Komatsu Hydraulic Excavators PC210LL Repair Service Manual

Komatsu Hydraulic Excavators PC210LL Repair Service Manual

CEBM029201 - Hydraulic Excavator PC210LL-10 Shop Manual (SN-A52001&up_Engine-6D107E-2).pdf

Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC210LL-10, with all the shop information to maintain, diagnostic, repair, rebuild like professional mechanics.

Komatsu Hydraulic Excavators PC210LL-10 workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 1,727 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
00 Index and foreword ..... 00-1
Index ..... 00-2
Foreword, safety and general information ..... 00-14
Important safety notice ....... 00-14
How to read the shop manual.... 00-21
Explanation of terms for maintenance standard .. 00-23
Handling equipment of fuel system devices .. 00-25
Handling of intake system parts....... 00-26
Handling of hydraulic equipment...... 00-27
Method of disconnecting and connecting of push-pull type coupler ..... 00-29
Handling of electrical equipment...... 00-32
How to read electric wire code... 00-40
Precautions when performing operation ....... 00-43
Practical use of KOMTRAX ....... 00-47
Standard tightening torque table...... 00-48
List of abbreviation ....... 00-52
Conversion table.... 00-57
01 Specification... 01-1
Table of contents ...01-1
Specifications...01-2
Specification drawing .......01-2
Working range drawings ...01-5
Specifications .......01-6
Weight table ...... 01-8
Table of fuel, coolant, and lubricants ......01-10
10 Structure and function ....... 10-1
Table of contents ...... 10-2
Engine and cooling system .... 10-3
Engine related parts ....... 10-3
KVGT.... 10-5
EGR system piping drawing ...... 10-12
EGR system circuit diagram...... 10-14
EGR valve....... 10-16
EGR cooler...... 10-18
KCCV layout drawing ... 10-19
KCCV ventilator ..... 10-21
KDPF.. 10-23
Cooling system ...... 10-27
Power train....... 10-29
Power train system....... 10-29
Swing circle ..... 10-31
Swing machinery ... 10-32
Final drive ....... 10-34
Undercarriage and frame..... 10-36
Track frame and idler cushion ... 10-36
Hydraulic system .... 10-38
Hydraulic equipment layout drawing ...... 10-38
Valve control.... 10-40
Hydraulic tank.. 10-42
CLSS .. 10-44
Main pump ...... 10-49
Control valve ... 10-74
Swing motor .. 10-131
Travel motor .....10-144
PPC valve ..... 10-156
Solenoid valve ..10-176
Center swivel joint ...... 10-186
Accumulator .. 10-188
Work equipment ... 10-189
Work equipment... 10-189
Work equipment shim....... 10-190
Bucket play adjustment shim... 10-191
Cab and its attachments.......10-193
Electrical system .. 10-194
Electrical control system ... 10-194
Machine monitor system ... 10-245
KOMTRAX system..... 10-267
Sensor .... 10-270
20 Standard value tables.. 20-1
Table of contents ...... 20-2
Standard service value table.. 20-3
Standard value table for engine ... 20-3
Standard value table for machine ...... 20-5
Standard value table for electrical system..... 20-18
30 Testing and adjusting .. 30-1
Table of contents ...... 30-2
General information on testing and adjusting... 30-3
Tools for testing and adjusting ..... 30-3
Sketch of tools for testing and adjusting ... 30-7
Engine and cooling system .... 30-8
Testing engine speed ..... 30-8
Testing boost pressure ... 30-9
Testing exhaust gas color ... 30-11
Measuring and adjusting valve clearance ..... 30-13
Testing compression pressure... 30-16
Testing blowby pressure ..... 30-20
Testing engine oil pressure ....... 30-21
Testing EGR valve and KVGT oil pressures .. 30-22
Measuring fuel pressure ..... 30-23
Measuring fuel delivery, return and leakage.. 30-29
Bleeding air from fuel system .... 30-34
Checking fuel circuit for leakage ...... 30-36
Handling cylinder cutout mode operation...... 30-37
Handling no injection cranking operation ...... 30-38
Checking and adjusting air conditioner compressor belt tension ... 30-39
Replacing fan belt .. 30-41
Power train....... 30-42
Testing swing circle bearing clearance ... 30-42
Undercarriage and frame..... 30-43
Testing and adjusting track shoe tension ...... 30-43
Hydraulic system .... 30-44
Releasing remaining pressure from hydraulic circuit.. 30-44
