Komatsu PC88MR-10 Hydraulic Excavator Shop Manual WENBM00050 PDF

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Komatsu PC88MR-10 Hydraulic Excavator Shop Manual WENBM00050 – PDF DOWNLOAD

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Komatsu PC88MR-10 Hydraulic Excavator Shop Manual WENBM00050 – PDF DOWNLOAD 

Language : English
Pages : 1404
Downloadable : Yes
File Type : PDF

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DESCRIPTION:

Komatsu PC88MR-10 Hydraulic Excavator Shop Manual WENBM00050 – PDF DOWNLOAD 

SERIAL NUMBERS PC88MR-10 F10003 and up

How to read the shop manual
Composition of shop manual
• This shop manual describes the technical information required for the services performed in a workshop.
The shop manual is divided into the following chapters for the convenience of use.
00. Index and foreword
• This section includes the index, foreword, safety and basic information.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of the machine. The section of “Structure and function”
serves not only to give an understanding for the structure of each component, but also serves as reference
material for troubleshooting.
20. Standard value table
• The standard values for a new machine and trouble shooting are indicated. This standard value table is
used for testing and adjusting, and determining a failure at troubleshooting.
30. Testing and adjusting
• This section describes the measuring tools and how to measure, and how to adjust various parts. As for the
standard value and failure criterion, see the standard value table.
40. Troubleshooting
• This section describes the troubleshooting in a suspected area when a failure occurs and the remedy for
the failure. Troubleshooting is described by each failure mode.
50. Disassembly and assembly
• This section explains the procedures for removing, installing, disassembling, and assembling each part or
component and the special tools for the works as well as precautions for doing them safely. In addition,
tightening torque, and quantity and weight of coating material, oil, grease, and coolant required for the
works are also explained.
60. Maintenance standard
• This section describes the maintenance standard values for each component. This section gives the criterion
values for each component and required remedy at disassembly or maintenance.
80. Appendix
• The structure and function, testing and adjusting, and troubleshooting for all of the other components or
equipment which can not be separately classified are explained together in the appendix.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.

TABLE OF CONTENTS:

Komatsu PC88MR-10 Hydraulic Excavator Shop Manual WENBM00050 – PDF DOWNLOAD 

SERIAL NUMBERS PC88MR-10 F10003 and up

00 Index and foreword 3
Table of contents 4
Foreword, safety and general information 16
Important safety notice 16
Fire prevention 21
Dispose of waste materials 22
How to read the shop manual 23
Explanation of terms for maintenance standard 25
Handling equipment of fuel system devices 27
Handling of intake system parts 28
Handling of hydraulic equipment 29
Method of disconnecting and connecting of push-pull type coupler 31
Type 1 31
Type 2 32
Type 3 33
Handling of electrical equipment 34
How to read electric wire code 42
Precautions when performing operation 45
Practical use of KOMTRAX 50
Standard tightening torque table 51
List of abbreviation 57
Conversion table 62
01 Specification 67
Contents 68
Specifications 69
Specification drawing 69
Working range drawings 70
Specifications 71
Weight table 75
Table of fuel, coolant, and lubricants 77
10 Structure and function 79
Contents 80
Engine and cooling system 81
Engine related parts 81
PTO 83
Variable flow turbocharger 84
EGR system piping drawing 88
EGR system circuit diagram 90
EGR valve 91
EGR cooler 93
KCCV layout drawing 95
KCCV ventilator 98
CDR valve 99
KDOC muffler 100
Cooling system 102
Power train 105
Power train system 105
Swing circle 107
Swing machinery 109
Undercarriage and frame 111
Track frame 111
Idler cushion 113
Hydraulic system 114
Hydraulic component layout 114
Valve control 116
Hydraulic tank 118
Pressure valve 120
Breather 121
CLSS 122
Structure of CLSS 122
Main pump 126
Servo valve 132
Control valve 138
9-spool valve 138
10-spool valve 152
11-spool valve 154
Hydraulic circuit diagram and names of valves 156
10-spool valve 158
11-spool valve 159
Unload valve 160
Introduction of LS pressure 166
Travel valve 167
LS bypass plug 168
Pressure compensation valve 170
