Komatsu HYDRAULIC EXCAVATOR PC240 -11 PC240LC -11 PC240NLC-11 Shop Manual UENBM00333

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Komatsu HYDRAULIC EXCAVATOR PC240 -11 PC240LC -11 PC240NLC-11 Shop Manual UENBM00333 – PDF DOWNLOAD

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Komatsu HYDRAULIC EXCAVATOR PC240 -11 PC240LC -11 PC240NLC-11 Shop Manual UENBM00333 – PDF DOWNLOAD

Language : English
Pages :2808
Downloadable : Yes
File Type : PDF

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Komatsu HYDRAULIC EXCAVATOR PC240 -11 PC240LC -11 PC240NLC-11 Shop Manual UENBM00333 – PDF DOWNLOAD

SERIAL NUMBERS K70001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and 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 describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC240 -11 PC240LC -11 PC240NLC-11 Shop Manual UENBM00333 – PDF DOWNLOAD

SERIAL NUMBERS K70001 and up

UENBM00333_PC240_LC_NLC-11_2102pdf 0
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 21
FOREWORD, SAFETY, BASIC INFORMATION 27
HOW TO READ THE SHOP MANUAL 27
SAFETY NOTICE FOR OPERATION 29
PRECAUTIONS TO PREVENT FIRE 37
ACTIONS IF FIRE OCCURS 39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 41
PRECAUTIONS FOR DEF 42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 42
PRECAUTIONS FOR ADDING 42
PRECAUTIONS FOR STORING 42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 42
THE OTHER PRECAUTIONS 42
STORE AdBlue/DEF 43
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 44
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 47
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 54
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 56
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 57
PRACTICAL USE OF KOMTRAX 58
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 61
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 63
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 73
HOW TO READ ELECTRICAL WIRE CODE 74
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 78
STANDARD TIGHTENING TORQUE TABLE 81
CONVERSION TABLE 88
01 SPECIFICATIONS 93
CONTENTS 94
ABBREVIATION LIST 95
SPECIFICATIONS 101
SPECIFICATION DRAWING 101
SPECIFICATION DRAWING: PC240LC-11, PC240NLC-11 101
WORKING RANGE DRAWINGS 102
WORKING RANGE: PC240LC-11, PC240NLC-11 102
SPECIFICATIONS 103
SPECIFICATIONS: PC240LC-11, PC240NLC-11 103
WEIGHT TABLE 106
WEIGHT TABLE: PC240LC-11, PC240NLC-11 106
TABLE OF FUEL, COOLANT, AND LUBRICANTS 108
10 STRUCTURE AND FUNCTION 109
CONTENTS 110
ABBREVIATION LIST 114
UREA SCR SYSTEM 120
LAYOUT DRAWING OF UREA SCR SYSTEM 121
UREA SCR SYSTEM DIAGRAM 126
FUNCTION OF UREA SCR SYSTEM 127
FUNCTION OF AdBlue/DEF SYSTEM 127
INDUCEMENT STRATEGY 129
COMPONENT PARTS OF UREA SCR SYSTEM 137
AdBlue/DEF MIXING TUBE 137
SCR ASSEMBLY 137
AdBlue/DEF TANK 140
AdBlue/DEF PUMP 142
AdBlue/DEF INJECTOR 143
AdBlue/DEF HOSE 144
AdBlue/DEF TANK HEATING VALVE 145
BOOT-UP SYSTEM 146
LAYOUT DRAWING OF BOOT-UP SYSTEM 146
SYSTEM OPERATING LAMP SYSTEM 148
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 148
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 148
BATTERY DISCONNECT SWITCH 150
FUNCTION OF BATTERY DISCONNECT SWITCH 150
ENGINE SYSTEM 151
LAYOUT DRAWING OF ENGINE SYSTEM 151
SPECIFICATIONS OF ENGINE SYSTEM 152
FUNCTION OF ENGINE SYSTEM 152
ENGINE CONTROL SYSTEM 153
ENGINE CONTROL SYSTEM DIAGRAM 153
FUNCTION OF ENGINE CONTROL SYSTEM 154
AUTO-DECELERATION SYSTEM 156
AUTO-DECELERATION SYSTEM DIAGRAM 156
FUNCTION OF AUTO-DECELERATION SYSTEM 156
OPERATION OF AUTO-DECELERATION SYSTEM 157
ENGINE AUTOMATIC WARM-UP SYSTEM 158
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 158
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 159
OVERHEAT PREVENTION SYSTEM 160
OVERHEAT PREVENTION SYSTEM DIAGRAM 160
FUNCTION OF OVERHEAT PREVENTION SYSTEM 161
TURBOCHARGER PROTECTION SYSTEM 163
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 163
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 164
AUTOMATIC IDLE STOP SYSTEM 165
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 165
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 165
COMPONENT PARTS OF ENGINE SYSTEM 168
VGT 168
EGR SYSTEM 172
EGR VALVE 174
EGR COOLER 176
KCCV SYSTEM 177
KCCV VENTILATOR 179
KDPF 181
COOLING SYSTEM 186
LAYOUT DRAWING OF COOLING SYSTEM 186
SPECIFICATIONS OF COOLING SYSTEM 187
CONTROL SYSTEM 188
LAYOUT DRAWING OF CONTROL SYSTEM 188
MACHINE MONITOR SYSTEM 191
MACHINE MONITOR SYSTEM DIAGRAM 191
KomVision SYSTEM 192
LAYOUT DRAWING OF KOMVISION SYSTEM 192
KomVision SYSTEM DIAGRAM 194
FUNCTION OF KomVision SYSTEM 194
KOMTRAX SYSTEM 196
KOMTRAX SYSTEM DIAGRAM 196
FUNCTION OF KOMTRAX SYSTEM 196
PPC LEVERS 197
LH PPC LEVER 197
RH PPC LEVER 198
AUTOMATIC GREASE SYSTEM 199
OUTLINE OF AUTO GREASE SYSTEM 199
COMPONENT PARTS OF CONTROL SYSTEM 214
MACHINE MONITOR 214
KomVision CONTROLLER 227
KomVision CAMERA 231
KOMTRAX TERMINAL 231
PUMP CONTROLLER 234
RESISTOR FOR PC-EPC VALVE 238
CAN TERMINATING RESISTOR 238
PPC OIL PRESSURE SWITCH 239
ENGINE CONTROLLER 240
FUEL CONTROL DIAL 246
SENSOR 248
STRUCTURE OF AMBIENT PRESSURE SENSOR 248
FUNCTION OF AMBIENT PRESSURE SENSOR 248
STRUCTURE OF ENGINE OIL PRESSURE SWITCH 248
FUNCTION OF ENGINE OIL PRESSURE SWITCH 249
STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR 249
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR 249
STRUCTURE OF COOLANT TEMPERATURE SENSOR 250
FUNCTION OF COOLANT TEMPERATURE SENSOR 250
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR 250
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR 251
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR 251
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR 251
STRUCTURE OF COMMON RAIL PRESSURE SENSOR 252
FUNCTION OF COMMON RAIL PRESSURE SENSOR 252
STRUCTURE OF EGR VALVE LIFT SENSOR 252
FUNCTION OF EGR VALVE LIFT SENSOR 252
STRUCTURE OF VGT SPEED SENSOR 253
FUNCTION OF KVGT SPEED SENSOR 253
STRUCTURE OF KVGT POSITION SENSOR 253
FUNCTION OF KVGT POSITION SENSOR 254
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR 254
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR 255
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR 255
STRUCTURE OF CRANKCASE PRESSURE SENSOR 255
FUNCTION OF CRANKCASE PRESSURE SENSOR 256
STRUCTURE OF ENGINE OIL LEVEL SENSOR 256
STRUCTURE OF AIR CLEANER CLOGGING SENSOR 256
FUNCTION OF AIR CLEANER CLOGGING SENSOR 257
STRUCTURE OF WATER-IN-FUEL SENSOR 257
FUNCTION OF WATER-IN-FUEL SENSOR 257
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 257
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 258
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 258
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 258
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 259
FUNCTION OF AUTO GREASE PRESSURE SWITCH 259
STRUCTURE OF OVERLOAD CAUTION SENSOR 259
