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KOMATSU PC240LC-11E0 PC240NLC-11E0 SHOP MANUAL UENBM00473 – PDF DOWNLOAD
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KOMATSU PC240LC-11E0 PC240NLC-11E0 SHOP MANUAL UENBM00473 – PDF DOWNLOAD
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KOMATSU PC240LC-11E0 PC240NLC-11E0 SHOP MANUAL UENBM00473 – PDF DOWNLOAD
Language : English
Pages : 2932
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC240LC-11E0 PC240NLC-11E0 SHOP MANUAL UENBM00473 – PDF DOWNLOAD
00 INDEX AND FOREWORD................................................................................................................... 3 INDEX............................................................................................................................... 4 ABBREVIATION LIST................................................................................................................... 22 FOREWORD, SAFETY, BASIC INFORMATION................................................................................................. 28 HOW TO READ THE SHOP MANUAL..................................................................................................... 28 SAFETY NOTICE FOR OPERATION..................................................................................................... 30 PRECAUTIONS TO PREVENT FIRE..................................................................................................... 38 ACTIONS IF FIRE OCCURS.......................................................................................................... 40 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS.................................................................................... 41 ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS................................................................................... 42 PRECAUTIONS FOR DEF............................................................................................................. 43 GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING.............................................................................. 43 PRECAUTIONS FOR ADDING...................................................................................................... 43 PRECAUTIONS FOR STORING..................................................................................................... 43 PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE..................................................................................... 43 THE OTHER PRECAUTIONS....................................................................................................... 43 STORE AdBlue/DEF................................................................................................................ 44 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT.................................................................................... 45 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS......................................................................... 48 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT................................................................................... 55 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT.................................................................................. 57 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT................................................................................ 58 PRACTICAL USE OF KOMTRAX........................................................................................................ 59 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER................................................................................... 60 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER....................................................... 60 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER....................................................... 61 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER....................................................... 62 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS...................................................................... 64 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR....................................................................... 68 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR............................................................... 69 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL............................................................. 71 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH............................................................. 72 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE........................................................ 74 HOW TO READ ELECTRICAL WIRE CODE................................................................................................ 75 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD................................................................................... 79 STANDARD TIGHTENING TORQUE TABLE................................................................................................ 82 CONVERSION TABLE................................................................................................................ 89 01 SPECIFICATIONS....................................................................................................................... 95 CONTENTS............................................................................................................................ 96 ABBREVIATION LIST................................................................................................................... 97 SPECIFICATIONS...................................................................................................................... 103 SPECIFICATION DRAWING........................................................................................................... 103 SPECIFICATION DRAWING: PC240LC-11E0, PC240NLC-11E0.......................................................................... 103 WORKING RANGE DRAWINGS.......................................................................................................... 104 WORKING RANGE: PC240LC-11E0, PC240NLC-11E0.................................................................................. 104 SPECIFICATIONS.................................................................................................................. 105 SPECIFICATIONS: PC240LC-11E0, PC240NLC-11E0................................................................................. 105 WEIGHT TABLE.................................................................................................................... 108 WEIGHT TABLE: PC240LC-11E0, PC240NLC-11E0................................................................................... 108 TABLE OF FUEL, COOLANT, AND LUBRICANTS.......................................................................................... 110 10 STRUCTURE AND FUNCTION............................................................................................................... 111 CONTENTS............................................................................................................................ 112 ABBREVIATION LIST................................................................................................................... 116 UREA SCR SYSTEM..................................................................................................................... 122 LAYOUT DRAWING OF UREA SCR SYSTEM............................................................................................... 123 UREA SCR SYSTEM DIAGRAM......................................................................................................... 128 FUNCTION OF UREA SCR SYSTEM..................................................................................................... 129 FUNCTION OF AdBlue/DEF SYSTEM............................................................................................... 129 INDUCEMENT STRATEGY......................................................................................................... 131 COMPONENT PARTS OF UREA SCR SYSTEM.............................................................................................. 139 AdBlue/DEF MIXING TUBE...................................................................................................... 139 SCR ASSEMBLY................................................................................................................ 139 AdBlue/DEF TANK............................................................................................................. 142 AdBlue/DEF PUMP............................................................................................................. 144 AdBlue/DEF INJECTOR......................................................................................................... 145 AdBlue/DEF HOSE............................................................................................................. 146 AdBlue/DEF TANK HEATING VALVE............................................................................................... 