Boom regeneration circuit 172
Arm regeneration circuit 174
Merge-divider valve 176
Self-pressure reducing valve 178
Travel junction valve 179
Travel LS air bleeding circuit, travel junction valve (PC88MR-C600-042-K-01-A) 182
Boom hydraulic drift prevention valve 185
Hydraulic oil cooler bypass valve 188
Swing motor 189
Swing parking brake 192
Relief valve 194
Travel motor 200
Brake valve 205
Parking brake 209
Work equipment and swing PPC valve 211
Travel PPC valve 218
Blade PPC valve 224
Boom swing PPC valve 226
Solenoid valve 228
Oil flow adjuster EPC valve for attachment 231
Center swivel joint 232
Accumulator 233
PPC circuit accumulator 233
Attachment circuit accumulator (for low pressure circuit) 234
Work equipment 235
Work equipment 235
Work equipment shim 236
Bucket play adjustment shim 237
Cab and its attachments 238
Cab mount and cab tipping stopper 238
ROPS cab 240
Take wiring harness out of cab 241
Electrical system 242
Electrical control system 242
General system drawing 242
Engine control function 245
Engine and pump combined control function 247
Auto-deceleration function 252
Engine automatic warm-up function 254
Overheat prevention function 257
Turbocharger protection function 258
Swing control function 259
Travel control function 261
PPC lock function 264
Automatic idle stop 265
Work equipment and travel automatic lock function 268
System operating lamp function 270
Battery disconnect switch function 271
Oil flow adjuster function for attachment 273
System component parts 274
Pump controller 280
Fuel control dial 284
Resister for PC-EPC valve 285
CAN terminating resistor 285
Engine oil pressure switch 286
PPC oil pressure switch 287
Machine monitor system 288
Machine monitor 289
Display 292
Gauges 296
Caution lamps 298
Pilot display 300
Switches 302
Guidance icon and function switch 304
KOMTRAX system 310
KOMTRAX terminal 310
Sensor 312
Ambient pressure sensor 312
Charge (boost) pressure and temperature sensor 312
Coolant temperature sensor 313
Ne (crankshaft) speed sensor 313
Bkup (camshaft) speed sensor 314
Common rail pressure sensor 314
Variable flow turbocharger motor (with built-in position sensor) 315
EGR valve (with built-in position sensor) 315
Mass air flow and temperature sensor 316
Crankcase pressure sensor 317
Fuel level sensor 317
Hydraulic oil temperature sensor 318
Front pump oil pressure sensor 318
PPC oil pressure sensor 319
20 Standard value tables 321
Contents 322
Standard service value table 323
Standard value table for engine 323
Standard value table for machine 325
Engine speed 325
Travel of control lever 325
Control effort of control lever 326
Hydraulic pressure 327
Swing 329
Travel 331
Work equipment 332
Pump performance 335
Machine posture and procedure for measuring performance 337
Standard value table for electrical system 342
Controller 342
Engine control 343
Machine control 344
30 Testing and adjusting 347
Table of contents 348
Related information on testing and adjusting 349
Tools for testing and adjusting 349
Sketch of tools for testing and adjusting 352
P4: Sensor adapter 352
P4: Nipple (the internal parts of the sensor adapter shown in the above figure) 352
-: Socket 353
Engine and cooling system 354
Testing engine speed 354
Testing exhaust gas color 355
Testing and adjusting valve clearance 356
Testing compression pressure 358
Testing blowby pressure 360
Testing engine oil pressure 361
Testing fuel pressure 362
Testing fuel return rate and leakage 363
Bleeding air from fuel system 366
Bleeding air 366
Testing fuel circuit for leakage 368
Handling cylinder cutout mode operation 369
Handling no-injection cranking operation 370
Testing and adjusting air conditioner compressor belt tension 371
Replacing fan belt 372
Writing compensation values at replacement of injector and engine controller 374
Power train 378
Testing swing circle bearing clearance 378
Undercarriage and frame 379
Testing and adjusting track tension 379
Hydraulic system 380
Releasing remaining pressure from hydraulic circuit 380
Testing and adjusting oil pressure in work equipment and travel circuits 382
Testing and adjusting swing and blade circuit oil pressure 385
Testing oil pressure of control circuit 388
Testing and adjusting oil pressure in pump PC control circuit 389
Testing and adjusting oil pressure in pump LS control circuit 392
Testing outlet pressure of solenoid valve 395
Testing PPC valve outlet pressure 396
Adjusting play of work equipment and swing PPC valves 397