Testing and adjusting oil pressure in work equipment, swing, and travel circuits..... 30-45
Testing oil pressure of control circuit ...... 30-49
Testing and adjusting oil pressure in pump PC control circuit.. 30-52
Testing and adjusting oil pressure in pump LS control circuit .. 30-55
Testing output pressure of solenoid valve ..... 30-60
Testing PPC valve output pressure .. 30-64
Adjusting play of work equipment and swing PPC valves....... 30-66
Testing pump swash plate sensor .... 30-67
Isolating the parts causing hydraulic drift in work equipment... 30-68
Testing oil leakage ....... 30-69
Bleeding air from hydraulic circuit .... 30-72
Cab and its attachments...30-75
Adjusting mirrors.... 30-75
Electrical system .... 30-77
Special functions of machine monitor..... 30-77
Adjusting rearview camera angle... 30-148
Handling voltage circuit of engine controller...... 30-150
Handling battery disconnect switch...... 30-151
Testing diodes ..... 30-152
Pm clinic .. 30-153
Pm Clinic service ....... 30-153
40 Troubleshooting.... 40-1
Table of contents ...... 40-2
General information on troubleshooting .... 40-9
Troubleshooting points ... 40-9
Sequence of events in troubleshooting... 40-11
Testing before troubleshooting .. 40-13
Inspection procedure before troubleshooting ...... 40-15
Preparation work for troubleshooting of electrical system....... 40-34
Classification and procedure for troubleshooting ....... 40-38
Symptom of probable failure and troubleshooting No....... 40-41
Information in troubleshooting table ....... 40-44
Diagnostic procedure for wiring harness open curcuit of pressure sensor system .. 40-46
Connector list and layout .... 40-48
Connector contact identification....... 40-59
T-branch box and T-branch adapter table ..... 40-95
Fuse location table ..... 40-101
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ... 40-103
Fabrication of dummy temperature sensor (for KDOC and KDPF temperature
sensors)....... 40-106
Fabrication of short-circuit connector (for CA1883 and CA3135)....... 40-107
Failure codes table..... 40-108
Troubleshooting by failure code (Display of code) .... 40-117
Failure code [879AKA] A/C Inner Sensor Open Circuit .. 40-117
Failure code [879AKB] A/C Inner Sensor Short Circuit... 40-118
Failure code [879BKA] A/C Outer Sensor Open Circuit.. 40-119
Failure code [879BKB] A/C Outer Sensor Short Circuit.. 40-120
Failure code [879CKA] Ventilating Sensor Open Circuit....... 40-121
Failure code [879CKB] Ventilating Sensor Short Circuit ....... 40-122
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit.... 40-123
Failure code [879EMC] Ventilation Damper Abnormality...... 40-124
Failure code [879FMC] Air Mix Damper Abnormality ..... 40-125
Failure code [879GKX] Refrigerant Abnormality...... 40-126
Failure code [989L00] Engine Controller Lock Caution1....... 40-127
Failure code [989M00] Engine Controller Lock Caution2...... 40-128
Failure code [989N00] Engine Controller Lock Caution3 ...... 40-129
Failure code [A1U0N3]: KDPF Dry Request (HC Release)... 40-130
Failure code [A1U0N4] KDPF Dry Request (HC Release).... 40-132
Failure code [A1U0R7] Manual Stationary Regeneration Request (96 Hour Timer Request)..40-133-1
Failure code [AA10NX] Air Cleaner Clogging.... 40-134
Failure code [AB00KE] Charge Voltage Low..... 40-136
Failure code [B@BAZG] Engine Oil Pressure Low .. 40-138
Failure code [B@BAZK] Eng Oil Level Low ...... 40-139
Failure code [B@BCNS] Engine Coolant Overheat ....... 40-140
Failure code [B@BCZK] Radiator Coolant Level Low .... 40-141
Failure code [B@HANS] Hyd Oil Overheat....... 40-143
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .. 40-144
Failure code [CA122] Chg Air Press Sensor High Error ....... 40-145
Failure code [CA123] Chg Air Press Sensor Low Error .. 40-147
Failure code [CA131] Throttle Sensor High Error..... 40-149
Failure code [CA132] Throttle Sensor Low Error ..... 40-151
Failure code [CA144] Coolant Temp Sens High Error .... 40-153
Failure code [CA145] Coolant Temp Sens Low Error ..... 40-155
Failure code [CA153] Chg Air Temp Sensor High Error.. 40-157
Failure code [CA154] Chg Air Temp Sensor Low Error... 40-159
Failure code [CA187] Sensor 2 Supply Volt Low Error ... 40-161
Failure code [CA221] Ambient Press Sens High Error ... 40-163
