Komatsu PC228USLC-10 Hydraulic Excavator Service Repair Shop Manual (1002 and up) - SEN06483-02

This complete service repair workshop manual PDF download for the PC228USLC-10 Komatsu Hydraulic Excavator (SN: 1002 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Machine Model : PC228USLC-10
Serial Numbers : 1002 and up


TABLE OF CONTENTS :

- Index and foreword
- Specification
- Structure and function
- Standard value table
- Testing and adjusting
- Troubleshooting
- Disassembly and assembly
- Maintenance standard
- Appendix
- Diagrams and drawings


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN06483-02
Total Pages : 1752


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00 Index and foreword
Index
Foreword, safety and general information
Important safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling equipment of fuel system devices
Handling of intake system parts
Handling of hydraulic equipment
Method of disconnecting and connecting of push-pull type coupler
Handling of electrical equipment
How to read electric wire code
Precautions when performing operation
Practical use of KOMTRAX
Standard tightening torque table
List of abbreviation
Conversion table

01 Specification
Table of contents
Specifications
Specification drawing
Working range drawings
Specifications
Weight table
Table of fuel, coolant, and lubricants

10 Structure and function
Table of contents
Engine and cooling system
Engine related parts
KVGT
EGR system piping drawing
EGR system circuit diagram
EGR valve
EGR cooler
KCCV layout drawing
KCCV ventilator
KDPF
Cooling system
Power train
Power train system
Swing circle
Swing machinery
Final drive
Undercarriage and frame
Track frame and idler cushion
Hydraulic system
Hydraulic component layout
Valve control
Hydraulic tank
CLSS
Main pump
Control valve
Swing motor
Travel motor
PPC valve
Solenoid valve
Attachment circuit selector valve (for high pressure circuit)
Attachment circuit selector valve (for low pressure circuit)
Center swivel joint
Accumulator
Work equipment
Work equipment
Work equipment shim
Bucket play adjustment shim
Cab and its attachments
Cab mount and cab tipping stopper
ROPS cab
Electrical system
Electrical control system
Machine monitor system
KOMTRAX system
Sensor

20 Standard value tables
Table of contents
Standard service value table
Standard value table for engine
Standard value table for machine
Standard value table for electrical system

30 Testing and adjusting
Table of contents
Related information on testing and adjusting
Tools for testing and adjusting
Sketch of tools for testing and adjusting
Engine and cooling system
Testing engine speed
Testing boost pressure
Testing exhaust gas color
Testing and adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Testing EGR valve and KVGT oil pressures
Measuring fuel pressure
Measuring fuel delivery, return and leakage
Bleeding air from fuel system
Testing fuel circuit for leakage
Handling cylinder cutout mode operation
Handling no-injection cranking operation
Checking and adjusting air conditioner compressor belt tension
Replacing fan belt
Power train
Testing swing circle bearing clearance
Undercarriage and frame
Testing and adjusting track tension
Hydraulic system
Releasing remaining pressure from hydraulic circuit
Testing and adjusting oil pressure in work equipment, swing, and travel circuits
Testing oil pressure of control circuit
Testing and adjusting oil pressure in pump PC control circuit
Testing and adjusting oil pressure in pump LS control circuit
Testing outlet pressure of solenoid valve
Testing PPC valve outlet pressure
Adjusting play of work equipment and swing PPC valves
Testing pump swash plate sensor
Isolating the parts causing hydraulic drift in work equipment
Testing and adjusting travel deviation
Testing oil leakage
Bleeding air from hydraulic circuit
Work equipment
Testing and adjusting boom angle potentiometer
Cab and its attachments
Checking cab tipping stopper
Adjusting mirrors
Electrical system
Special functions of machine monitor
KOMTRAX terminal start-up procedure
Adjusting rearview camera angle
Handling voltage circuit of engine controller
Handling battery disconnect switch
Testing diodes
Pm clinic
Pm Clinic service