Isolating the parts causing hydraulic drift in work equipment 398
Testing and adjusting travel deviation 399
Adjusting 400
Testing oil leakage 401
Bleeding air from hydraulic circuit 405
Cab and its attachments 408
Testing, cleaning and lubricating slide door rail and roller 408
Adjusting mirrors 409
Testing and adjusting hood catcher 410
Electrical system 412
Special functions of machine monitor 412
Ordinary functions and special functions of machine monitor 414
Operator mode (outline) 417
KOMTRAX terminal start-up procedure 460
Adjusting rearview camera angle 464
Handling voltage circuit of engine controller 466
Handling battery disconnect switch 467
Testing diodes 468
Pm clinic 469
Pm Clinic service 469
Check sheet 471
40 Troubleshooting 479
Table of contents 480
Related information on troubleshooting 486
Troubleshooting points 486
Sequence of events in troubleshooting 488
Checks before troubleshooting 490
Inspection procedure before troubleshooting 492
Walk-around check 492
Testing in accordance with testing procedure 493
Preparation for troubleshooting of electrical system 509
Classification and procedures for troubleshooting 514
Symptom and troubleshooting numbers 517
Information in troubleshooting table 520
Troubleshooting method for open circuit in wiring harness of pressure sensor system 522
Connector contact identification 524
T-branch box and T-branch adapter table 562
Fuse location table 567
Failure codes table 569
Troubleshooting by failure code (Display of code) 575
Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit 575
Failure code [879AKB] A/C Recirc Air Temp Sens Short 576
Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit 577
Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit 578
Failure code [879CKA] Ventilating Sensor Open Circuit 579
Failure code [879CKB] Ventilating Sensor Short Circuit 580
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 581
Failure code [879EMC] Ventilation Damper Malfunction 582
Failure code [879FMC] Air Mix Damper Malfunction 583
Failure code [879GKX] Refrigerant Press Input Sig Out of Range 584
Failure code [989L00] Engine Controller Lock Caution 1 585
Failure code [989M00] Engine Controller Lock Caution 2 586
Failure code [989N00] Engine Controller Lock Caution 3 587
Failure code [A900FR] Abrupt Engine Stop by Auto Idle Stop 3 588
Failure code [A900N6] Abrupt Engine Stop by Auto Idle Stop 1 589
Failure code [A900NY] Abrupt Engine Stop by Auto Idle Stop 2 590
Failure code [AB00KE] Charge Voltage Low 591
Failure code [B@BAZG] Eng Oil Press Low 593
Failure code [B@BCNS] Eng Water Overheat 594
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 595
Failure code [CA122] Charge Air Pressure Sensor High Error 596
Failure code [CA123] Charge Air Pressure Sensor Low Error 598
Failure code [CA131] Throttle Sensor High Error 600
Failure code [CA132] Throttle Sensor Low Error 602
Failure code [CA144] Coolant Temperature Sensor High Error 604
Failure code [CA145] Coolant Temperature Sensor Low Error 606
Failure code [CA153] Charge Air Temperature Sensor High Error 608
Failure code [CA154] Charge Air Temperature Sensor Low Error 610
Failure code [CA187] Sensor 2 Supply Voltage Low Error 612
Failure code [CA221] Ambient Pressure Sensor High Error 614
Failure code [CA222] Ambient Pressure Sensor Low Error 616
Failure code [CA227] Sensor 2 Supply Voltage High Error 618
Failure code [CA234] Engine Overspeed 619
Failure code [CA238] NE Speed Sensor Supply Voltage Error 620
Failure code [CA239] NE Speed Sensor Supply Voltage High Error 621
Failure code [CA271] PCV1 Short Circuit Error 622
Failure code [CA272] PCV1 Open Circuit Error 623
Failure code [CA322] Injector #1 (L#1) Open or Short Circuit 624
Failure code [CA324] Injector #3 (L#3) Open or Short Circuit 626
Failure code [CA331] Injector #2 (L#2) Open or Short Circuit 628
Failure code [CA332] Injector #4 (L#4) Open or Short Circuit 630
Failure code [CA343] Engine Controller Internal Failure 632
Failure code [CA351] Injectors Drive Circuit Error 633
Failure code [CA352] Sensor1 Supply Voltage Low Error 634
Failure code [CA356] MAF Sensor High Error 636
Failure code [CA357] MAF Sensor Low Error 638
Failure code [CA386] Sensor1 Supply Voltage High Error 640
Failure code [CA435] Engine Oil Pressure SW Error 641
Failure code [CA441] Battery Voltage Low Error 642
Failure code [CA442] Battery Voltage High Error 644
Failure code [CA449] Common Rail Pressure High Error 2 645
Failure code [CA451] Common Rail Pressure Sensor High Error 646