Failure code [CA222] Ambient Press Sens Low Error.... 40-165
Failure code [CA227] Sensor 2 Supply Volt High Error... 40-167
Failure code [CA234] Eng Overspeed.. 40-168
Failure code [CA238] Ne Speed Sensor Supply Volt Error ... 40-169
Failure code [CA239] Ne Speed Sens Supply Volt High Error..... 40-170
Failure code [CA271] IMV/PCV1 Short Error .... 40-171
Failure code [CA272] IMV/PCV1 Open Error .... 40-173
Failure code [CA295] Ambient Press Sens In Range Error... 40-175
Failure code [CA322] Inj #1(L#1) Open/Short Error ....... 40-176
Failure code [CA323] Inj #5(L#5) Open/Short Error ....... 40-178
Failure code [CA324] Inj #3(L#3) Open/Short Error ....... 40-180
Failure code [CA325] Inj #6(L#6) Open/Short Error ....... 40-182
Failure code [CA331] Inj #2(L#2) Open/Short Error ....... 40-184
Failure code [CA332] Inj #4(L#4) Open/Short Error ....... 40-186
Failure code [CA343] ECM Critical Internal Failure.. 40-188
Failure code [CA351] Injectors Drive Circuit Error ... 40-189
Failure code [CA352] Sensor 1 Supply Volt Low Error ... 40-190
Failure code [CA356] Mass Air Flow Sensor High Error ....... 40-192
Failure code [CA357] Mass Air Flow Sensor Low Error.. 40-194
Failure code [CA386] Sensor 1 Supply Volt High Error... 40-196
Failure code [CA428] Water in Fuel Sensor High Error .. 40-197
Failure code [CA429] Water in Fuel Sensor Low Error ... 40-199
Failure code [CA435] Eng Oil Press Sw Error ... 40-201
Failure code [CA441] Battery Voltage Low Error ..... 40-202
Failure code [CA442] Battery Voltage High Error..... 40-204
Failure code [CA449] Rail Press Very High Error..... 40-205
Failure code [CA451] Rail Press Sensor High Error....... 40-206
Failure code [CA452] Rail Press Sensor Low Error ....... 40-208
Failure code [CA488] Chg Air Temp High Torque Derate...... 40-210
Failure code [CA515] Rail Press Sens Sup Volt High Error .. 40-211
Failure code [CA516] Rail Press Sens Sup Volt Low Error ... 40-213
Failure code [CA553] Rail Press High Error ...... 40-215
Failure code [CA555] Crankcase Press High Error 1 ..... 40-216
Failure code [CA556] Crankcase Press High Error 2 ..... 40-217
Failure code [CA559] Rail Press Low Error....... 40-218
Failure code [CA595] Turbo Speed High Error 2 ..... 40-220
Failure code [CA687] Turbo Speed Low Error... 40-221
Failure code [CA689] Eng Ne Speed Sensor Error.. 40-223
Failure code [CA691] Intake Air Temp Sens High Error.. 40-225
Failure code [CA692] Intake Air Temp Sens Low Error... 40-227
Failure code [CA697] ECM Int Temp Sensor High Error....... 40-229
Failure code [CA698] ECM Int Temp Sensor Low Error.. 40-230
Failure code [CA731] Eng Bkup Speed Sens Phase Error ... 40-231
Failure code [CA778] Eng Bkup Speed Sensor Error..... 40-233
Failure code [CA1117] Persistent Data Lost Error.... 40-238
Failure code [CA1664] KDOC Malfunction.. 40-239
Failure code [CA1691] Regeneration Ineffective ..... 40-241
Failure code [CA1695] Sensor 5 Supply Volt High Error....... 40-244
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....... 40-246
Failure code [CA1843] Crankcase Press Sens High Error.... 40-248
Failure code [CA1844] Crankcase Press Sens Low Error .... 40-250
Failure code [CA1879] KDPF Delta P Sensor High Error ..... 40-252
Failure code [CA1881] KDPF Delta P Sensor Low Error ...... 40-254
Failure code [CA1883] KDPF Delta P Sens In Range Error.. 40-256
Failure code [CA1921] KDPF Soot Load High Error 1.... 40-259
Failure code [CA1922] KDPF Soot Load High Error 2.... 40-262
Failure code [CA1942] Crankcase Press Sens In Range Error ... 40-267
Failure code [CA1993] KDPF Delta Pressure Low Error ...... 40-268
Failure code [CA2185] Throt Sensor Sup Volt High Error ..... 40-271
Failure code [CA2186] Throt Sensor Sup Volt Low Error...... 40-273
Failure code [CA2249] Rail Press Very Low Error ... 40-275
Failure code [CA2271] EGR Valve Pos Sens High Error ...... 40-276
Failure code [CA2272] EGR Valve Pos Sens Low Error....... 40-278
Failure code [CA2288] Turbo Speed High Error 1.... 40-281
Failure code [CA2311] IMV Solenoid Error ....... 40-282
Failure code [CA2349] EGR Valve Solenoid Open Error ...... 40-283
Failure code [CA2353] EGR Valve Solenoid Short Error ...... 40-285