40 Troubleshooting
Table of contents
Related information on troubleshooting
Troubleshooting points
Sequence of events in troubleshooting
Testing before troubleshooting
Inspection procedure before troubleshooting
Preparation work for troubleshooting of electrical system
Classification and procedure for troubleshooting
Symptom of probable failure and troubleshooting No.
Information in troubleshooting table
Diagnostic procedure for wiring harness open curcuit of pressure sensor system
Connector list and layout
Connector contact identification
T-branch box and T-branch adapter table
Fuse location table
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors)
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135])
Failure codes table
Troubleshooting by failure code (Display of code)
Failure code [879AKA] A/C Inner Sensor Open Circuit
Failure code [879AKB] A/C Inner Sensor Short Circuit
Failure code [879BKA] A/C Outer Sensor Open Circuit
Failure code [879BKB] A/C Outer Sensor Short Circuit
Failure code [879CKA] Ventilating Sensor Open Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit
Failure code [879EMC] Ventilation Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality
Failure code [879GKX] Refrigerant Abnormality
Failure code [989L00] Engine Controller Lock Caution 1
Failure code [989M00] Engine Controller Lock Caution 2
Failure code [989N00] Engine Controller Lock Caution 3
Failure code [A1U0N3] HC Desorb Request 1
Failure code [A1U0N4] HC Desorb Request 2
Failure code [AA10NX] Air Cleaner Clogging
Failure code [AB00KE] Charge Voltage Low
Failure code [B@BAZG] Eng Oil Press Low
Failure code [B@BAZK] Eng Oil Level Low
Failure code [B@BCNS] Eng Water Overheat
Failure code [B@BCZK] Eng Water Level Low
Failure code [B@HANS] Hyd Oil Overheat
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA187] Sensor 2 Supply Volt Low Error
Failure code [CA221] Ambient Press Sensor High Error
Failure code [CA222] Ambient Press Sensor Low Error
Failure code [CA227] Sensor 2 Supply Volt High Error
Failure code [CA234] Eng Overspeed
Failure code [CA238] Ne Speed Sensor Supply Volt Error
Failure code [CA239] Ne Speed Sens Supply Volt High Error
Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA295] Ambient Press Sens In Range Error
Failure code [CA322] Inj #1(L#1) Open/Short Error
Failure code [CA323] Inj #5(L#5) Open/Short Error
Failure code [CA324] Inj #3(L#3) Open/Short Error
Failure code [CA325] Inj #6(L#6) Open/Short Error
Failure code [CA331] Inj #2(L#2) Open/Short Error
Failure code [CA332] Inj #4(L#4) Open/Short Error
Failure code [CA343] ECM Critical Internal Failure
Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA352] Sensor 1 Supply Volt Low Error
Failure code [CA356] Mass Air Flow Sensor High Error
Failure code [CA357] Mass Air Flow Sensor Low Error
Failure code [CA386] Sensor 1 Supply Volt High Error
Failure code [CA428] Water in Fuel Sensor High Error
Failure code [CA429] Water in Fuel Sensor Low Error
Failure code [CA435] Eng Oil Press Sw Error
Failure code [CA441] Battery Voltage Low Error
Failure code [CA442] Battery Voltage High Error
Failure code [CA449] Rail Press Very High Error
Failure code [CA451] Rail Press Sensor High Error
Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA488] Chg Air Temp High Torque Derate
Failure code [CA515] Rail Press Sens Sup Volt High Error
Failure code [CA516] Rail Press Sens Sup Volt Low Error
Failure code [CA553] Rail Press High Error
Failure code [CA555] Crankcase Press High Error 1
Failure code [CA556] Crankcase Press High Error 2
Failure code [CA559] Rail Press Low Error
Failure code [CA595] Turbo Speed High Error 2
Failure code [CA687] Turbo Speed Low Error
Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA691] Intake Air Temp Sens High Error
Failure code [CA692] Intake Air Temp Sens Low Error
Failure code [CA697] ECM Int Temp Sensor High Error
Failure code [CA698] ECM Int Temp Sensor Low Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA1117] Persistent Data Lost Error
Failure code [CA1664] KDOC Malfunction
Failure code [CA1691] Regeneration Ineffective
Failure code [CA1695] Sensor 5 Supply Volt High Error
Failure code [CA1696] Sensor 5 Supply Volt Low Error
Failure code [CA1843] Crankcase Press Sens High Error
Failure code [CA1844] Crankcase Press Sens Low Error
Failure code [CA1879] KDPF Delta P Sensor High Error
Failure code [CA1881] KDPF Delta P Sensor Low Error
Failure code [CA1883] KDPF Delta P Sens In Range Error
Failure code [CA1921] KDPF Soot Load High Error 1
Failure code [CA1922] KDPF Soot Load High Error 2
Failure code [CA1942] Crankcase Press Sens In Range Error
Failure code [CA1993] KDPF Delta Pressure Low Error
Failure code [CA2185] Throt Sensor Sup Volt High Error
Failure code [CA2186] Throt Sensor Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2271] EGR Valve Pos Sens High Error
Failure code [CA2272] EGR Valve Pos Sens Low Error
Failure code [CA2288] Turbo Speed High Error 1
Failure code [CA2311] IMV Solenoid Error
Failure code [CA2349] EGR Valve Solenoid Open Error
Failure code [CA2353] EGR Valve Solenoid Short Error
Failure code [CA2357] EGR Valve Servo Error
Failure code [CA2373] Exhaust Manifold Press Sens High error
Failure code [CA2374] Exhaust Manifold Press Sens Low error
Failure code [CA2375] EGR Orifice Temp Sens High Error
Failure code [CA2376] EGR Orifice Temp Sens Low Error
Failure code [CA2381] KVGT Pos Sens High Error
Failure code [CA2382] KVGT Pos Sens Low Error
Failure code [CA2383] KVGT Solenoid Open Error
Failure code [CA2386] KVGT Solenoid Short Error
Failure code [CA2387] KVGT Servo Error
Failure code [CA2554] Exh Manifold Press Sens In Range Error
Failure code [CA2555] Grid Htr Relay Volt Low Error
Failure code [CA2556] Grid Htr Relay Volt High Error
Failure code [CA2637] KDOC Face Plugging
Failure code [CA2639] Manual Stationary Regeneration Request
Failure code [CA2961] EGR Orifice Temp High Error 1
Failure code [CA2973] Chg Air Press Sensor In Range Error