Failure code [CA452] Common Rail Pressure Sensor Low Error 648
Failure code [CA466] KVGT Motor Driver Position Error 650
Failure code [CA515] Rail Pressure Sensor Sup Volt High Error 652
Failure code [CA516] Rail Pressure Sensor Sup Volt Low Error 654
Failure code [CA553] Common Rail Pressure High Error 1 656
Failure code [CA555] Crankcase Pressure High Error 1 657
Failure code [CA556] Crankcase Pressure High Error 2 658
Failure code [CA559] Common Rail Pressure Low Error 1 659
Failure code [CA689] Engine NE Speed Sensor Error 662
Failure code [CA691] Intake Air Temperature Sensor High Error 664
Failure code [CA692] Intake Air Temperature Sensor Low Error 666
Failure code [CA697] Engine Con Internal Temp Sens High Error 668
Failure code [CA698] Engine Con Internal Temp Sens Low Error 669
Failure code [CA731] Engine Backup Speed Sensor Phase Error 670
Failure code [CA778] Engine Backup Speed Sensor Error 672
Failure code [CA1117] Engine Controller Partial Data Lost Error 676
Failure code [CA1695] Sensor 5 Supply Voltage High Error 677
Failure code [CA1696] Sensor 5 Supply Voltage Low Error 678
Failure code [CA1843] Crankcase Pressure Sensor High Error 679
Failure code [CA1844] Crankcase Pressure Sensor Low Error 681
Failure code [CA1896] EGR Valve Stuck Error 683
Failure code [CA1942] Crankcase Pressure Sensor In Range Error 684
Failure code [CA1961] EGR_Motor Driver IC Over Temp Error 685
Failure code [CA2185] Throttle Sensor Supply Voltage High Error 686
Failure code [CA2186] Throttle Sensor Supply Voltage Low Error 688
Failure code [CA2249] Common Rail Pressure Low Error 2 690
Failure code [CA2272] EGR Valve Position Sensor Low Error 691
Failure code [CA2311] IMV Solenoid Error 693
Failure code [CA2349] EGR Valve Solenoid Open Circuit Error 694
Failure code [CA2353] EGR Valve Solenoid Short Circuit Error 696
Failure code [CA2357] EGR Valve Servo Error 698
Failure code [CA2765] Injector Trim Data Mismatch 699
Failure code [CA3419] MAF Sensor Supply Voltage High Error 700
Failure code [CA3421] MAF Sensor Supply Voltage Low Error 702
Failure code [CA3724] EGR/KVGT Motor Driver Power Low Error 704
Failure code [CA3918] KVGT Stuck Error (D37-CA3918-400-A-Z0-A) 706
Failure code [CA3919] KVGT Motor Driver IC Over Temp Error 707
Failure code [CA3921] KVGT Servo Error 2 708
Failure code [CA3922] KVGT Motor Driver Open Error 709
Failure code [CA3923] KVGT Motor Driver Short Error 711
Failure code [D110KB] Battery Relay Output Short Circuit 713
Failure code [D19JKZ] Personal Code Relay Open or Short 715
Failure code [D811MC] KOMTRAX Malfunction 718
Failure code [D862KA] GPS Antenna Open Circuit 719
Failure code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX) 720
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 722
Failure code [D8AQKR] CAN 2 Defective Communication (KOMTRAX) 723
Failure code [DA20MC] Pump Controller Malfunction 725
Failure code [DA22KK] Pump Con Solenoid Power Volt Low Error 726
Failure code [DA25KP] 5V Sensor 1 Power Voltage Low Error 728
Failure code [DA29KQ] Model Selection Sig Mismatch (Pump Con) 731
Failure code [DA2LKA] Operating Lamp Open Circuit (Pump Con) 733
Failure code [DA2LKB] Operating Lamp Short Circuit (Pump Con) 735
Failure code [DA2QKR] CAN 2 Defective Communication (Pump Con) 736
Failure code [DA2RKR] CAN 1 Defective Communication (Pump Con) 738
Failure code [DAF0MB] Monitor ROM Abnormality 739
Failure code [DAF0MC] Monitor Malfunction 740
Failure code [DAF8KB] Camera Power Supply Short Circuit 741
Failure code [DAF9KQ] Model Selection Signal Mismatch (Monitor) 743
Failure code [DAFGMC] GPS Module Malfunction 744
Failure code [DAFLKA] Operating Lamp Open Circuit (Monitor) 745
Failure code [DAFLKB] Operating Lamp Short Circuit (Monitor) 747
Failure code [DAFQKR] CAN 2 Defective Communication (Monitor) 748
Failure code [DAZ9KQ] Model Selection Sig Mismatch (A/C) 749
Failure code [DAZQKR] CAN2 Defective Communication (A/C ECU) 750
Failure code [DB2QKR] CAN2 Defective Communication (Engine Con) 754
Failure code [DB2RKR] CAN1 Defective Communication (Engine Con) 758
Failure code [DDNRKA] WE Lever Lock SW Open Circuit 762
Failure code [DDNRKY] WE Lever Lock SW Short Circuit 764
Failure code [DDNS00] Lock Lever Auto Lock Release SW On 766
Failure code [DGH2KB] Hydraulic Oil Temp Sensor Ground Fault 768
Failure code [DHPAMA] Front Pump Press Sens Defective Function 770
Failure code [DHS3MA] Arm IN PPC Press Sensor Def Function 772
Failure code [DHS4MA] Bucket CURL PPC Press Sens Def Function 774