Failure code [CA2357] EGR Valve Servo Error ....... 40-287
Failure code [CA2373] Exhaust Manifold Press Sens High error....... 40-288
Failure code [CA2374] Exhaust Manifold Press Sens Low error ....... 40-290
Failure code [CA2375] EGR Orifice Temp Sens High Error .. 40-292
Failure code [CA2376] EGR Orifice Temp Sens Low Error ... 40-294
Failure code [CA2381] KVGT Pos Sens High Error ....... 40-296
Failure code [CA2382] KVGT Pos Sens Low Error.. 40-298
Failure code [CA2383] KVGT Solenoid Open Error ....... 40-301
Failure code [CA2386] KVGT Solenoid Short Error ....... 40-303
Failure code [CA2387] KVGT Servo Error .. 40-305
Failure code [CA2554] Exh Manifold Press Sens In Range Error...... 40-306
Failure code [CA2555] Grid Htr Relay Volt Low Error..... 40-307
Failure code [CA2556] Grid Htr Relay Volt High Error .... 40-309
Failure code [CA2637] KDOC Face Plugging ... 40-311
Failure code [CA2639] Manual Stationary Regeneration Request..... 40-313
Failure code [CA2961] EGR Orifice Temp High Error 1 .. 40-316
Failure code [CA2973] Chg Air Press Sensor In Range Error ..... 40-317
Failure code [CA3133] KDPF Outlet Press Sens High Error ....... 40-318
Failure code [CA3134] KDPF Outlet Press Sens Low Error.. 40-320
Failure code [CA3135] KDPF Outlet Press Sens In Range Error ...... 40-322
Failure code [CA3251] KDOC Inlet Temp High Error...... 40-326
Failure code [CA3253] KDOC Temp Error - Non Regeneration... 40-329
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...... 40-332
Failure code [CA3255] KDPF Temp Error - Non Regeneration.... 40-335
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....... 40-338
Failure code [CA3311] KDOC Outlet Temp High Error 2....... 40-341
Failure code [CA3312] KDPF Outlet Temp High Error 2 ....... 40-344
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ....... 40-347
Failure code [CA3314] KDOC Inlet Temp Sens High Error ... 40-350
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error... 40-353
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ....... 40-357
Failure code [CA3317] KDOC Outlet Temp Sens High Error....... 40-360
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ...... 40-364
Failure code [CA3319] KDPF Outlet Temp Sens High Error ....... 40-368
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .. 40-372
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error....... 40-375
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error .... 40-379
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error..... 40-381
Failure code [CA3741] Rail Press Valve Trip Error... 40-383
Failure code [D110KB] Battery Relay Output Voltage .... 40-384
Failure code [D19JKZ] Personal Code Relay Abnormality.... 40-386
Failure code [D811MC] KOMTRAX Error.... 40-389
Failure code [D862KA] GPS Antenna Open Circuit ....... 40-390
Failure code [D8ALKA] System Operating Lamp Disconnection (KOMTRAX)...... 40-391
Failure code [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) .. 40-393
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ...... 40-394
Failure code [DA20MC] Pump Controller.... 40-395
Failure code [DA22KK] Pump Solenoid Power Low Error..... 40-396
Failure code [DA25KP] 5V Sensor 1 Power Abnormality...... 40-398
Failure code [DA29KQ] Model Selection Abnormality .... 40-401
Failure code [DA2LKA] System Operating Lamp Disconnection (Pump Con) ...... 40-403
Failure code [DA2LKB] System Operating Lamp Short Circuit (Pump Con) ... 40-405
Failure code [DA2QKR] CAN2 Discon (Pump Con)....... 40-406
Failure code [DA2RKR] CAN1 Discon (Pump Con) ....... 40-409
Failure code [DAF0MB] Monitor ROM Abnormality.. 40-410
Failure code [DAF0MC] Monitor Error .. 40-411
Failure code [DAF8KB] Camera Power Supply Short Circuit ...... 40-412
Failure code [DAF9KQ] Model Selection Abnormality.... 40-414
Failure code [DAFGMC] GPS Module Error...... 40-415
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) .. 40-416
Failure code [DAFLKB] System Operating Lamp Short Circuit (Monitor).. 40-418
Failure code [DAFQKR] CAN2 Discon (Monitor) ..... 40-419
Failure code [DAZ9KQ] A/C Model Selection Abnormality.... 40-420
Failure code [DAZQKR] CAN2 Discon (AC)...... 40-421
Failure code [DB2QKR] CAN2 Discon (Engine Con) ..... 40-426