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 259
FUNCTION OF OVERLOAD CAUTION SENSOR 259
HYDRAULIC SYSTEM 260
LAYOUT DRAWING OF HYDRAULIC SYSTEM 260
CLSS 266
STRUCTURE OF CLSS 266
OPERATION OF UNLOAD VALVE AND LS PRESSURE 268
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 269
PRESSURE COMPENSATION CONTROL 282
ENGINE AND PUMP COMBINED CONTROL SYSTEM 285
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 285
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 286
PUMP AND VALVE CONTROL SYSTEM 291
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 291
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 292
COMPONENT PARTS OF HYDRAULIC SYSTEM 294
HYDRAULIC TANK 294
MAIN PUMP 296
PC-EPC VALVE 320
PILOT OIL FILTER 322
CONTROL VALVE 322
WORK EQUIPMENT SYSTEM 379
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 379
STRUCTURE OF VALVE CONTROL 384
ONE-TOUCH POWER MAXIMIZING SYSTEM 386
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 386
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 387
PPC LOCK SYSTEM 388
PPC LOCK SYSTEM DIAGRAM 388
FUNCTION OF PPC LOCK SYSTEM 388
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 389
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 389
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 389
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 390
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 391
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 391
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 393
TOOL CONTROL SYSTEM 394
TOOL CONTROL SYSTEM DIAGRAM 394
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 396
WORK EQUIPMENT AND SWING PPC VALVE 396
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 401
SOLENOID VALVE 407
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 410
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 412
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE 415
2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE 417
ATTACHMENT BYPASS SOLENOID VALVE 420
ATT EPC VALVE ASSEMBLY 422
PILOT CIRCUIT ACCUMULATOR 423
ATTACHMENT CIRCUIT ACCUMULATOR 424
SWING SYSTEM 425
LAYOUT DRAWING OF SWING SYSTEM 425
SWING CONTROL SYSTEM DIAGRAM 429
FUNCTION OF SWING CONTROL SYSTEM 429
COMPONENT PARTS OF SWING SYSTEM 433
SWING MOTOR 433
SWING MACHINERY 444
SWING CIRCLE 445
TRAVEL SYSTEM 447
LAYOUT DRAWING OF TRAVEL SYSTEM 447
TRAVEL CONTROL SYSTEM DIAGRAM 451
FUNCTION OF TRAVEL CONTROL SYSTEM 451
COMPONENT PARTS OF TRAVEL SYSTEM 453
TRAVEL MOTOR 453
FINAL DRIVE 465
TRAVEL PPC VALVE 467
CENTER SWIVEL JOINT 472
UNDERCARRIAGE AND FRAME 474
LAYOUT DRAWING OF UNDERCARRIAGE 474
SPECIFICATIONS OF UNDERCARRIAGE 475
WORK EQUIPMENT 476
STRUCTURE OF WORK EQUIPMENT 476
FUNCTION OF WORK EQUIPMENT 477
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 478
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 478
BUCKET CLEARANCE ADJUSTMENT SHIM 479
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 479
CAB AND ITS ATTACHMENTS 480
ROPS CAB 480
STRUCTURE OF ROPS CAB 480
FUNCTION OF ROPS CAB 480
CAB MOUNT 481
STRUCTURE OF CAB MOUNT 481
FUNCTION OF CAB MOUNT 481
CAB TIPPING STOPPER 482
STRUCTURE OF CAB TIPPING STOPPER 482
FUNCTION OF CAB TIPPING STOPPER 482
20 STANDARD VALUE TABLE 483
CONTENTS 484
ABBREVIATION LIST 485
STANDARD VALUE TABLE FOR ENGINE 491
STANDARD VALUE TABLE FOR ENGINE: PC240LC-11, PC240NLC-11 491
STANDARD VALUE TABLE FOR MACHINE 495
STANDARD VALUE TABLE FOR MACHINE: PC240LC-11, PC240NLC-11 495
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 508
STANDARD VALUE TABLE FOR ELECTRICAL 512
STANDARD VALUE TABLE FOR ELECTRICAL 512
30 TESTING AND ADJUSTING 523
CONTENTS 524
ABBREVIATION LIST 527
RELATED INFORMATION ON TESTING AND ADJUSTING 533
TOOLS FOR TESTING AND ADJUSTING 533
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 540
ENGINE AND COOLING SYSTEM 542
TEST ENGINE SPEED 542
METHOD FOR TESTING ENGINE SPEED 542
TEST BOOST PRESSURE 545
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 545
METHOD FOR TESTING BOOST PRESSURE 546
TEST EXHAUST GAS COLOR 547
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 547
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 548
TEST AND ADJUST VALVE CLEARANCE 550
METHOD FOR TESTING VALVE CLEARANCE 550
METHOD FOR ADJUSTING VALVE CLEARANCE 551
TEST COMPRESSION PRESSURE 553
METHOD FOR TESTING COMPRESSION PRESSURE 553
TEST BLOWBY PRESSURE 558
METHOD FOR TESTING BLOWBY PRESSURE 558
TEST ENGINE OIL PRESSURE 560
METHOD FOR TESTING ENGINE OIL PRESSURE 560
TEST EGR VALVE AND VGT OIL PRESSURE 561
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 561
TEST FUEL PRESSURE 563
METHOD FOR TESTING FUEL PRESSURE 564
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 569
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 570
BLEEDING AIR FROM FUEL SYSTEM 576
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 576
TEST FUEL CIRCUIT FOR LEAKAGE 577
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 577
HANDLE CYLINDER CUT-OUT MODE OPERATION 579
HANDLE NO-INJECTION CRANKING OPERATION 580
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 581
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 581
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 581
REPLACING FAN BELT 583
METHOD FOR REPLACING FAN BELT 583
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 584
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 584
TEST SCR RELATED FUNCTIONS 585
TEST AdBlue/DEF PUMP RAISED PRESSURE 588
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 591
TEST AdBlue/DEF LINE HEATER RELAY 1 595
TEST AdBlue/DEF LINE HEATER RELAY 2 598
TEST AdBlue/DEF PUMP HEATER RELAY 600
TEST AdBlue/DEF TANK HEATER VALVE 603
TEST DENITRATION EFFICIENCY OF SCR 606
CLEAN AdBlue/DEF TANK 610
METHOD FOR CLEANING AdBlue/DEF TANK 610
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 614
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 614
POWER TRAIN 616
TEST SWING CIRCLE BEARING CLEARANCE 616
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 616
UNDERCARRIAGE AND FRAME 617
TEST AND ADJUST TRACK TENSION 617
METHOD FOR TESTING TRACK TENSION 617
METHOD FOR ADJUSTING TRACK TENSION 617
HYDRAULIC SYSTEM 619
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 619
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 619
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 623
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 625
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 626
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 632
TEST OIL PRESSURE OF CONTROL CIRCUIT 635
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 635
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 637
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 637
TEST PC-EPC VALVE OUTLET PRESSURE 638
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 639
