Komatsu A27001, Shop Manual

Page 1: ...to improve our products whenever it is possible and practical to do so We reserve the right to make changes or improvements at any time without incurring any obligation to install such changes on pro...

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Page 3: ...00 INDEX AND FOREWORD PC290LC 11 00 1 Find manuals at https best manuals com...

Page 4: ...OR WITH LOCK TO PULL 00 65 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 00 66 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 00 68 HOW TO READ ELECTRIC...

Page 5: ...ONTROL SYSTEM DIAGRAM 10 276 COMPONENT PARTS OF SWING SYSTEM 10 280 TRAVEL SYSTEM 10 294 LAYOUT DRAWING OF TRAVEL SYSTEM 10 294 TRAVEL CONTROL SYSTEM DIAGRAM 10 298 COMPONENT PARTS OF TRAVEL SYSTEM 10...

Page 6: ...AULIC SYSTEM 30 89 TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT SWING AND TRAVEL CIRCUITS 30 90 TEST OIL PRESSURE OF CONTROL CIRCUIT 30 100 TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 30...

Page 7: ...ne Controller Lock Caution 1 40 179 FAILURE CODE 989M00 Engine Controller Lock Caution 2 40 180 FAILURE CODE 989N00 Engine Controller Lock Caution 3 40 181 FAILURE CODE A1U0N3 HC Desorb Request 1 40 1...

Page 8: ...rror 40 271 FAILURE CODE CA386 Sensor 1 Supply Voltage High Error 40 273 FAILURE CODE CA428 Water in Fuel Sensor High Error 40 274 FAILURE CODE CA429 Water in Fuel Sensor Low Error 40 276 FAILURE CODE...

Page 9: ...82 FAILURE CODE CA2186 Throttle Sensor Supply Voltage Low Error 40 383 FAILURE CODE CA2249 Common Rail Pressure Low Error 2 40 385 FAILURE CODE CA2271 EGR Valve Position Sensor High Error 40 386 FAILU...

Page 10: ...DEF Level Low Error 2 40 516 FAILURE CODE CA3543 AdBlue DEF Quality Error SCR Catalyst Efficiency Low 40 517 FAILURE CODE CA3545 SCR Outlet NOx Sensor Unstable Error 40 523 FAILURE CODE CA3547 AdBlue...

Page 11: ...e Sensor 1 In Range Error 40 661 FAILURE CODE CA4251 AdBlue DEF Pump Temperature Sensor 2 In Range Error 40 663 FAILURE CODE CA4259 KDOC and KDPF Temperature Sensor Power Interrupt Error 40 665 FAILUR...

Page 12: ...Sensor Defective Function 40 791 FAILURE CODE DHS8MA Boom RAISE PPC Pressure Sensor Defective Function 40 794 FAILURE CODE DHS9MA Boom LOWER PPC Pressure Sensor Defective Function 40 797 FAILURE CODE...

Page 13: ...low Regulating EPC 2 Solenoid Short Circuit 40 915 FAILURE CODE DXE7KY Attachment Flow Regulating EPC 2 Hot Short Circuit 40 917 FAILURE CODE DXE8KA Attachment Flow Regulating EPC 3 Solenoid Open Circ...

Page 14: ...ARE NOT DISPLAYED 40 994 E 24 FUNCTION SWITCH DOES NOT OPERATE 40 995 E 25 AUTOMATIC WARM UP SYSTEM DOES NOT WORK IN COLD WEATHER 40 996 E 26 WHEN AUTO DECELERATOR SWITCH IS OPERATED AUTO DECELERATOR...

Page 15: ...057 H 2 ALL OF WORK EQUIPMENTS SWING AND TRAVEL OPERATION LACK SPEED OR POWER 40 1058 H 3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 40 1061 H 4 UNUSUAL SOUND IS HEARD FROM AROUND HYDRAULIC PUMP 40...

Page 16: ...E 40 1124 S 10 ENGINE OIL CONSUMPTION IS EXCESSIVE 40 1126 S 11 OIL BECOMES CONTAMINATED QUICKLY 40 1127 S 12 FUEL CONSUMPTION IS EXCESSIVE 40 1128 S 13 OIL IS IN COOLANT OR COOLANT SPURTS BACK OR COO...

Page 17: ...RAVEL MOTOR AND FINAL DRIVE ASSEMBLY 50 283 DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 50 285 REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 50 298 DISASSEMBLE AND ASSEMBLE SWING MACHI...