Failure code [DB2RKR] CAN1 Discon (Engine Con) ..... 40-431
Failure code [DGH2KB] Hyd Oil Sensor Short .. 40-435
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ... 40-437
Failure code [DHPAMA] F Pump Press Sensor Abnormality....... 40-438
Failure code [DHPBMA] R Pump Press Sensor Abnormality...... 40-441
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality ....... 40-444
Failure code [DHS4MA] Bucket Curl/Heel Out PPC Press Sensor Abnormality ..... 40-446
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality..... 40-449
Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality... 40-452
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality ....... 40-455
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality .. 40-458
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality ...... 40-461
Failure code [DHSDMA] Bucket Dump/Heel In PPC Press Sensor Abnormality..... 40-464
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality ....... 40-467
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality...... 40-470
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality ....... 40-473
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality ....... 40-476
Failure code [DKR0MA] F pump S/P sensor Abnormality..... 40-479
Failure code [DKR1MA] R pump S/P sensor Abnormality .... 40-481
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality .... 40-483
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality .... 40-485
Failure code [DV20KB] Travel Alarm Short Circuit... 40-487
Failure code [DW43KA] Travel Speed Sol Open Circuit ....... 40-489
Failure code [DW43KB] Travel Speed Sol Short Circuit ....... 40-491
Failure code [DW45KA] Swing holding brake Sol Open Circuit... 40-493
Failure code [DW45KB] Swing holding brake Sol Short Circuit ... 40-496
Failure code [DW91KA] Travel Junction Sol Open Circuit .... 40-499
Failure code [DW91KB] Travel Junction Sol Short Circuit..... 40-501
Failure code [DWA2KA] Attachment Sol Open Circuit.... 40-503
Failure code [DWA2KB] Attachment Sol Short Circuit.... 40-505
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit ..... 40-507
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit ...... 40-509
Failure code [DWK2KA] Variable Back Press Sol Open Circuit... 40-511
Failure code [DWK2KB] Variable Back Press Sol Short Circuit... 40-513
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit ....... 40-515
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit ....... 40-517
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit.... 40-519
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit.... 40-521
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ... 40-523
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ... 40-525
Failure code [DXE0KA] LS-EPC Sol Open Circuit ... 40-527
Failure code [DXE0KB] LS-EPC Sol Short Circuit ... 40-529
Failure code [DXE4KA] Attachment Flow EPC Open Circuit ...... 40-531
Failure code [DXE4KB] Attachment Flow EPC Short Circuit....... 40-533
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ...... 40-535
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit ...... 40-537
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ... 40-539
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit ... 40-541
Failure code [DY20KA] Wiper Working Abnormality ...... 40-543
Failure code [DY20MA] Wiper Parking Abnormality....... 40-545
Failure code [DY2CKB] Washer Drive Short Circuit....... 40-547
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ...... 40-549
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit....... 40-551
Troubleshooting of electrical system (E-mode) .. 40-553
E-1 Engine does not start (Engine does not crank).. 40-553
E-2 Manual preheating system does not work... 40-559
E-3 Automatic preheating system does not work..... 40-562
E-4 Preheating monitor does not light up when preheater is operated ..... 40-564
E-5 When starting switch is turned to ON position, machine monitor displays nothing....... 40-566
E-6 When starting switch is turned to ON position (before starting engine), engine oil level
monitor lights up in yellow...... 40-569
E-7 When starting switch is turned to ON position (before starting engine), radiator coolant