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 641
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 641
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL 642
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 645
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE 646
METHOD FOR ADJUSTING LS VALVE 647
TEST OUTLET PRESSURE OF SOLENOID VALVE 648
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 648
OPERATING CONDITION OF SOLENOID VALVE 649
TEST PPC VALVE OUTLET PRESSURE 652
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 652
TEST ATTACHMENT CIRCUIT OIL PRESSURE 654
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 654
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 656
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 656
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE 657
TEST PUMP SWASH PLATE SENSOR 659
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 659
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 660
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 660
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 660
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 661
TEST OIL LEAKAGE 662
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 662
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 662
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 663
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR 664
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 664
BLEED AIR FROM HYDRAULIC CIRCUIT 665
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 667
CAB AND ITS ATTACHMENTS 669
TEST CAB TIPPING STOPPER 669
METHOD FOR TESTING CAB TIPPING STOPPER 669
METHOD FOR ADJUSTING MIRRORS 670
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 670
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 671
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 672
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 673
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 674
ELECTRICAL SYSTEM 676
ELECTRICAL SYSTEM 677
SET AND OPERATE MACHINE MONITOR 677
OPERATOR MODE 680
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 681
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 681
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 682
CHECKING FUNCTION OF SERVICE METER 682
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 682
SERVICE MODE 685
SERVICE MODE 685
METHOD FOR OPERATING SERVICE MODE 687
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 689
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 695
ABNORMALITY RECORD MENU 706
METHOD FOR CONFIRMING MAINTENANCE RECORD 711
METHOD FOR OPERATING MAINTENANCE MODE SETTING 712
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 716
DEFAULT MENU 717
DIAGNOSTIC TESTS MENU 728
ADJUSTMENT MENU 738
METHOD FOR PERFORMING NO-INJECTION CRANKING 772
KOMTRAX SETTINGS MENU 773
METHOD FOR DISPLAYING SERVICE MESSAGE 775
METHOD FOR STARTING UP KOMTRAX TERMINAL 777
ADJUST REARVIEW CAMERA ANGLE 782
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 782
ADJUST KomVision CAMERA ANGLE 785
METHOD FOR ADJUSTING KomVision CAMERA ANGLE 786
ADJUST KomVision RELATED ITEMS 790
SETTING OF KomVision (MAIN SETTING) 790
SETTING OF KomVision (CAMERA SETTING) 792
SETTING OF KomVision (CAMERA CALIBRATION) 792
KomVision screen – Check 12 m visibility 806
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 809
HANDLE BATTERY DISCONNECT SWITCH 810
TEST DIODES 811
METHOD FOR TESTING DIODE USING DIGITAL TESTER 811
METHOD FOR TESTING DIODE USING ANALOG TESTER 811
Pm CLINIC 812
Pm CLINIC SERVICE 812
Pm CLINIC SERVICE 814
Pm CLINIC CHECK SHEET 818
40 TROUBLESHOOTING 829
CONTENTS 830
ABBREVIATION LIST 841
RELATED INFORMATION ON TROUBLESHOOTING 847
GENERAL TROUBLESHOOTING POINTS 847
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 848
SEQUENCE OF EVENTS IN TROUBLESHOOTING 860
CHECKS BEFORE TROUBLESHOOTING 862
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 864
WALK-AROUND CHECK 864
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 866
CHECK FUEL LEVEL AND TYPE 866
CHECK IMPURE INGREDIENT IN FUEL 866
CHECK FUEL PREFILTER 867
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 867
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE 868
CHECK MAIN FILTER 869
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 871
CHECK COOLANT LEVEL (RESERVOIR TANK) 872
CHECK CLOGGING OF AIR CLEANER 872
OUTER ELEMENT – CLEAN 873
ELEMENTS – REPLACE 875
CHECK HYDRAULIC OIL LEVEL 876
CHECK HYDRAULIC OIL STRAINER 877
CHECK HYDRAULIC FILTER 878
CHECK OIL LEVEL IN SWING MACHINERY CASE 879
CHECK OIL LEVEL IN DAMPER CASE 880
CHECK OIL LEVEL IN FINAL DRIVE CASE 880
BLEED AIR FROM FUEL SYSTEM 881
BLEED AIR FROM HYDRAULIC SYSTEM 881
ELECTRICAL EQUIPMENT – CHECK METHOD 881
AUTOMATIC GREASE SYSTEM 889
FINDING MALFUNCTIONS 889
MALFUNCTION FINDING PROCEDURES 891
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM 893
PROCEDURE FOR TESTING AND TROUBLESHOOTING 903
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 906
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 910
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 912
CONNECTOR LIST AND LAYOUT 915
CONNECTOR CONTACT IDENTIFICATION 928
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 968
FUSE LOCATION TABLE 974
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 976
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 980
FAILURE CODE TABLE 982
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)1000
FAILURE CODE [879AKA]1000
FAILURE CODE [879AKB]1001
FAILURE CODE [879BKA]1002
FAILURE CODE [879BKB]1004
FAILURE CODE [879CKA]1006
FAILURE CODE [879CKB]1007
FAILURE CODE [879DKZ]1008
FAILURE CODE [879EMC]1010
FAILURE CODE [879FMC]1011
FAILURE CODE [879GKX]1012
FAILURE CODE [989L00]1014
FAILURE CODE [989M00]1015
FAILURE CODE [989N00]1016
FAILURE CODE [A1U0N3]1017
FAILURE CODE [A1U0N4]1019
FAILURE CODE [A900FR]1021
FAILURE CODE [A900N6]1022
FAILURE CODE [A900NY]1023
FAILURE CODE [AA10NX]1024
FAILURE CODE [AB00KE]1026
FAILURE CODE [AQ10N3]1029
FAILURE CODE [AS00N3]1031
FAILURE CODE [AS00R2]1033
FAILURE CODE [AS00R3]1034
FAILURE CODE [AS00R4]1035
FAILURE CODE [AS00R5]1036
FAILURE CODE [AS00R6]1037
FAILURE CODE [AS00ZK]1038
FAILURE CODE [AS10KM]1039
FAILURE CODE [AS10NR]1040
FAILURE CODE [AS10NT]1041
FAILURE CODE [B@BAZG]1042
FAILURE CODE [B@BAZK]1043
FAILURE CODE [B@BCNS]1045
FAILURE CODE [B@BCQA]1046
FAILURE CODE [B@BCZK]1048
FAILURE CODE [B@HANS]1050
FAILURE CODE [CA115]1051
FAILURE CODE [CA122]1052
FAILURE CODE [CA123]1054
FAILURE CODE [CA131]1056
FAILURE CODE [CA132]1058
FAILURE CODE [CA144]1060
FAILURE CODE [CA145]1062
FAILURE CODE [CA153]1064
FAILURE CODE [CA154]1067
FAILURE CODE [CA187]1069
FAILURE CODE [CA221]1071
FAILURE CODE [CA222]1073
FAILURE CODE [CA227]1075
FAILURE CODE [CA234]1076
FAILURE CODE [CA238]1077