Page 18: ...AND FRAME 60 18 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 60 18 MAINTENANCE STANDARD OF IDLER 60 20 MAINTENANCE STANDARD OF TRACK ROLLER 60 22 MAINTENANCE STANDARD OF CARRIER ROLLER 60 24...

Page 19: ...SUNLIGHT SENSOR 80 49 METHOD FOR TESTING SUNLIGHT SENSOR 80 49 TEST DUAL PRESSURE SWITCH FOR REFRIGERANT 80 50 METHOD FOR TESTING DUAL PRESSURE SWITCH FOR REFRIGERANT 80 50 TEST RELAYS 80 51 METHOD FO...

Page 20: ...M 90 8 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 90 8 HYDRAULIC CIRCUIT DIAGRAM 1 2 90 13 HYDRAULIC CIRCUIT DIAGRAM 2 2 90 15 ELECTRICAL CIRCUIT DIAGRAM 90 17 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRA...

Page 21: ...n auto matically applies the retarder with a constant braking force HD HM ARSC Automatic Retarder Speed Control Travel and brake When the accelerator pedal is released while the machine is traveling d...

Page 22: ...raulic system This mechanism allows actuators to be operated in proportion to the current supplied FOPS Falling Object Protective Structure Cab and canopy This structure protects the operator s head f...

Page 23: ...the opti mum force and at the same time activates the in ter axle differential lock when the wheels idle while the machine travels on the soft ground road HM KVGT Komatsu Variable Ge ometry Turbochar...

Page 24: ...essure PPM Piston Pump and Motor Hydraulic system Piston type hydraulic pump and motor D PC etc PTO Power Take Off Power train system Power take off mechanism PTP Power Tilt and power Pitch dozer Work...

Page 25: ...attery Relay CW Clockwise CCW Counter Clockwise ECU Electronic Control Unit ECM Electronic Control Module ENG Engine EXGND External Ground F G Frame Ground GND Ground IMA Inlet Metering Actuator NC No...

Page 26: ...adjusting and troubleshooting Use the standard values table to check the standard values for testing and adjusting and judge troubles in troubleshooting 30 TESTING AND ADJUSTING This section describe...

Page 27: ...ing posture for slinging work Tightening torque This signal indicates the tightening torque for portions which requires spe cial care in assembling work Coat This signal indicates a place to be coated...

Page 28: ...in good physical condition and good preparation Always be alert and careful General precautions k If the machine is handled incorrectly it is dangerous Read and understand what is described in the ope...

Page 29: ...levers and hang UNDER REPAIR warning tag on them When performing the disassembling or assembling work support the machine securely with blocks jacks or stands before starting the work Remove all mud...

Page 30: ...caught in ro tating parts or moving parts When raising a heavy component heavier than 25 kg use a hoist or crane Before starting work check that the slings wire ropes webbing slings chains and hooks a...

Page 31: ...workers must communicate with each other fre quently The appointed signaler must make specified signals clearly at a place where he is well seen from the operator s seat and where he can see the worki...

Page 32: ...ok is maximum at its central part Never use a wire rope which has breaks in strands A re duced diameter B or kinks C There is a danger that the rope may break during the towing operation Precautions f...

Page 33: ...o work and passage After operating the hoist do not swing the control switch Remember the position of the main switch so that you can turn off the power immediately in an emer gency If the hoist stops...

Page 34: ...to use 2 wrenches use one wrench to fix and use the other one to loosen the nut Precautions for air conditioner piping When installing the air conditioner piping be careful so that dirt dusts and wate...

Page 35: ...g An O ring is fitted to every joint of the air conditioner piping For tightening torques see THE OTHER INFORMATION Pre cautions for disconnection and connection of air conditioner piping 00 INDEX AND...

Page 36: ...umulated or attached to or around the engine exhaust manifold muffler or battery or on the undercovers To prevent fires from being caught remove any flammable materials such as dry leaves chips pieces...

Page 37: ...ee the Operation and Maintenance Manual for the setting procedure Explosion caused by lighting equipment When checking fuel oil battery electrolyte or coolant always use lighting equipment with anti e...

Page 38: ...hen they are inhaled Do not breathe the fumes After a fire there may be harmful compounds left If they touch your skin they may have a bad influence on your body Be sure to wear rubber gloves when han...