level monitor lights up in yellow .... 40-570
E-8 Coolant temperature monitor lights up in white while engine is running ... 40-571
E-9 Hydraulic oil temperature monitor lights up in white while engine is running ... 40-572
E-10 Charge level monitor lights up while engine is running ....... 40-573
E-11 Fuel level monitor lights up in red while engine is running... 40-574
E-12 Air cleaner clogging monitor lights up in yellow while engine is running ....... 40-575
E-13 Water separator monitor lights up while engine is running .. 40-576
E-14 Coolant temperature monitor lights up in red while engine is running..... 40-577
E-15 Hydraulic oil temperature monitor lights up in red while engine is running .... 40-578
E-16 Engine oil pressure monitor lights up in red while engine is running ...... 40-579
E-17 Fuel gauge indicates either full or empty and does not move.... 40-580
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty)...... 40-581
E-19 Coolant temperature gauge indicates either Min. or Max. and does not move .... 40-582
E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min. nor
Max.) ..... 40-583
E-21 Hydraulic oil temperature gauge indicates either Min. or Max. and does not
move ..... 40-584
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min.
nor Max.) ..... 40-586
E-23 Content of display on machine monitor is different from that of actual machine .. 40-587
E-24 Machine monitor does not display some items ...... 40-588
E-25 Function switch does not work..... 40-589
E-26 Automatic preheating system does not work (In cold season)... 40-590
E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration
switch is operated..... 40-591
E-28 Auto-deceleration is not actuated or canceled when lever is operated... 40-592
E-29 Working mode selection screen is not diplayed when working mode switch is
operated ...... 40-593
E-30 Engine or hydraulic pump setting does not change when working mode is
changed....... 40-594
E-31 Travel speed monitor does not change when travel speed switch is operated .... 40-595
E-32 Travel speed does not change while travel speed selection is changed....... 40-596
E-33 Alarm buzzer does not stop sounding....... 40-597
E-35 Service mode cannot be selected ...... 40-599
E-36 Any of work equipment, swing and travel does not work..... 40-600
E-37 Any of work equipment, swing and travel cannot be locked ...... 40-602
E-38 Machine cannot swing while swing brake cancel switch is canceled ..... 40-603
E-39 Swing brake does not operate while swing brake cancel switch is locked .... 40-605
E-40 One-touch power maximizing function does not work or monitor is not displayed ..... 40-607
E-41 One-touch power maximizing function cannot be canceled ...... 40-609
E-42 Travel alarm does not sound when machine travels..... 40-610
E-43 Alarm does not stop sounding while machine is stopped.... 40-611
E-44 Horn does not sound ...... 40-612
E-45 Horn does not stop sounding....... 40-614
E-46 Wiper monitor does not light up or go out when wiper switch is operated ..... 40-615
E-47 Wiper does not operate when wiper switch is operated ...... 40-616
E-48 Window washer does not operate when window washer switch is operated....... 40-618
E-49 BOOM LOWER indication is not displayed properly with monitoring function ..... 40-619
E-50 ARM DUMP indication is not displayed properly with monitoring function .... 40-620
E-51 ARM IN indication is not displayed properly with monitoring function..... 40-621
E-52 BOOM RAISE indication is not displayed properly with monitoring function ....... 40-622
E-53 BUCKET Curl/Heel Out indication is not displayed properly with monitoring function..40-623
E-54 BUCKET Dump/Heel In indication is not displayed properly with monitoring function .......40-624
E-55 SWING indication is not displayed properly with monitoring function ..... 40-625
E-56 TRAVEL indication is not displayed properly with monitoring function.... 40-626
E-57 Service is not displayed properly with monitoring function .. 40-627
E-58 Attachment hydraulic circuit cannot be changed.... 40-630
E-59 KOMTRAX system does not operate normally ...... 40-631
No Code, Short or open in attachment solenoid System (E-mode).....40-632-1