Failure code [DHS5MA] Travel PPC Sensor Abnormality 776
Failure code [DHS8MA] Boom Raise PPC Press Sens Def Function 778
Failure code [DHS9MA] Boom Lower PPC Press Sens Def Function 780
Failure code [DHSAMA] Swing Right PPC Press Sens Def Function 782
Failure code [DHSBMA] Swing Left PPC Press Sensor Def Function 784
Failure code [DHSCMA] Arm OUT PPC Press Sens Def Function 786
Failure code [DHSDMA] Bucket DUMP PPC Press Sens Def Function 788
Failure code [DHSPMA] Boom Swing LH PPC Press Sensor Abnormality 790
Failure code [DHSQMA] Boom Swing RH PPC Press Sensor Abnormality 792
Failure code [DKULKA] PPC Lock Relay Open Circuit 794
Failure code [DKULKB] PPC Lock Relay Short Circuit 796
Failure code [DKULKY] PPC Lock Relay Hot Short Circuit 798
Failure code [DV20KB] Travel Alarm Short Circuit 800
Failure code [DW43KA] Travel Speed Solenoid Open Circuit 802
Failure code [DW43KB] Travel Speed Solenoid Short Circuit 804
Failure code [DW43KY] Travel Speed Sol Hot Short Circuit 806
Failure code [DW45KA] Swing Parking Brake Solenoid Open Circuit 807
Failure code [DW45KB] Swing Parking Brake Solenoid Short Circuit 810
Failure code [DW45KY] Swing Brake Sol Hot Short Circuit 813
Failure code [DW4CKY] PPC lock Sol Hot Short Circuit 815
Failure code [DWJ0KA] Merge-divider Sol Open Circuit 817
Failure code [DWJ0KB] Merge-divider Sol Short Circuit 819
Failure code [DWJ0KY] Merge-divider Sol Short Circuit 821
Failure code [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit 822
Failure code [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit 824
Failure code [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid Open Circuit 826
Failure code [DXE7KB] Att Flow Regulating EPC 2 Short Circuit 828
Failure code [DXE7KY] Attachment Flow Regulating EPC 2 Solenoid Hot Short Circuit 830
Failure code [DXEAKA] Att Flow Regulating EPC 5 Open Circuit 832
Failure code [DXEAKB] Att Flow Regulating EPC 5 Short Circuit 834
Failure code [DXEAKY] Service Current EPC5 Hot Short Circuit 836
Failure code [DY20KA] Wiper Motor Open Circuit 838
Failure code [DY20MA] Wiper Motor Defective Function 840
Failure code [DY2CKB] Washer Motor Short Circuit 842
Failure code [DY2DKB] Wiper Motor (Normal) Short Circuit 844
Failure code [DY2EKB] Wiper Motor (Reverse) Short Circuit 846
Troubleshooting of electrical system (E-mode) 848
E-1 Engine does not start (Engine does not crank) 848
E-2 Manual preheating system does not work 854
E-3 While preheating is working, preheating monitor does not light up 857
E-4 When starting switch is turned to ON position, machine monitor displays nothing 859
E-5 Engine coolant temperature monitor lights up in white while engine is running 862
E-6 Hydraulic oil temperature monitor lights up in white while engine is running 863
E-7 Charge level monitor lights up while engine is running 864
E-8 Fuel level monitor lights up in red while engine is running 865
E-9 Engine coolant temperature monitor lights up in red while engine is running 866
E-10 Hydraulic oil temperature monitor lights up in red while engine is running 867
E-11 Engine oil pressure monitor lights up in red while engine is running 868
E-12 Fuel gauge display does not move from minimum or maximum 869
E-13 Fuel gauge indicates incorrect amount (indicates neither full nor empty) 870
E-14 Engine coolant temperature gauge display does not move from minimum or maximum 871
E-15 Engine coolant temperature gauge indicates incorrect temperature (indicates neither full nor empty) 872
E-16 Hydraulic oil temperature gauge does not move from minimum or maximum 873
E-17 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither full nor empty) 875
E-18 Some areas of machine monitor screen are not displayed 876
E-19 Function switch does not work 877
E-20 Automatic warm-up system does not operate (in cold season) 878
E-21 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration switch is operated 879
E-22 Auto-deceleration function does not operate or is not canceled while lever is operated 880
E-23 Working mode selection screen is not displayed while working mode selector switch is operated 882
E-24 Setting of engine and hydraulic pump is not changed while working mode is changed 883
E-25 Travel speed monitor does not change when travel speed switch is operated 884
E-26 Travel speed does not change while travel speed selection is changed 885
E-27 Alarm buzzer does not stop sounding 886
E-28 Service meter is not displayed, while starting switch is in OFF position 887