FAILURE CODE [CA239]1079
FAILURE CODE [CA249]1081
FAILURE CODE [CA256]1083
FAILURE CODE [CA271]1085
FAILURE CODE [CA272]1087
FAILURE CODE [CA322]1089
FAILURE CODE [CA323]1091
FAILURE CODE [CA324]1093
FAILURE CODE [CA325]1095
FAILURE CODE [CA331]1097
FAILURE CODE [CA332]1099
FAILURE CODE [CA343]1101
FAILURE CODE [CA351]1102
FAILURE CODE [CA352]1103
FAILURE CODE [CA356]1106
FAILURE CODE [CA357]1108
FAILURE CODE [CA386]1110
FAILURE CODE [CA428]1111
FAILURE CODE [CA429]1113
FAILURE CODE [CA435]1115
FAILURE CODE [CA441]1117
FAILURE CODE [CA442]1119
FAILURE CODE [CA449]1120
FAILURE CODE [CA451]1121
FAILURE CODE [CA452]1123
FAILURE CODE [CA488]1125
FAILURE CODE [CA515]1126
FAILURE CODE [CA516]1128
FAILURE CODE [CA553]1130
FAILURE CODE [CA555]1131
FAILURE CODE [CA556]1132
FAILURE CODE [CA559]1133
FAILURE CODE [CA595]1136
FAILURE CODE [CA687]1137
FAILURE CODE [CA689]1139
FAILURE CODE [CA691]1142
FAILURE CODE [CA692]1144
FAILURE CODE [CA697]1146
FAILURE CODE [CA698]1147
FAILURE CODE [CA731]1148
FAILURE CODE [CA778]1150
FAILURE CODE [CA1117]1155
FAILURE CODE [CA1664]1156
FAILURE CODE [CA1669]1158
FAILURE CODE [CA1673]1159
FAILURE CODE [CA1677]1160
FAILURE CODE [CA1678]1161
FAILURE CODE [CA1682]1162
FAILURE CODE [CA1683]1164
FAILURE CODE [CA1684]1166
FAILURE CODE [CA1686]1168
FAILURE CODE [CA1691]1169
FAILURE CODE [CA1694]1172
FAILURE CODE [CA1695]1175
FAILURE CODE [CA1696]1176
FAILURE CODE [CA1712]1178
FAILURE CODE [CA1713]1181
FAILURE CODE [CA1714]1183
FAILURE CODE [CA1715]1184
FAILURE CODE [CA1776]1185
FAILURE CODE [CA1777]1188
FAILURE CODE [CA1843]1191
FAILURE CODE [CA1844]1193
FAILURE CODE [CA1879]1196
FAILURE CODE [CA1881]1198
FAILURE CODE [CA1883]1200
FAILURE CODE [CA1885]1203
FAILURE CODE [CA1887]1205
FAILURE CODE [CA1921]1207
FAILURE CODE [CA1922]1210
FAILURE CODE [CA1942]1215
FAILURE CODE [CA1993]1216
FAILURE CODE [CA2185]1219
FAILURE CODE [CA2186]1220
FAILURE CODE [CA2249]1222
FAILURE CODE [CA2271]1223
FAILURE CODE [CA2272]1226
FAILURE CODE [CA2288]1229
FAILURE CODE [CA2311]1230
FAILURE CODE [CA2349]1231
FAILURE CODE [CA2353]1234
FAILURE CODE [CA2357]1236
FAILURE CODE [CA2381]1237
FAILURE CODE [CA2382]1240
FAILURE CODE [CA2383]1243
FAILURE CODE [CA2386]1246
FAILURE CODE [CA2387]1248
FAILURE CODE [CA2555]1249
FAILURE CODE [CA2556]1252
FAILURE CODE [CA2637]1255
FAILURE CODE [CA2639]1257
FAILURE CODE [CA2771]1260
FAILURE CODE [CA2777]1266
FAILURE CODE [CA2976]1269
FAILURE CODE [CA3133]1271
FAILURE CODE [CA3134]1274
FAILURE CODE [CA3135]1276
FAILURE CODE [CA3142]1279
FAILURE CODE [CA3143]1280
FAILURE CODE [CA3144]1281
FAILURE CODE [CA3146]1283
FAILURE CODE [CA3147]1284
FAILURE CODE [CA3148]1285
FAILURE CODE [CA3151]1287
FAILURE CODE [CA3165]1293
FAILURE CODE [CA3229]1295
FAILURE CODE [CA3231]1297
FAILURE CODE [CA3232]1299
FAILURE CODE [CA3235]1303
FAILURE CODE [CA3239]1305
FAILURE CODE [CA3241]1308
FAILURE CODE [CA3242]1311
FAILURE CODE [CA3251]1314
FAILURE CODE [CA3253]1316
FAILURE CODE [CA3254]1319
FAILURE CODE [CA3255]1322
FAILURE CODE [CA3256]1326
FAILURE CODE [CA3311]1328
FAILURE CODE [CA3312]1330
FAILURE CODE [CA3313]1333
FAILURE CODE [CA3314]1334
FAILURE CODE [CA3315]1335
FAILURE CODE [CA3316]1337
FAILURE CODE [CA3317]1338
FAILURE CODE [CA3318]1339
FAILURE CODE [CA3319]1341
FAILURE CODE [CA3321]1342
FAILURE CODE [CA3322]1344
FAILURE CODE [CA3419]1346
FAILURE CODE [CA3421]1348
FAILURE CODE [CA3497]1350
FAILURE CODE [CA3498]1351
FAILURE CODE [CA3543]1352
FAILURE CODE [CA3545]1359
FAILURE CODE [CA3547]1361
FAILURE CODE [CA3558]1362
FAILURE CODE [CA3559]1364
FAILURE CODE [CA3562]1366
FAILURE CODE [CA3563]1368
FAILURE CODE [CA3567]1371
FAILURE CODE [CA3568]1374
FAILURE CODE [CA3571]1378
FAILURE CODE [CA3572]1380
FAILURE CODE [CA3574]1382
FAILURE CODE [CA3575]1384
FAILURE CODE [CA3577]1386
FAILURE CODE [CA3578]1388
FAILURE CODE [CA3582]1390
FAILURE CODE [CA3583]1396
FAILURE CODE [CA3596]1398
FAILURE CODE [CA3649]1400
FAILURE CODE [CA3681]1402
FAILURE CODE [CA3682]1407
FAILURE CODE [CA3713]1413
FAILURE CODE [CA3717]1416
FAILURE CODE [CA3718]1417
FAILURE CODE [CA3725]1418
FAILURE CODE [CA3741]1421
FAILURE CODE [CA3748]1422
FAILURE CODE [CA3751]1424
FAILURE CODE [CA3755]1426
FAILURE CODE [CA3866]1428
FAILURE CODE [CA3867]1432
FAILURE CODE [CA3868]1435
FAILURE CODE [CA3899]1439
FAILURE CODE [CA3911]1441
FAILURE CODE [CA3912]1445
FAILURE CODE [CA3932]1447
FAILURE CODE [CA3933]1449
FAILURE CODE [CA3934]1451
FAILURE CODE [CA3935]1454
FAILURE CODE [CA3936]1456
FAILURE CODE [CA4151]1458
FAILURE CODE [CA4152]1462
FAILURE CODE [CA4155]1466
FAILURE CODE [CA4156]1468
FAILURE CODE [CA4157]1471
FAILURE CODE [CA4158]1473
FAILURE CODE [CA4159]1474
FAILURE CODE [CA4161]1475
FAILURE CODE [CA4162]1478
FAILURE CODE [CA4163]1481
FAILURE CODE [CA4164]1482
FAILURE CODE [CA4165]1484
FAILURE CODE [CA4166]1486
FAILURE CODE [CA4168]1487
FAILURE CODE [CA4169]1490
FAILURE CODE [CA4171]1492
FAILURE CODE [CA4249]1495
FAILURE CODE [CA4251]1497
FAILURE CODE [CA4259]1499
FAILURE CODE [CA4261]1502
FAILURE CODE [CA4277]1505
FAILURE CODE [CA4281]1509
FAILURE CODE [CA4459]1512
FAILURE CODE [CA4461]1515
FAILURE CODE [CA4658]1518
FAILURE CODE [CA4731]1522
FAILURE CODE [CA4732]1523
FAILURE CODE [CA4739]1524
FAILURE CODE [CA4768]1525
FAILURE CODE [CA4769]1527
FAILURE CODE [CA4842]1530
FAILURE CODE [CA4952]1534
FAILURE CODE [CA5115]1536
FAILURE CODE [CA5179]1539
FAILURE CODE [CA5181]1541
FAILURE CODE [CA5383]1543
FAILURE CODE [D110KB]1545
FAILURE CODE [D19JKZ]1547
FAILURE CODE [D811MC]1550
FAILURE CODE [D862KA]1551
FAILURE CODE [D8ALKA]1552
FAILURE CODE [D8ALKB]1554
FAILURE CODE [D8AQKR]1556
FAILURE CODE [DA20MC]1558
FAILURE CODE [DA22KK]1559
FAILURE CODE [DA25KP]1562
FAILURE CODE [DA26KP]1565
FAILURE CODE [DA29KQ]1568
FAILURE CODE [DA2LKA]1570
FAILURE CODE [DA2LKB]1572
FAILURE CODE [DA2QKR]1574
FAILURE CODE [DA2RKR]1577
FAILURE CODE [DAF0KM]1578
FAILURE CODE [DAF0MB]1579
FAILURE CODE [DAF0MC]1580
FAILURE CODE [DAF8KB]1581
FAILURE CODE [DAF9KQ]1583
FAILURE CODE [DAFGMC]1584
FAILURE CODE [DAFLKA]1585
FAILURE CODE [DAFLKB]1587
FAILURE CODE [DAFQKR]1589
FAILURE CODE [DAZ9KQ]1590
FAILURE CODE [DAZQKR]1591
FAILURE CODE [DB2QKR]1596
FAILURE CODE [DBP0KM]1601
FAILURE CODE [DBP0KT]1602
FAILURE CODE [DB2RKR]1603
FAILURE CODE [DBP5KB]1608
FAILURE CODE [DBP5KY]1611
FAILURE CODE [DBPQKR]1614
FAILURE CODE [DDNRKA]1619
FAILURE CODE [DDNRKY]1621
FAILURE CODE [DDNS00]1623
FAILURE CODE [DFB1KZ]1625
FAILURE CODE [DFB2KZ]1627
FAILURE CODE [DFB3L8]1629
FAILURE CODE [DFB4L8]1631
FAILURE CODE [DFB5KZ]1633
FAILURE CODE [DFB6KZ]1635
FAILURE CODE [DGH2KA]1637
FAILURE CODE [DGH2KB]1639
FAILURE CODE [DHA4KA]1641
FAILURE CODE [DHAAMA]1643
FAILURE CODE [DHACMA]1645
FAILURE CODE [DHPAMA]1647
FAILURE CODE [DHPBMA]1650
FAILURE CODE [DHS3MA]1653
FAILURE CODE [DHS4MA]1656
FAILURE CODE [DHS8MA]1659
FAILURE CODE [DHS9MA]1662
FAILURE CODE [DHSAMA]1665
FAILURE CODE [DHSBMA]1668