Page 39: ...or lakes Obey appropriate laws and regulations when disposing of harmful objects such as oil fuel coolant solvent filters batteries and DEF Avoid exposure to burning rubber or plastics which produce a...

Page 40: ...Association of Germany DEF is the abbreviation for Diesel Exhaust Fluid Commercial DEF that is API approved and meets all the requirements defined in ISO 22241 1 This solution will be represented as...

Page 41: ...When opening the container perform it where there is good ventilation For storage see STORE AdBlue DEF Store AdBlue DEF avoiding direct sunlight Always use the original container at the time of purch...

Page 42: ...ax 10 C Up to 36 months Max 25 C Up to 18 months Max 30 C Up to 12 months Max 35 C Up to 6 months Do not store AdBlue DEF in the temperature of 35 C or above Handling AdBlue DEF in cold weather AdBlue...

Page 43: ...aling of openings prevention of flowing out of oil Plug the openings of the piping and the device which have been removed to prevent foreign material from enter ing and oil from flowing out NOTICE Do...

Page 44: ...required to completely dislodge the contami nants and sludges and existing oil containing those inside the hydraulic circuit after disassembling and assembling and when replacing the oil with the new...

Page 45: ...ckness and number of shims when storing shims When hoisting the components prepare the slings with sufficient strength When using forcing screws to remove any component tighten the forcing screws unif...

Page 46: ...n of the split flange type hoses and tubes Nomi nal No Bolt pitch mm Hose side Tube side O ring 4 Bolt 5 Washer 6 a b Flange 1 Split flange 2 Sleeve head 3 04 38 1 17 5 07379 00400 07371 30400 07378 1...

Page 47: ...1643 51232 30 106 4 62 07379 03010 07371 13010 07378 13000 07000 12085 07372 51650 01643 51645 34 120 6 69 8 07379 03411 07371 13411 07378 13400 07000 12100 07372 51650 01643 51645 40 130 2 77 8 07379...

Page 48: ...ps of adhesive to the threaded portion When applying liquid gasket clean and degrease the surface and apply it uniformly after making sure that the surface is free from dust or damage Clean all of the...

Page 49: ...specified amount of grease to the work equipment parts When the coolant is drained be sure that the drain valve is securely tightened then refill the coolant reser voir with the coolant Komatsu recomm...

Page 50: ...s installation portion If there is any damage replace the part Check that there is no looseness on the exhaust equipment and mounting bolts nuts and clamps on the instal lation portion If there is any...

Page 51: ...necessary to be extremely careful when handling and maintenance of the wiring harnesses If AdBlue DEF is spilled over wiring harness and connectors it may cause corrosion and defective contact Be care...

Page 52: ...icity Entry of water dirt or dust when disconnecting a con nector If any water mud or dust is stuck to the outside surface of a connector it can enter inside the connector when the connector is discon...

Page 53: ...y pollute the environ ment Do not discard the oil inconsiderately Ask the customer for disposal or bring it back to dispose it appropriately How to clean parts when dirt is stuck If any dirt or dust s...

Page 54: ...l when servicing the intake system Select an appropriate workplace Avoid the work of adding hydraulic oil replacing filters or repairing the machine in rainy or windy weather or in dusty environment S...

Page 55: ...undness of machine in addition to KOMTRAX function described above These data can be used on per sonal computer screens How to make a full use of KOMTRAX Making use of KOMTRAX enables the following ac...

Page 56: ...connection 1 Hold adapter 1 and push hose joint 2 into mating adapter 3 REMARK Push it in approximately 3 5 mm Do not hold rubber cap portion 4 2 While having adapter 3 inserted into hose side joint 2...

Page 57: ...isconnection 1 Hold the tightening adapter part and push body 2 straight until sliding prevention ring 1 contacts contact surface a of the hexagonal part at the male end 2 While keeping the condition...

Page 58: ...traight until sliding prevention ring 1 contacts contact surface a of the hexagonal part at the male end 2 While keeping the condition of step 1 push cover 3 straight until it contacts contact surface...

Page 59: ...ning adapter part and push body 2 straight un til sliding prevention ring 1 contacts contact surface a of the hexagonal part at the male end 00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH PULL TYPE...

Page 60: ...ith each other when the connec tor is connected When removing a connector from a clip pull the con nector in parallel with the clip as removing stoppers NOTICE If the connector is pried up and down or...

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