E-29 Service mode cannot be selected 888
E-30 Any of work equipment, swing and travel does not work 889
E-31 Any of work equipment, swing and travel cannot be locked 892
E-32 Upper structure does not swing while swing parking brake cancel switch is set to CANCEL position 894
E-33 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position 896
E-34 Work equipment does not operate while lock lever automatic release switch is in release position 898
E-35 Alarm does not sound during travel 900
E-36 Alarm does not stop sounding while machine is stopped 901
E-37 Horn does not sound 902
E-38 Horn does not stop sounding 904
E-39 Wiper monitor does not light up, or does not go out, while wiper switch is operated 905
E-40 Wiper does not operate while wiper switch is operated 906
E-41 Window washer does not operate while window washer switch is operated 908
E-42 Boom LOWER is not displayed correctly with monitoring function 909
A-43 Arm OUT is not displayed correctly with monitoring function 910
E-44 Arm IN is not displayed correctly with monitoring function 911
E-45 Boom RAISE is not displayed correctly with monitoring function 912
E-46 Bucket CURL is not displayed correctly with monitoring function 913
E-47 Bucket DUMP is not displayed correctly with monitoring function 914
E-48 Boom swing left is not displayed correctly with monitoring function 915
E-49 Boom swing right is not displayed correctly with monitoring function 916
E-50 Swing is not displayed correctly with monitoring function 917
E-51 Travel is not displayed correctly with monitoring function 918
E-52 Blade RAISE ON is not displayed correctly with monitoring function 919
E-53 Blade LOWER ON is not displayed correctly with monitoring function 921
E-54 KOMTRAX system does not operate normally 923
Troubleshooting of hydraulic and mechanical system (H-mode) 925
Information described in troubleshooting table (H-mode) 925
System chart of hydraulic and mechanical systems 926
Failure mode and cause table 928
H-1 All of work equipments, swing and travel operations lack speed or power 936
H-2 Engine speed drops significantly or engine stalls 938
H-3 Any of work equipment, swing and travel does not work 939
H-4 Unusual sound is heard from around hydraulic pump 940
H-5 Fine control performance or response is poor 941
H-6 Boom speed or power is low 942
H-7 Arm speed or power is low 945
H-8 Bucket speed or power is low 947
H-9 Boom swing speed or power is low 949
H-10 Blade speed or power is low 951
H-11Work equipment does not move in single operation 953
H-12 Hydraulic drift of boom is large 954
H-13 Hydraulic drift of arm is large 955
H-14 Hydraulic drift of bucket is large 956
H-15 Hydraulic drift of blade is large 957
H-16 Time lag of work equipment is large 958
H-17 In combined operation of work equipment, equipment having heavier load moves slower 960
H-18 In combined operation of swing and boom RAISE, boom rising speed is low 961
H-19 In combined operation of work equipment or swing and travel, travel speed drops largely 962
H-20 Machine does not travel straight 964
H-21 Travel speed is slow 966
H-22 Machine is hard to steer or travel power is low 968
H-23 Travel speed does not change, or travel speed is too slow or fast 971
H-24 One of tracks does not run 972
H-25 Upper structure does not swing to the right or left 974
H-26 Upper structure swing only to the right or left 975
H-27 Swing acceleration or swing speed is low in both directions (right and left 976
H-28 Swing acceleration performance is poor or swing speed is slow in only one direction 977
H-29 Upper structure overruns excessively when it stops swinging (both right and left) 978
H-30 Upper structure overruns excessively when it stops swinging (either right or left) 979
H-31 Shock is large when upper structure stops swinging 980
H-32 Large unusual noise is heard when upper structure stops swinging 981
H-33 Swing drift on a slope is large while swing parking brake is applied 982
H-34 Swing drift on a slope is large while swing parking brake is released 983
H-35 Oil flow in attachment circuit cannot be controlled 984
Troubleshooting of engine (S-mode) 985
Information mentioned in troubleshooting table (S mode) 985
S-1 Engine does not crank when starting switch is turned to START position 986
S-2 Engine cranks but no exhaust smoke comes out 987
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start) 988
S-4 Engine startability is poor 989
S-5 Engine does not pick up smoothly 991
S-6 Engine stops during operation 993