FAILURE CODE [DHSCMA]1671
FAILURE CODE [DHSDMA]1674
FAILURE CODE [DHSFMA]1677
FAILURE CODE [DHSGMA]1680
FAILURE CODE [DHSHMA]1683
FAILURE CODE [DHSJMA]1686
FAILURE CODE [DHX1MA]1689
FAILURE CODE [DKR0MA]1692
FAILURE CODE [DKR1MA]1695
FAILURE CODE [DKULKA]1698
FAILURE CODE [DKULKB]1700
FAILURE CODE [DKULKY]1702
FAILURE CODE [DR10KA]1704
FAILURE CODE [DR12KA]1707
FAILURE CODE [DR20KA]1709
FAILURE CODE [DR21KX]1711
FAILURE CODE [DR30KA]1713
FAILURE CODE [DR31KX]1715
FAILURE CODE [DR40KA]1717
FAILURE CODE [DUMBKA]1719
FAILURE CODE [DUMBKB]1721
FAILURE CODE [DV20KB]1723
FAILURE CODE [DW43KA]1725
FAILURE CODE [DW43KB]1727
FAILURE CODE [DW43KY]1729
FAILURE CODE [DW45KA]1731
FAILURE CODE [DW45KB]1734
FAILURE CODE [DW45KY]1737
FAILURE CODE [DW4CKY]1739
FAILURE CODE [DW91KA]1741
FAILURE CODE [DW91KB]1743
FAILURE CODE [DW91KY]1745
FAILURE CODE [DWA2KA]1747
FAILURE CODE [DWA2KB]1749
FAILURE CODE [DWA2KY]1751
FAILURE CODE [DWK0KA]1753
FAILURE CODE [DWK0KB]1755
FAILURE CODE [DWK0KY]1757
FAILURE CODE [DWK2KA]1759
FAILURE CODE [DWK2KB]1761
FAILURE CODE [DWK2KY]1763
FAILURE CODE [DWK8KA]1765
FAILURE CODE [DWK8KB]1767
FAILURE CODE [DWK8KY]1769
FAILURE CODE [DXA8KA]1771
FAILURE CODE [DXA8KB]1773
FAILURE CODE [DXA9KA]1775
FAILURE CODE [DXA9KB]1777
FAILURE CODE [DXE0KA]1779
FAILURE CODE [DXE0KB]1780
FAILURE CODE [DXE4KA]1782
FAILURE CODE [DXE4KB]1784
FAILURE CODE [DXE4KY]1786
FAILURE CODE [DXE5KA]1788
FAILURE CODE [DXE5KB]1790
FAILURE CODE [DXE6KA]1792
FAILURE CODE [DXE6KB]1794
FAILURE CODE [DXE7KA]1796
FAILURE CODE [DXE7KB]1798
FAILURE CODE [DXE7KY]1800
FAILURE CODE [DXE8KA]1802
FAILURE CODE [DXE8KB]1804
FAILURE CODE [DXE8KY]1806
FAILURE CODE [DXE9KA]1808
FAILURE CODE [DXE9KB]1810
FAILURE CODE [DXE9KY]1812
FAILURE CODE [DXEAKA]1814
FAILURE CODE [DXEAKB]1816
FAILURE CODE [DXEAKY]1818
FAILURE CODE [DY20KA]1820
FAILURE CODE [DY20MA]1822
FAILURE CODE [DY2CKB]1824
FAILURE CODE [DY2DKB]1827
FAILURE CODE [DY2EKB]1829
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1831
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)1831
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK1837
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK1840
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP1842
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING1844
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW1847
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW1848
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING1849
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING1850
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING1851
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1852
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1853
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1854
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1855
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1856
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1857
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1858
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL1860
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1861
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE1862
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1863
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE1865
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED1866
E-24 FUNCTION SWITCH DOES NOT OPERATE1867
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)1868
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF1869
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER1870
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED1871
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED1872
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE1873
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE1874
E-32 ALARM BUZZER CANNOT BE CANCELED1876
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION1877
E-34 SERVICE MODE CANNOT BE SELECTED1878
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE1879
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK1882
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING1884
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE1887
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR1889
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED1892
E-41 ALARM DOES NOT SOUND DURING TRAVEL1893
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED1895
E-43 HORN DOES NOT SOUND1896
E-44 HORN DOES NOT STOP SOUNDING1899
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF1901
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE1902
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE1904
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1905
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1906
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1907
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1908
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1909
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1910
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1911
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1912
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1913
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED1915
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY1916
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)1917
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)1917
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS1918
FAILURE MODE AND CAUSE TABLE1920
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK1929
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER1930
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR1933
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP1934
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS1935
H-6 SPEED OR POWER OF BOOM IS LOW1937
H-7 ARM SPEED OR POWER IS LOW1941
H-8 BUCKET SPEED OR POWER IS LOW1946
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION1949
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE1950
H-11 HYDRAULIC DRIFT OF ARM IS LARGE1952
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE1954
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES1955
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE1956
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE1957
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED1958
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED1959
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER1960
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY1961
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW1962
H-21 MACHINE DOES NOT TRAVEL STRAIGHT1963
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW1965
H-23 TRAVEL SPEED IS LOW1968
H-24 ONE OF TRACKS DOES NOT RUN1970
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST1971