Failure code [CA3133] KDPF Outlet Press Sens High Error
Failure code [CA3134] KDPF Outlet Press Sens Low Error
Failure code [CA3135] KDPF Outlet Press Sens In Range Error
Failure code [CA3251] KDOC Inlet Temp High Error
Failure code [CA3253] KDOC Temp Error - Non Regeneration
Failure code [CA3254] KDOC Outlet Temp High Error 1
Failure code [CA3255] KDPF Temp Error - Non Regeneration
Failure code [CA3256] KDPF Outlet Temp High Error 1
Failure code [CA3311] KDOC Outlet Temp High Error 2
Failure code [CA3312] KDPF Outlet Temp High Error 2
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error
Failure code [CA3314] KDOC Inlet Temp Sens High Error
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error
Failure code [CA3316] KDOC Outlet Temp Sens Low Error
Failure code [CA3317] KDOC Outlet Temp Sens High Error
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error
Failure code [CA3319] KDPF Outlet Temp Sens High Error
Failure code [CA3321] KDPF Outlet Temp Sens Low Error
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error
Failure code [CA3741] Rail Press Valve Trip Error
Failure code [D110KB] Battery Relay Drive Short Circuit
Failure code [D19JKZ] Personal Code Relay Abnormality
Failure code [D811MC] KOMTRAX Error
Failure code [D862KA] GPS Antenna Open Circuit
Failure code [D8ALKA] System Operating Lamp Disconnection (KOMTRAX)
Failure code [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX)
Failure code [D8AQKR] CAN2 Discon (KOMTRAX)
Failure code [DA20MC] Pump Controller
Failure code [DA22KK] Pump Solenoid Power Low Error
Failure code [DA25KP] 5V Sensor 1 Power Abnormality
Failure code [DA26KP] 5V Sensor 2 Power Abnormality
Failure code [DA29KQ] Model Selection Abnormality
Failure code [DA2LKA] System Operating Lamp Disconnection (Pump Con)
Failure code [DA2LKB] System Operating Lamp Short Circuit (Pump Con)
Failure code [DA2QKR] CAN2 Discon (Pump Con)
Failure code [DA2RKR] CAN1 Discon (Pump Con)
Failure code [DAF0MB] Monitor ROM Abnormality
Failure code [DAF0MC] Monitor Error
Failure code [DAF8KB] Camera Power Supply Short Circuit
Failure code [DAF9KQ] Model Selection Abnormality
Failure code [DAFGMC] GPS Module Error
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor)
Failure code [DAFLKB] System Operating Lamp Short Circuit (Monitor)
Failure code [DAFQKR] CAN2 Discon (Monitor)
Failure code [DAZ9KQ] A/C Model Selection Abnormality
Failure code [DAZQKR] CAN2 Discon (Aircon ECU)
Failure code [DB2QKR] CAN2 Discon (Engine Con)
Failure code [DB2RKR] CAN1 Discon (Engine Con)
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit
Failure code [DHPAMA] F Pump Press Sensor Abnormality
Failure code [DHPBMA] R Pump Press Sensor Abnormality
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality
Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality
Failure code [DKA0KA] Failure of Boom Angle Sensor (Open circuit)
Failure code [DKA0KB] Failure of Boom Angle Sensor (Short circuit)
Failure code [DKA0PH] Boom Angle Sensor installation error
Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality
Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality
Failure code [DV20KB] Travel Alarm Short Circuit
Failure code [DW43KA] Travel Speed Sol Open Circuit
Failure code [DW43KB] Travel Speed Sol Short Circuit
Failure code [DW45KA] Swing Brake Sol Open Circuit
Failure code [DW45KB] Swing Brake Sol Short Circuit
Failure code [DW4GKA] Boom slow down EPC sol disconnection
Failure code [DW4GKB] Boom slow down EPC sol short circuit
Failure code [DW91KA] Travel Junction Sol Open Circuit
Failure code [DW91KB] Travel Junction Sol Short Circuit
Failure code [DWA2KA] Attachment Sol Open Circuit
Failure code [DWA2KB] Attachment Sol Short Circuit
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit
Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit
Failure code [DWK2KA] Variable Back Press Sol Open Circuit
Failure code [DWK2KB] Variable Back Press Sol Short Circuit
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit
Failure code [DXE0KA] LS-EPC Sol Open Circuit
Failure code [DXE0KB] LS-EPC Sol Short Circuit
Failure code [DXE4KA] Attachment Flow EPC Open Circuit
Failure code [DXE4KB] Attachment Flow EPC Short Circuit
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit
Failure code [DY20KA] Wiper Working Abnormality
Failure code [DY20MA] Wiper Parking Abnormality
Failure code [DY2CKB] Washer Drive Short Circuit
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit
Troubleshooting of electrical system (E-mode)
E-1 Engine does not start (Engine does not crank)
E-2 Manual preheating system does not work
E-3 Automatic preheating system does not work
E-4 While preheating is working, preheating monitor does not light up
E-5 When starting switch is turned to ON position, machine monitor displays nothing
E-6 While starting switch is turned to ON position (with engine stopped), engine oil level monitor lights up in yellow
E-7 While starting switch is turned to ON position (with engine stopped), radiator coolant level monitor lights up in yellow
E-8 Engine coolant temperature monitor lights up in red while engine is running
E-9 Hydraulic oil temperature monitor lights up in white while engine is running
E-10 Charge level monitor lights up in red while engine is running
E-11 Fuel level monitor lights up in red while engine is running
E-12 Air cleaner clogging monitor lights up in yellow while engine is running
E-13 Water separator monitor lights up in red while engine is running
E-14 Engine coolant temperature monitor lights up in red while engine is running
E-15 Hydraulic oil temperature monitor lights up in red while engine is running
E-16 Engine oil pressure monitor lights up in red while engine is running
E-17 Fuel gauge display does not move from minimum or maximum
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty)
E-19 Engine coolant temperature gauge display does not move from minimum or maximum
E-20 Engine coolant temperature gauge indicates incorrect temperature (indicates neither full nor empty)