Eletrical circuit diagram for attachment solenoid system..40-632-3
Open in cab tilt system.....40-632-4
Electrical circuit diagram for cab tilt system...40-632-5
Troubleshooting of hydraulic and mechanical system (H-mode).. 40-633
Information described in troubleshooting table (H-mode) ..... 40-633
System chart for hydraulic system ....... 40-634
Failure mode and cause table ....... 40-636
H-1 All of work equipment, swing and travel operation lacks speed or power ....... 40-644
H-2 Engine speed drops significantly or engine stalls .... 40-647
H-3 All work equipment, swing and travel does not work...... 40-650
H-4 Unusual sound is heard from around hydraulic pump .... 40-651
H-5 Fine control performance or response is poor ... 40-652
H-6 Boom speed or power is low ... 40-654
H-7 Arm speed or power is low...... 40-658
H-8 Bucket speed or power is low.. 40-663
H-9 Work equipment does not move in single operation....... 40-666
H-10 Hydraulic drift of boom is large .... 40-667
H-11 Hydraulic drift of arm is large ....... 40-668
H-12 Hydraulic drift of bucket is large... 40-669
H-13 Time lag of work equipment is large ... 40-670
H-14 When part of work equipment is relieved singly, other parts of work equipment
move ..... 40-672
H-15 One-touch power maximizing function does not operate .... 40-673
H-16 In combined operation of work equipment, equipment having heavier load moves
slower.... 40-674
H-17 In combined operations of swing and boom RAISE, boom rising speed is low.... 40-675
H-18 In combined operations of swing and travel, travel speed drops largely....... 40-676
H-19 Machine does not travel straight .. 40-677
H-20 Travel speed is slow ....... 40-680
H-21 Machine is hard to steer or travel power is low ...... 40-682
H-22 Travel speed does not change, or travel speed is too slow or fast ... 40-685
H-23 One of tracks does not run .... 40-686
H-24 Upper structure does not swing to the right or left .. 40-688
H-25 Upper structure swing only to the right or left .. 40-689
H-26 Swing acceleration or swing speed is low in both directions (right and left) .. 40-690
H-27 Swing acceleration performance is poor or swing speed is slow in only one
direction....... 40-691
H-28 Upper structure overruns excessively when it stops swinging (both right and
left).. 40-692
H-29 Upper structure overruns excessively when it stops swinging (either right or left) ..... 40-693
H-30 Shock is large when upper structure stops swinging.... 40-694
H-31 Large unusual noise is heard when upper structure stops swinging ...... 40-695
H-32 Swing drift on a slope is large while swing holding brake is applied....... 40-696
H-33 Swing drift on a slope is large while swing holding brake is released..... 40-697
H-34 Attachment hydraulic circuit cannot be changed while attachment is installed.... 40-698
H-35 Oil flow in attachment circuit cannot be controlled ....... 40-699
Troubleshooting of engine (S-mode)..... 40-700
Information mentioned in troubleshooting table (S mode)..... 40-700
S-1 When starting switch is turned to START position, engine does not crank ..... 40-701
S-2 Engine cranks but no exhaust smoke comes out..... 40-702
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not
start)...... 40-703
S-4 Engine startability is poor .. 40-704
S-5 Engine does not pick up smoothly ....... 40-706
S-6 Engine stops during operation....... 40-708
S-7 Engine runs rough or is unstable ... 40-710
S-8 Engine lacks power .... 40-711
S-9 Exhaust smoke is black (KDPF clogs up early) ....... 40-713
S-10 Engine oil consumption is excessive .. 40-715
S-11 Engine oil becomes contaminated early.... 40-716
S-12 Fuel consumption is excessive .... 40-717
S-13 Oil is in coolant (or coolant spurts or coolant level goes down).. 40-718
S-14 Engine oil pressure drops ..... 40-719
S-15 Fuel is contaminated in engine oil ...... 40-720
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white)... 40-721
S-17 Coolant temperature rises too high (overheating) .. 40-722
S-18 Unusual noise is heard ... 40-723
S-19 Vibration is excessive ..... 40-724
S-20 Air cannot be bled from fuel circuit ..... 40-725
S-21 Active regeneration is executed frequently ..... 40-726