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT1972
H-27 SWINGS ONLY IN ONE DIRECTION1973
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)1974
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION1975
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)1976
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)1977
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING1978
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING1979
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)1980
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)1981
H-36 Quick coupler cylinder will not extend1982
H-37 Quick coupler cylinder will not retract (but buzzer doesnot sound)1984
H-38 Buzzer does not sound (but quick coupler cylinder doesretract)1986
H-39 Quick coupler cylinder extends and retracts slowly1988
TROUBLESHOOTING OF ENGINE (S-MODE)1989
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)1989
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION1990
S-1 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT1991
S-2 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)1992
S-3 ENGINE STARTABILITY IS POOR1994
S-5 ENGINE DOES NOT PICK UP SMOOTHLY1996
S-6 ENGINE STOPS DURING OPERATION1998
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE2000
S-8 ENGINE LACKS POWER2001
S-9 KDPF GETS CLOGGED IN A SHORT TIME2003
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE2005
S-11 OIL BECOMES CONTAMINATED QUICKLY2006
S-4 FUEL CONSUMPTION IS EXCESSIVE2007
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)2008
S-14 OIL PRESSURE DROPS2009
S-15 FUEL MIXES INTO ENGINE OIL2011
S-16 WATER MIXES INTO ENGINE OIL (MILKY)2012
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)2013
S-18 UNUSUAL NOISE IS HEARD2014
S-19 VIBRATION IS EXCESSIVE2015
S-5 AIR CANNOT BE BLED FROM FUEL CIRCUIT2016
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY2017
S-22 ACTIVE REGENERATION TAKES TIME2019
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION2020
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE2021
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)2023
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)2024
50 DISASSEMBLY AND ASSEMBLY2025
CONTENTS2026
ABBREVIATION LIST2031
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY2037
HOW TO READ THIS MANUAL2037
COATING MATERIALS LIST2039
SPECIAL TOOLS LIST2043
SKETCHES OF SPECIAL TOOLS2055
ENGINE AND COOLING SYSTEM2061
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY2061
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY2061
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY2064
REMOVE AND INSTALL INJECTOR ASSEMBLY2068
METHOD FOR REMOVING INJECTOR ASSEMBLY2068
METHOD FOR INSTALLING INJECTOR ASSEMBLY2073
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY2081
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY2082
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY2091
REMOVE AND INSTALL EGR VALVE ASSEMBLY2107
METHOD FOR REMOVING EGR VALVE ASSEMBLY2107
METHOD FOR INSTALLING EGR VALVE ASSEMBLY2108
REMOVE AND INSTALL EGR COOLER ASSEMBLY2111
METHOD FOR REMOVING EGR COOLER ASSEMBLY2111
METHOD FOR INSTALLING EGR COOLER ASSEMBLY2114
REMOVE AND INSTALL STARTER ASSEMBLY2119
METHOD FOR REMOVING STARTER ASSEMBLY2119
METHOD FOR INSTALLING STARTER ASSEMBLY2121
REMOVE AND INSTALL ALTERNATOR BELT2123
METHOD FOR REMOVING ALTERNATOR BELT2123
METHOD FOR INSTALLING ALTERNATOR BELT2125
REMOVE AND INSTALL RADIATOR ASSEMBLY2127
METHOD FOR REMOVING RADIATOR ASSEMBLY2127
METHOD FOR INSTALLING RADIATOR ASSEMBLY2129
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY2131
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY2131
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY2134
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2137
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY2137
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY2138
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY2140
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY2141
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY2149
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2160
METHOD FOR REMOVING ENGINE FRONT OIL SEAL2160
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL2163
REMOVE AND INSTALL ENGINE REAR OIL SEAL2167
METHOD FOR REMOVING ENGINE REAR OIL SEAL2167
METHOD FOR INSTALLING ENGINE REAR OIL SEAL2168
REMOVE AND INSTALL FUEL COOLER ASSEMBLY2171
METHOD FOR REMOVING FUEL COOLER ASSEMBLY2171
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY2172
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY2173
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY2173
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY2175
REMOVE AND INSTALL FUEL TANK ASSEMBLY2181
METHOD FOR REMOVING FUEL TANK ASSEMBLY2181
METHOD FOR INSTALLING FUEL TANK ASSEMBLY2185
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2191
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY2191
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY2196
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2202
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2202
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2207
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR2213
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR2213
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR2213
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER2215
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER2215
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER2215
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER2217
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER2217
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER2219
REMOVE AND INSTALL KDPF ASSEMBLY2222
METHOD FOR REMOVING KDPF ASSEMBLY2222
METHOD FOR INSTALLING KDPF ASSEMBLY2224
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY2226
METHOD FOR DISASSEMBLING KDPF ASSEMBLY2227
METHOD FOR ASSEMBLING KDPF ASSEMBLY2230
REMOVE AND INSTALL SCR ASSEMBLY2235
METHOD FOR REMOVING SCR ASSEMBLY2235
METHOD FOR INSTALLING SCR ASSEMBLY2237
REMOVE AND INSTALL KDPF, SCR ASSEMBLY2239
METHOD FOR REMOVING KDPF, SCR ASSEMBLY2239
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY2245
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET2251
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET2251
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET2258
REMOVE AND INSTALL KCCV ASSEMBLY2266
METHOD FOR REMOVING KCCV ASSEMBLY2266
METHOD FOR INSTALLING KCCV ASSEMBLY2269
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2273
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE2273
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE2278
REMOVE AND INSTALL AdBlue/DEF INJECTOR2283
METHOD FOR REMOVING AdBlue/DEF INJECTOR2283