E-21 Hydraulic oil temperature gauge does not move from minimum or maximum
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither full nor empty)
E-23 Contents of display on machine monitor is different from actual machine condition
E-24 Some areas of machine monitor screen are not displayed
E-25 Function switch does not work
E-26 Automatic warm-up system does not operate (in cold season)
E-27 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration switch is operated
E-28 Auto-deceleration function does not operate or is not canceled while lever is operated
E-29 Working mode selection screen is not displayed while working mode selector switch is operated
E-30 Setting of engine and hydraulic pump is not changed while working mode is changed
E-31 Travel speed monitor does not change when travel speed switch is operated
E-32 Travel speed does not change while travel speed selection is changed
E-33 Alarm buzzer does not stop sounding
E-34 Service meter is not displayed, while starting switch is in OFF position
E-35 Service mode cannot be selected
E-36 Any of work equipment, swing and travel does not work
E-37 Any of work equipment, swing and travel cannot be locked
E-38 Upper structure does not swing while swing parking brake cancel switch is set to CANCEL position
E-39 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position
E-40 One-touch power maximizing function does not operate, or indicator is not displayed on monitor
E-41 One-touch power maximizing function cannot be canceled
E-42 Alarm does not sound during travel
E-43 Alarm does not stop sounding while machine is stopped
E-44 Horn does not sound
E-45 Horn does not stop sounding
E-46 Wiper monitor does not light up, or does not go out, while wiper switch is operated
E-47 Wiper does not operate while wiper switch is operated
E-48 Window washer does not operate while window washer switch is operated
E-49 Boom LOWER is not displayed correctly with monitoring function
E-50 Arm OUT is not displayed correctly with monitoring function
E-51 Arm IN is not displayed correctly with monitoring function
E-52 Boom RAISE is not displayed correctly with monitoring function
E-53 Bucket CURL is not displayed correctly with monitoring function
E-54 Bucket DUMP is not displayed correctly with monitoring function
E-55 Swing is not displayed correctly with monitoring function
E-56 Travel is not displayed correctly with monitoring function
E-57 Service is not displayed correctly with monitoring function
E-58 Attachment hydraulic circuit cannot be changed
E-59 KOMTRAX system does not operate normally
Troubleshooting of hydraulic and mechanical system (H-mode)
Information described in troubleshooting table (H-mode)
System chart of hydraulic and mechanical systems
Failure mode and cause table
H-1 All of work equipment, swing and travel operation lacks speed or power
H-2 Engine speed drops significantly or engine stalls
H-3 All work equipment, swing and travel does not work
H-4 Unusual sound is heard from around hydraulic pump
H-5 Fine control performance or response is poor
H-6 Boom speed or power is low
H-7 Arm speed or power is low
H-8 Bucket speed or power is low
H-9 Work equipment does not move in single operation
H-10 Hydraulic drift of boom is large
H-11 Hydraulic drift of arm is large
H-12 Hydraulic drift of bucket is large
H-13 Time lag of work equipment is large
H-14 When part of work equipment is relieved singly, other parts of work equipment move
H-15 One-touch power maximizing function does not operate
H-16 In combined operation of work equipment, equipment having heavier load moves slower
H-17 In combined operations of swing and boom RAISE, boom rising speed is low
H-18 In combined operations of swing and travel, travel speed drops largely
H-19 Machine does not travel straight
H-20 Travel speed is slow
H-21 Machine is hard to steer or travel power is low
H-22 Travel speed does not change, or travel speed is too slow or fast
H-23 One of tracks does not run
H-24 Upper structure does not swing to the right or left
H-25 Upper structure swing only to the right or left
H-26 Swing acceleration or swing speed is low in both directions (right and left)
H-27 Swing acceleration performance is poor or swing speed is slow in only one direction
H-28 Upper structure overruns excessively when it stops swinging (both right and left)
H-29 Upper structure overruns excessively when it stops swinging (either right or left)
H-30 Shock is large when upper structure stops swinging
H-31 Large unusual noise is heard when upper structure stops swinging
H-32 Swing drift on a slope is large while swing holding brake is applied
H-33 Swing drift on a slope is large while swing holding brake is released
H-34 Attachment hydraulic circuit cannot be changed while attachment is installed
H-35 Oil flow in attachment circuit cannot be controlled
Troubleshooting of engine (S-mode)
Information mentioned in troubleshooting table (S mode)
S-1 When starting switch is turned to START position, engine does not crank
S-2 Engine cranks but no exhaust smoke comes out
S-3 Fuel is being injected but engine does not start (misfiring: engine cranks but does not start)
S-4 Engine startability is poor
S-5 Engine does not pick up smoothly
S-6 Engine stops during operation
S-7 Engine runs rough or is unstable
S-8 Engine lacks power
S-9 Exhaust smoke is black (KDPF clogs up early)
S-10 Engine oil consumption is excessive
S-11 Engine oil becomes contaminated early
S-12 Fuel consumption is excessive
S-13 Oil is in coolant (or coolant spurts or coolant level goes down)
S-14 Engine oil pressure drops
S-15 Fuel is contaminated in engine oil
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white)
S-17 Coolant temperature rises too high (overheating)
S-18 Unusual noise is heard
S-19 Vibration is excessive
S-20 Air cannot be bled from fuel circuit
S-21 Active regeneration is executed frequently
S-22 Active regeneration takes time
S-23 White smoke is exhausted during active regeneration