S-22 Active regeneration takes time..... 40-727
S-23 White smoke is exhausted during active regeneration ....... 40-728
60 Maintenance standard....... 60-1
Table of contents ...... 60-2
Engine and cooling system .... 60-3
Engine mount .... 60-3
Cooling system .. 60-4
Power train... 60-5
Swing circle ....... 60-5
Swing machinery ..... 60-6
Final drive ... 60-8
Sprocket.... 60-10
Undercarriage and frame..... 60-12
Track frame and idler cushion ... 60-12
Idler .... 60-14
Track roller ...... 60-16
Carrier roller .... 60-17
Track shoe ...... 60-18
Hydraulic system .... 60-24
Hydraulic tank.. 60-24
Main pump ...... 60-25
Control valve ... 60-26
Swing motor .... 60-36
Travel motor .... 60-38
Work equipment and swing PPC valve... 60-41
Travel PPC valve ... 60-44
1st-line attachment PPC valve (with EPC valve) ....... 60-47
2nd-line attachment PPC valve ....... 60-50
Solenoid valve ....... 60-52
Attachment circuit selector valve (for high-pressure circuit) .... 60-53
Attachment circuit selector valve (for low-pressure circuit) ..... 60-54
Center swivel joint .. 60-55
Work equipment ..... 60-56
Work equipment..... 60-56
Boom cylinder (large diameter piston) .... 60-65
Arm cylinder .... 60-66
Bucket cylinder ...... 60-67
80 Appendix.. 80-1
Table of contents ...... 80-2
Air conditioner components ... 80-3
Precautions for refrigerant..... 80-3
Air conditioner component .... 80-4
Configuration and function of refrigeration cycle.... 80-7
Outline of refrigeration cycle.. 80-8
Air conditioner unit ....... 80-10
Dual pressure switch .... 80-17
Air conditioner controller ..... 80-18
Compressor..... 80-19
Air conditioner condenser ... 80-20
Sunlight sensor...... 80-22
Outer temperature sensor (outside air temperature sensor) ... 80-23
Procedure for testing and troubleshooting .... 80-24
Circuit diagram and arrangement of connector pins... 80-26
System diagram..... 80-28
Input and output signals of the air conditioner controller... 80-29
Parts and connectors layout...... 80-31
Testing air leakage (duct).... 80-35
Testing with self-diagnosis function.. 80-38
Testing vent (mode) changeover...... 80-40
Testing FRESH/RECIRC air changeover...... 80-42
Testing sunlight sensor ....... 80-43
Testing (dual) pressure switch for refrigerant....... 80-44
Testing relays .. 80-45
Troubleshooting chart 1 ...... 80-46
Troubleshooting chart 2 ...... 80-47
Information in troubleshooting table ....... 80-50
Failure code list related to air conditioner...... 80-51
Failure code [879AKA] A/C Inner Sensor Open Circuit .... 80-52
Failure code [879AKB] A/C Inner Sensor Short Circuit..... 80-53
Failure code [879BKA] A/C Outer sensor Open Circuit .... 80-54
Failure code [879BKB] A/C Outer sensor Short Circuit .... 80-56
Failure code [879CKA] Ventilating Sensor Open Circuit... 80-58
Failure code [879CKB] Ventilating Sensor Short Circuit ... 80-59
Failure code [879DKZ] Sunlight sensor Open or Short Circuit ...... 80-60
Failure code [879EMC] Ventilation Damper Abnormality.. 80-62
Failure code [879FMC] Air Mix Damper Abnormality ....... 80-63
Failure code [879GKX] Refrigerant Abnormality.. 80-64
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ... 80-65
A-2 Troubleshooting of compressor system (Air is not cooled)...... 80-67
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ...... 80-70
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ... 80-65
A-2 Troubleshooting of compressor system (Air is not cooled)...... 80-67
A-3 Troubleshooting for blower motor system (No air comes out or air flow is
abnormal) ...... 80-70
A-4 Troubleshooting for FRESH/RECIRC air changeover ...... 80-72
Troubleshooting with gauge pressure..... 80-74
Connection of service tool... 80-77
Precautions for disconnecting and connecting air conditioner piping ... 80-79
Handling of compressor oil.. 80-81
Desiccant replacement ....... 80-83
90 Diagrams and drawings..... 90-1
Table of contents ...... 90-2
Hydraulic circuit diagram ....... 90-3
Symbols in hydraulic circuit diagram .. 90-3
Hydraulic circuit diagram....... 90-7
Electric circuit diagram .... 90-9
Symbols in electric circuit diagram..... 90-9
Electric circuit diagram.. 90-13
Electric circuit diagram for air conditioner unit ..... 90-25