METHOD FOR INSTALLING AdBlue/DEF INJECTOR2285
REMOVE AND INSTALL AdBlue/DEF PUMP2287
METHOD FOR REMOVING AdBlue/DEF PUMP2287
METHOD FOR INSTALLING AdBlue/DEF PUMP2289
REMOVE AND INSTALL AdBlue/DEF HOSE2292
METHOD FOR REMOVING AdBlue/DEF HOSE2292
METHOD FOR INSTALLING AdBlue/DEF HOSE2300
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2306
METHOD FOR REMOVING AIR CLEANER ASSEMBLY2306
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY2307
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2309
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2309
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY2311
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY2314
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY2314
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY2315
POWER TRAIN2316
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2316
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2316
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2317
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY2319
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY2319
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY2323
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY2332
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY2332
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY2335
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY2338
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY2338
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY2342
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY2349
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY2349
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY2349
UNDERCARRIAGE AND FRAME2351
SEPARATION AND CONNECTION OF TRACK ASSEMBLY2351
METHOD FOR SEPARATING TRACK ASSEMBLY2351
METHOD FOR INSTALLING TRACK ASSEMBLY2353
REMOVE AND INSTALL SPROCKET2356
METHOD FOR REMOVING SPROCKET2356
METHOD FOR INSTALLING SPROCKET2356
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY2358
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY2358
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY2359
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY2360
METHOD FOR DISASSEMBLING IDLER ASSEMBLY2360
METHOD FOR ASSEMBLING IDLER ASSEMBLY2361
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY2365
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY2366
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY2367
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY2368
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY2369
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY2370
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY2372
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY2372
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY2374
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY2376
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY2376
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY2378
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY2381
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY2381
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY2384
HYDRAULIC SYSTEM2388
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY2388
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY2388
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY2390
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY2393
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2394
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2395
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2396
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY2396
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY2399
REMOVE AND INSTALL MAIN PUMP ASSEMBLY2402
METHOD FOR REMOVING MAIN PUMP ASSEMBLY2402
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY2405
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY2408
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY2408
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY2415
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY2423
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING2423
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY2425
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY2429
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2429
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2429
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY2431
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY2431
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY2432
REMOVE AND INSTALL QUICK COUPLER VALVE2434
WORK EQUIPMENT2436
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY2436
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY2436
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY2440
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY2446
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2446
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2449
CAB AND ITS ATTACHMENTS2455
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY2455
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY2455
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY2461
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)2468
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY2470
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY2470
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY2480
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY2480
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY2483
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY2489
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY2489
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY2496
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY2503
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY2503
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY2509
REMOVE AND INSTALL OPERATOR’S SEAT2516
METHOD FOR REMOVING OPERATOR’S SEAT2516
METHOD FOR INSTALLING OPERATOR’S SEAT2518
REMOVE AND INSTALL SEAT BELT2521
METHOD FOR REMOVING SEAT BELT2521
METHOD FOR INSTALLING SEAT BELT2522
REMOVE AND INSTALL FRONT WIPER ASSEMBLY2523
METHOD FOR REMOVING FRONT WIPER ASSEMBLY2523
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY2528
ELECTRICAL SYSTEM2537
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY2537
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY2537
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY2539
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY2540
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY2540
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY2544
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY2549
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY2549
METHOD FOR INSTALLING KomVision CONTROLLER2550
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY2552