S-7 Engine runs rough or is unstable 995
S-8 Engine lacks power 996
S-9 Exhaust smoke is black 997
S-10 Engine oil consumption is excessive 999
S-11 Oil becomes contaminated quickly 1000
S-12 Fuel consumption is excessive 1001
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1002
S-14 Oil pressure drops 1003
S-15 Fuel mixes into engine oil (PC400-B31-400-A-Z0-A) 1004
S-16 Water mixes into engine oil (milky) 1005
S-17 Coolant temperature rises too high (overheating) 1006
S-18 Unusual noise is heard 1007
S-19 Vibration is excessive 1008
S-20 Air cannot be bled from fuel circuit 1009
50 Disassembly and assembly 1011
Contents 1012
General information on disassembly and assembly 1014
How to read this manual 1014
Coating materials list 1016
Adhesive 1016
Liquid gasket 1017
Molybdenum disulfide lubricant 1017
Seizure prevention compound 1018
Grease 1018
Primer 1019
Adhesive 1019
Caulking material 1019
Special tools list 1020
Sketches of special tools 1021
A2 Push tool 1021
A3: Plate 1021
F7: Push tool 1022
R: Guide 1022
Engine and cooling system 1023
Removal and installation of supply pump assembly 1023
Removal and installation of injector assembly 1026
Removal and installation of cylinder head assembly 1032
Removal and installation of radiator assembly 1044
Removal and installation of hydraulic oil cooler assembly 1047
Removal and installation of aftercooler assembly 1050
Removal and installation of engine and main pump assembly 1052
Removal and installation of engine front oil seal 1060
Removal and installation of engine rear oil seal 1061
Removal and installation of fuel cooler assembly 1063
Removal and installation of fuel tank assembly 1064
Removal and installation of engine hood assembly 1066
Removal and installation of KDOC muffler 1067
Removal and installation of KCCV ventilator 1070
Removal and installation of air cleaner assembly 1072
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly 1074
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly 1076
Removal and installation of fan belt 1077
Power train system 1078
Removal and installation of travel motor and final drive assembly 1078
Disassembly and assembly of travel motor and final drive assembly 1080
Assembly 1101
Removal and installation of swing motor and swing machinery assembly 1114
Disassembly and assembly of swing machinery assembly 1116
Removal and installation of swing circle assembly 1124
Undercarriage and frame 1125
Separation and connection of track 1125
Removal and installation of sprocket 1126
Removal and installation of idler and idler cushion assembly 1127
Disassembly and assembly of idler assembly 1128
Disassembly and assembly of idler cushion assembly 1131
Disassembly 1131
Assembly 1132
Disassembly and assembly of track roller assembly 1134
Removal and installation of revolving frame assembly 1137
Removal and installation of counterweight assembly [For machines with additional counterweight] 1139
Hydraulic system 1141
Removal and installation of center swivel joint assembly 1141
Disassembly and assembly of center swivel joint assembly 1143
Removal and installation of hydraulic tank assembly 1144
Removal and installation of main pump assembly 1147
Removal and installation of control valve assembly 1151
Disassembly and assembly of control valve assembly 1155
Assembly 1155
Disassembly and assembly of work equipment PPC valve assembly 1158
Disassembly 1158
Disassembly and assembly of travel PPC valve assembly 1160
Disassembly and assembly of work equipment cylinder assembly 1161
Disassembly and assembly of 2-piece boom cylinder assembly 1165
Work equipment 1170
Removal and installation of work equipment assembly 1170
Removal and installation of work equipment assembly (with 2-piece boom) 1173
Removal and installation of boom swing bracket 1175
Removal and installation of blade assembly 1176
Cab and its attachments 1178
Removal and installation of operator’s cab assembly 1178
Removal and installation of operator’s cab door 1182
Removal and installation of operator’s cab glass (adhered glass) 1185
Removal and installation of front window assembly 1195
Removal and installation of floor frame assembly 1196
Removal and installation of air conditioner unit assembly 1201
Removal and installation of air conditioner compressor assembly 1207
Removal and installation of air conditioner condenser assembly 1209
Removal and installation of operator’s seat 1211
Removal and installation of seat belt 1212
Removal and installation of front wiper assembly 1213