50 Disassembly and assembly
Table of contents
Related information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of supply pump assembly
Removal and installation of injector assembly
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of aftercooler assembly
Removal and installation of engine assembly
Removal and installation of engine front oil seal
Removal and installation of engine rear oil seal
Removal and installation of fuel cooler assembly
Removal and installation of fuel tank assembly
Removal and installation of engine hood assembly
Removal and installation of KDPF assembly
Disassembly and assembly of KDPF assembly
Removal and installation of KCCV assembly
Removal and installation of air cleaner assembly
Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly
Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly
Power train
Removal and installation of travel motor and final drive assembly
Disassembly and assembly of final drive
Removal and installation of swing motor and swing machinery assembly
Disassembly and assembly of swing machinery assembly
Removal and installation of swing circle assembly
Undercarriage and frame
Separation and connection of track shoe assembly
Removal and installation of sprocket
Removal and installation of idler and idler cushion assembly
Disassembly and assembly of idler assembly
Disassembly and assembly of idler cushion assembly
Disassembly and assembly of track roller assembly
Disassembly and assembly of carrier roller assembly
Removal and installation of revolving frame assembly
Removal and installation of counterweight assembly
Removal and installation of counterweight assembly for maintenance
Hydraulic system
Removal and installation of center swivel joint assembly
Disassembly and assembly of center swivel joint assembly
Removal and installation of hydraulic tank assembly
Removal and installation of main pump assembly
Removal and installation of main pump input shaft oil seal
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
Disassembly and assembly of work equipment PPC valve assembly
Disassembly and assembly of travel PPC valve assembly
Work equipment
Removal and installation of work equipment assembly
Disassembly and assembly of work equipment cylinder assembly
Cab and its attachments
Removal and installation of operator's cab assembly
Removal and installation of operator's cab glass (adhered glass)
Removal and installation of front window assembly
Removal and installation of floor frame assembly
Removal and installation of air conditioner unit assembly
Removal and installation of operator's seat
Removal and installation of seat belt
Removal and installation of front wiper assembly
Removal and installation of air conditioner compressor assembly
Removal and installation of air conditioner condenser assembly
Electrical system
Removal and installation of engine controller assembly
Removal and installation of pump controller assembly
Removal and installation of machine monitor assembly
Removal and installation of pump swash plate sensor
Removal and installation of mass air flow and temperature sensor
Removal and installation of KOMTRAX terminal