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY2552
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY2555
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR2558
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR2558
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR2559
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR2560
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR2560
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR2561
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR2562
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR2562
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR2563
REMOVE AND INSTALL SCR TEMPERATURE SENSOR2565
METHOD FOR REMOVING SCR TEMPERATURE SENSOR2565
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR2567
REMOVE AND INSTALL KomVision CAMERA2570
METHOD FOR REMOVING KomVision CAMERA2570
METHOD FOR INSTALLING KomVision CAMERA2573
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY2576
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY2576
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY2579
60 MAINTENANCE STANDARD2583
CONTENTS2584
ABBREVIATION LIST2585
ENGINE AND COOLING SYSTEM2591
MAINTENANCE STANDARD OF ENGINE MOUNT2591
MAINTENANCE STANDARD OF COOLING SYSTEM2592
POWER TRAIN2593
MAINTENANCE STANDARD OF SWING CIRCLE2593
MAINTENANCE STANDARD OF SWING MACHINERY2594
MAINTENANCE STANDARD OF FINAL DRIVE2596
MAINTENANCE STANDARD OF SPROCKET2598
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING2599
UNDERCARRIAGE AND FRAME2601
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION2601
MAINTENANCE STANDARD OF IDLER2603
MAINTENANCE STANDARD OF TRACK ROLLER2605
MAINTENANCE STANDARD OF CARRIER ROLLER2606
MAINTENANCE STANDARD OF TRACK SHOE2607
MAINTENANCE STANDARD OF TRIPLE SHOE2610
MAINTENANCE STANDARD OF SWAMP SHOE2611
MAINTENANCE STANDARD OF ROAD LINER2612
HYDRAULIC SYSTEM2613
MAINTENANCE STANDARD OF HYDRAULIC TANK2613
MAINTENANCE STANDARD OF MAIN PUMP2614
MAINTENANCE STANDARD OF LS-EPC VALVE2615
MAINTENANCE STANDARD OF PC-EPC VALVE2616
MAINTENANCE STANDARD OF SWING MOTOR2617
MAINTENANCE STANDARD OF TRAVEL MOTOR2620
MAINTENANCE STANDARD OF CONTROL VALVE2623
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE2633
MAINTENANCE STANDARD OF TRAVEL PPC VALVE2636
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)2639
MAINTENANCE STANDARD OF EPC VALVE2640
MAINTENANCE STANDARD OF SOLENOID VALVE2642
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE2643
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)2645
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)2646
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT2647
WORK EQUIPMENT2648
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE2648
DIMENSION OF ARM2653
DIMENSIONS OF BUCKET2655
MAINTENANCE STANDARD OF BOOM CYLINDER2657
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON)2658
MAINTENANCE STANDARD OF ARM CYLINDER2659
MAINTENANCE STANDARD OF BUCKET CYLINDER2660
80 APPENDIX2661
CONTENTS2662
ABBREVIATION LIST2664
AIR CONDITIONER SYSTEM2670
PRECAUTIONS FOR REFRIGERANT2670
AIR CONDITIONER COMPONENT2671
SPECIFICATIONS OF AIR CONDITIONER2673
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE2674
OUTLINE OF REFRIGERATION CYCLE2675
COMPONENT PARTS OF AIR CONDITIONER SYSTEM2677
AIR CONDITIONER UNIT2677
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT2677
FUNCTION OF AIR CONDITIONER UNIT2679
COMPONENT PARTS OF AIR CONDITIONER UNIT2681
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT2682
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT2682
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT2682
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT2682
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2683
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2683
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2683
FUNCTION OF DUAL PRESSURE SWITCH2684
AIR CONDITIONER CONTROLLER2685
STRUCTURE OF AIR CONDITIONER CONTROLLER2685
COMPRESSOR2686
STRUCTURE OF COMPRESSOR2686
SPECIFICATIONS OF COMPRESSOR2686
FUNCTION OF COMPRESSOR2686
CONDENSER2687
STRUCTURE OF CONDENSER2687
SPECIFICATIONS OF CONDENSER2687
FUNCTION OF CONDENSER2687
SENSORS FOR AIR CONDITIONER SYSTEM2689
STRUCTURE OF SUNLIGHT SENSOR2689
FUNCTION OF SUNLIGHT SENSOR2689
STRUCTURE OF AMBIENT TEMPERATURE SENSOR2689
FUNCTION OF AMBIENT TEMPERATURE SENSOR2689
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER2691
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER2693
AIR CONDITIONER SYSTEM DIAGRAM2695
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER2696
FUNCTION OF AIR CONDITIONER CONTROLLER2697
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS2698
TESTING AIR LEAKAGE (DUCT)2702
METHOD FOR TESTING AIR LEAKAGE (DUCT)2702
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION2704
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR2705
TEST VENT (MODE) CHANGEOVER2706
METHOD FOR TESTING VENT (MODE) CHANGEOVER2706
TESTING FRESH/RECIRC AIR CHANGEOVER2708
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER2708
TEST SUNLIGHT SENSOR2709
METHOD FOR TESTING SUNLIGHT SENSOR2709
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT2710
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT2710
TEST RELAYS2711
METHOD FOR TESTING RELAYS2711
AIR CONDITIONER TROUBLESHOOTING CHART 12712
AIR CONDITIONER TROUBLESHOOTING CHART 22713
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE2716
FAILURE CODE [879AKA]2718
FAILURE CODE [879AKB]2719
FAILURE CODE [879BKA]2720
FAILURE CODE [879BKB]2722
FAILURE CODE [879CKA]2724
FAILURE CODE [879CKB]2725
FAILURE CODE [879DKZ]2726
FAILURE CODE [879EMC]2728
FAILURE CODE [879FMC]2729
FAILURE CODE [879GKX]2730
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)2732
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)2734
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)2737
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER2739
TROUBLESHOOTING USING GAUGE PRESSURE2741
CONNECTION OF SERVICE TOOL2744
METHOD FOR CONNECTING SERVICE TOOL2744
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS2746
HANDLE COMPRESSOR OIL2748
METHOD FOR REPLACING DESICCANT2750
90 CIRCUIT DIAGRAMS2753
CONTENTS2754
ABBREVIATION LIST2755
HYDRAULIC CIRCUIT DIAGRAM2761
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM2761
HYDRAULIC CIRCUIT DIAGRAM (1/2)2765
HYDRAULIC CIRCUIT DIAGRAM (2/2)2767
ELECTRICAL CIRCUIT DIAGRAM2769
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM2769
ELECTRICAL CIRCUIT DIAGRAM (1/8)2773
ELECTRICAL CIRCUIT DIAGRAM (2/8)2775
ELECTRICAL CIRCUIT DIAGRAM (3/8)2777
ELECTRICAL CIRCUIT DIAGRAM (4/8)2779
ELECTRICAL CIRCUIT DIAGRAM (5/8)2781
ELECTRICAL CIRCUIT DIAGRAM (6/8)2783
ELECTRICAL CIRCUIT DIAGRAM (7/8)2785
ELECTRICAL CIRCUIT DIAGRAM (8/8)2787
INDEX2789

S.M 31/12/24