezing) Prevention................................................................................................1731 Air Flow Adjustment...............................................................................................................1731 Vent (Mode) Changeover............................................................................................................1731 FRESH/RECIRC Air Changeover.......................................................................................................1732 Automatic Air Conditioner.........................................................................................................1732 Selection Pattern Of Vent (Mode) Changeover Door..............................................................................1732 Selection Pattern Of Air Mix Door (6).........................................................................................1732 Functions of Major Components.....................................................................................................1733 Evaporator....................................................................................................................1733 Heater Core...................................................................................................................1733 Evaporator Temperature Sensor.................................................................................................1733 Servomotor....................................................................................................................1733 Expansion Valve...............................................................................................................1734 DUAL PRESSURE SWITCH..................................................................................................................1736 AIR CONDITIONER CONTROLLER............................................................................................................1736 AIR CONDITIONER COMPRESSOR............................................................................................................1737 AIR CONDITIONER CONDENSER.............................................................................................................1738 RECEIVER DRIER........................................................................................................................1739 SUNLIGHT SENSOR.......................................................................................................................1740 OUTSIDE AIR TEMPERATURE SENSOR........................................................................................................1740 PROCEDURE FOR TESTING AND TROUBLESHOOTING.............................................................................................1741 Basic Inspection and Troubleshooting Sequence.....................................................................................1742 Air Conditioner Circuit Diagram and Arrangement of Connector Pins.................................................................1743 System Diagram....................................................................................................................1744 Air Conditioner Controller Input and Output Signals...............................................................................1745 PARTS AND CONNECTORS LAYOUT...........................................................................................................1747 Layout of Air Conditioner Related Parts and Connectors............................................................................1748 TESTING AIR LEAKAGE (DUCT)............................................................................................................1751 TESTING WITH SELF-DIAGNOSIS FUNCTION..................................................................................................1753 How to Enter Air Conditioner “Electrical Systems” Screen in Service Mode of the Machine Monitor...................................1754 TESTING VENT (MODE) CHANGEOVER........................................................................................................1756 TESTING FRESH/RECIRC AIR CHANGEOVER...................................................................................................1758 TESTING SUNLIGHT SENSOR...............................................................................................................1759 TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT........................................................................................1760 TESTING RELAY.........................................................................................................................1761 Troubleshooting Chart 1...........................................................................................................1762 Troubleshooting Chart 2...........................................................................................................1763 INFORMATION IN TROUBLESHOOTING TABLE..................................................................................................1766 Information in Troubleshooting Table..............................................................................................1766 FAILURE CODES FOR AIR CONDITIONER.....................................................................................................1768 879AKA - A/C Inner Sensor Open Circuit............................................................................................1769 879AKB - A/C Inner Sensor Short Circuit...........................................................................................1769 879BKA - A/C Outer Sensor Open Circuit............................................................................................1770 879BKB - A/C Outer Sensor Short Circuit...........................................................................................1772 879CKA - Ventilating Sensor Open Circuit..........................................................................................1774 879CKB - Ventilating Sensor Short Circuit.........................................................................................1775 879DKZ - Sunlight Sensor Open or Short Circuit....................................................................................1776 879EMC - Ventilation Damper Abnormality...........................................................................................1778 879FMC - Air Mix Damper Abnormality...............................................................................................1779 879GKX - Refrigerant Abnormality..................................................................................................1780 A-1 Troubleshooting for Power Supply System (The Air Conditioner Does Not Operate)................................................1782 A-2 Troubleshooting of Compressor System (Air is Not Cooled)......................................................................1784 A-3 Troubleshooting of Blower Motor System (Air Does Not Come Out or Air Flow is Normal)..........................................1788 A-4 Troubleshooting for FRESH/RECIRC Air Changeover...............................................................................1790 Troubleshooting with Gauge Pressure...............................................................................................1792 [Measurement Condition for Pressure]..........................................................................................1792 Testing Refrigerant Pressure......................................................................................................1795 Check.........................................................................................................................1796 Precautions for Disconnecting and Connecting Refrigerant Piping...................................................................1798 Disconnection.................................................................................................................1798 Connection....................................................................................................................1798 Tightening Torque for Joint Portion of Refrigerant Piping.........................................................................1799 HANDLING OF COMPRESSOR OIL............................................................................................................1800 Oil Level Control of Compressor...................................................................................................1800 Refilling of Compressor Oil.......................................................................................................1800 Replacement of compressor in case of compressor seizure or breakage...............................................................1801 Other cases.......................................................................................................................1801 Applying compressor oil to O-rings................................................................................................1802 90 DIAGRAMS AND SCHEMATICS................................................................................................................1803 HYDRAULIC SYSTEM......................................................................................................................1805 Hydraulic Circuit Diagram & Name of Valves........................................................................................1806 Hydcircuit Diagram (1/2)..........................................................................................................1806 Hydraulic Diagram (2/2)...........................................................................................................1808 ELECTRICAL SYSTEM.....................................................................................................................1809 Electrical Circuit Symbols........................................................................................................1809 Air Conditioner Electrical Circuit................................................................................................1810 Electrical Circuit Diagram (1/5)..................................................................................................1811 Electrical Circuit Diagram (2/5)..................................................................................................1812 Electrical Circuit Diagram (3/5)..................................................................................................1813 Electrical Circuit Diagram (4/5)..................................................................................................1814 Electrical Circuit Diagram (5/5)..................................................................................................1815
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- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
- No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
- Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
- So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com