Electrical system 1220
Removal and installation of starting motor assembly 1220
Removal and installation of engine controller assembly 1221
Removal and installation of pump controller assembly 1222
Removal and installation of machine monitor assembly 1223
Removal and installation of mass air flow and temperature sensor 1225
Removal and installation of KOMTRAX terminal assembly 1226
60 Maintenance standard 1227
Contents 1228
Engine and cooling system 1229
Engine mount 1229
PTO 1230
Cooling system 1231
Power train system 1233
Swing circle 1233
Swing machinery 1235
Sprocket 1237
Undercarriage and frame 1238
Track frame 1238
Idler cushion 1239
Idler 1240
Track roller 1241
Carrier roller 1242
Track shoe 1243
Triple grouser shoe 1246
Road liner 1247
Rubber shoe 1248
Hydraulic system 1249
Hydraulic tank 1249
Main pump 1250
Servo valve 1252
PC-EPC valve 1253
Control valve 1254
9-spool valve 1254
Swing motor 1263
Travel motor 1265
PPC valve 1266
Work equipment and swing PPC valve 1266
Travel PPC valve 1269
Blade PPC valve 1271
Boom swing PPC valve 1273
Solenoid valve 1275
Attachment flow adjustment EPC valve 1276
Center swivel joint 1277
Cab and its attachments 1278
Cab mount and cab tipping stopper 1278
Work equipment 1279
Work equipment 1279
Dimensions of arm 1284
Dimensions of bucket 1288
Boom cylinder 1290
Arm cylinder 1291
Bucket cylinder 1292
Boom swing cylinder 1293
Blade cylinder 1294
80 Appendix 1295
Contents 1296
Air conditioner components 1297
Precautions for refrigerant 1297
Air conditioner component 1298
Specifications 1300
Configuration and function of refrigeration cycle 1301
Outline of refrigeration cycle 1302
Air conditioner unit 1304
Function 1305
Functions of major components 1306
Dual pressure switch 1309
Function 1309
Air conditioner controller 1310
Compressor 1311
Specification 1311
Function 1311
Condenser 1312
Specification 1312
Function 1312
Receiver drier 1313
Function 1313
Specification 1313
Sunlight sensor 1314
Function 1314
Output characteristics 1314
Outer temperature sensor (outside air temperature sensor) 1315
Function 1315
Procedure for testing and troubleshooting 1316
Circuit diagram and arrangement of connector pins 1318
System diagram 1320
Input and output signals of the air conditioner controller 1321
Function 1321
Air conditioner unit 1323
Parts and connectors layout 1325
Details 1325
Testing air leakage (duct) 1331
Testing with self-diagnosis function 1333
Testing outline 1333
How to open the electrical system abnormality record screen in service mode of the machine monitor 1333
Testing vent (mode) changeover 1336
Testing 1336
Testing FRESH/RECIRC air changeover 1337
Testing 1337
Testing sunlight sensor 1338
Testing 1338
Testing (dual) pressure switch for refrigerant 1339
Testing 1339
Testing relays 1341
Testing 1341
Troubleshooting chart 1 1342
Troubleshooting chart 2 1343
Information in troubleshooting table 1346
Failure code list related to air conditioner 1347
Failure code [879AKA] A/C Recirc Air Temp Sens Open Circuit 1348
Failure code [879AKB] A/C Recirc Air Temp Sens Short 1349
Failure code [879BKA] A/C Fresh Air Temp Sens Open Circuit 1350
Failure code [879BKB] A/C Fresh Air Temp Sens Short Circuit 1352
Failure code [879CKA] Ventilating Sensor Open Circuit 1354
Failure code [879CKB] Ventilating Sensor Short Circuit 1355
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 1356
Failure code [879EMC] Ventilation Damper Malfunction 1358
Failure code [879FMC] Air Mix Damper Malfunction 1359
Failure code [879GKX] Refrigerant Press Input Sig Out of Range 1360
A-1 Troubleshooting for power supply system (Air conditioner does not operate) 1361
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) 1363
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1366
A-4 Troubleshooting for FRESH/RECIRC air changeover 1368
Troubleshooting with gauge pressure 1370
Connection of service tool 1373
Precautions for disconnecting and connecting refrigerant piping 1375
Handling of compressor oil 1377
90 Diagrams and drawings 1379
Contents 1380
Hydraulic circuit diagram 1381
Symbols in hydraulic circuit diagram 1381
Hydraulic circuit diagram (1/2) 1385
Hydraulic circuit diagram (2/2) 1387
Electric circuit diagram 1389
Symbols in electric circuit diagram 1389
Electrical circuit diagram (1/6) 1393
Electrical circuit diagram (2/6) 1395
Electrical circuit diagram (3/6) 1397
Electrical circuit diagram (4/6) 1399
Electrical circuit diagram (5/6) 1401
Electrical circuit diagram (6/6) 1403

S.V 12/12/24