60 Maintenance standard
Table of contents
Engine and cooling system
Engine mount
Cooling system
Power train
Swing circle
Swing machinery
Final drive
Sprocket
Undercarriage and frame
Track frame and idler cushion
Idler
Track roller
Carrier roller
Track shoe
Hydraulic system
Hydraulic tank
Main pump
Control valve
Swing motor
Travel motor
PPC valve
Solenoid valve
Attachment circuit selector valve (for high-pressure circuit)
Attachment circuit selector valve (for low-pressure circuit)
Center swivel joint
Work equipment
Work equipment
Work equipment cylinder

80 Appendix
Table of contents
Air conditioner components
Precautions for refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Dual pressure switch
Air conditioner controller
Compressor
Air conditioner condenser
Sunlight sensor
Outer temperature sensor (outside air temperature sensor)
Procedure for testing and troubleshooting
Circuit diagram and arrangement of connector pins
System diagram
Input and output signals of the air conditioner controller
Air conditioner unit
Parts and connectors layout
Testing air leakage (duct)
Testing with self-diagnosis function
Testing vent (mode) changeover
Testing FRESH/RECIRC air changeover
Testing sunlight sensor
Testing (dual) pressure switch for refrigerant
Testing relays
Troubleshooting chart 1
Troubleshooting chart 2
Information in troubleshooting table
Failure code list related to air conditioner
Failure code [879AKA] A/C Inner Sensor Open Circuit
Failure code [879AKB] A/C Inner Sensor Short Circuit
Failure code [879BKA] A/C Outer Sensor Open Circuit
Failure code [879BKB] A/C Outer Sensor Short Circuit
Failure code [879CKA] Ventilating Sensor Open Circuit
Failure code [879CKB] Ventilating Sensor Short Circuit
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
Failure code [879EMC] Ventilation Damper Abnormality
Failure code [879FMC] Air Mix Damper Abnormality
Failure code [879GKX] Refrigerant Abnormality
A-1 Troubleshooting for power supply system (Air conditioner does not operate)
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled)
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal)
A-4 Troubleshooting for FRESH/RECIRC air changeover
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting refrigerant piping
Handling of compressor oil
Desiccant replacement

90 Diagrams and drawings
Table of contents
Hydraulic circuit diagram
Symbols in hydraulic circuit diagram
Hydraulic circuit diagram
Electric circuit diagram
Symbols in electric circuit diagram
Electrical circuit diagram
Electrical circuit diagram of air conditioner unit

INDEX

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