147 BOOT-UP SYSTEM...................................................................................................................... 148 LAYOUT DRAWING OF BOOT-UP SYSTEM................................................................................................ 148 SYSTEM OPERATING LAMP SYSTEM.................................................................................................... 150 SYSTEM OPERATING LAMP SYSTEM DIAGRAM........................................................................................ 150 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM.................................................................................... 150 BATTERY DISCONNECT SWITCH....................................................................................................... 151 FUNCTION OF BATTERY DISCONNECT SWITCH....................................................................................... 151 ENGINE SYSTEM....................................................................................................................... 152 LAYOUT DRAWING OF ENGINE SYSTEM................................................................................................. 152 SPECIFICATIONS OF ENGINE SYSTEM............................................................................................. 153 FUNCTION OF ENGINE SYSTEM................................................................................................... 153 ENGINE CONTROL SYSTEM........................................................................................................... 154 ENGINE CONTROL SYSTEM DIAGRAM............................................................................................... 154 OPERATION OF ENGINE CONTROL SYSTEM.......................................................................................... 155 AUTO-DECELERATION SYSTEM........................................................................................................ 157 AUTO-DECELERATION SYSTEM DIAGRAM............................................................................................ 157 FUNCTION OF AUTO-DECELERATION SYSTEM........................................................................................ 157 OPERATION OF AUTO-DECELERATION SYSTEM....................................................................................... 158 ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................................. 159 ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM..................................................................................... 159 FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................. 160 OVERHEAT PREVENTION SYSTEM...................................................................................................... 161 OVERHEAT PREVENTION SYSTEM DIAGRAM.......................................................................................... 161 FUNCTION OF OVERHEAT PREVENTION SYSTEM...................................................................................... 162 TURBOCHARGER PROTECTION SYSTEM.................................................................................................. 164 TURBOCHARGER PROTECTION SYSTEM DIAGRAM...................................................................................... 164 FUNCTION OF TURBOCHARGER PROTECTION SYSTEM.................................................................................. 165 AUTOMATIC IDLE STOP SYSTEM...................................................................................................... 166 AUTOMATIC IDLE STOP SYSTEM DIAGRAM.......................................................................................... 166 FUNCTION OF AUTOMATIC IDLE STOP SYSTEM...................................................................................... 166 COMPONENT PARTS OF ENGINE SYSTEM................................................................................................ 169 VGT......................................................................................................................... 169 EGR SYSTEM.................................................................................................................. 173 EGR VALVE................................................................................................................... 175 EGR COOLER.................................................................................................................. 177 KCCV SYSTEM................................................................................................................. 178 KCCV VENTILATOR............................................................................................................. 180 KDPF........................................................................................................................ 182 COOLING SYSTEM...................................................................................................................... 187 LAYOUT DRAWING OF COOLING SYSTEM................................................................................................ 187 SPECIFICATIONS OF COOLING SYSTEM............................................................................................ 188 CONTROL SYSTEM...................................................................................................................... 189 LAYOUT DRAWING OF CONTROL SYSTEM................................................................................................ 189 MACHINE MONITOR SYSTEM.......................................................................................................... 192 MACHINE MONITOR SYSTEM DIAGRAM.............................................................................................. 192 KomVision SYSTEM................................................................................................................ 193 LAYOUT DRAWING OF KOMVISION SYSTEM.......................................................................................... 193 KomVision SYSTEM DIAGRAM.................................................................................................... 195 FUNCTION OF KomVision SYSTEM................................................................................................ 195 KOMTRAX SYSTEM.................................................................................................................. 197 KOMTRAX SYSTEM DIAGRAM...................................................................................................... 197 FUNCTION OF KOMTRAX SYSTEM.................................................................................................. 197 PPC LEVERS...................................................................................................................... 198 LH PPC LEVER................................................................................................................ 198 RH PPC LEVER................................................................................................................ 199 AUTOMATIC GREASE SYSTEM......................................................................................................... 200 OUTLINE OF AUTO GREASE SYSTEM............................................................................................... 200 OUTLINE OF AUTO GREASE SYSTEM................................................................................................... 214 COMPONENT PARTS OF CONTROL SYSTEM............................................................................................... 228 MACHINE MONITOR............................................................................................................. 228 KomVision CONTROLLER........................................................................................................ 241 KomVision CAMERA............................................................................................................ 245 GATEWAY FUNCTION CONTROLLER................................................................................................. 246 COMMUNICATION TERMINAL...................................................................................................... 249 PUMP CONTROLLER............................................................................................................. 251 RESISTOR FOR PC-EPC VALVE................................................................................................... 255 CAN TERMINATING RESISTOR.................................................................................................... 255 PPC OIL PRESSURE SWITCH..................................................................................................... 256 ENGINE CONTROLLER........................................................................................................... 257 FUEL CONTROL DIAL........................................................................................................... 263 SENSOR.......................................................................................................................... 265 STRUCTURE OF AMBIENT PRESSURE SENSOR........................................................................................ 265 FUNCTION OF AMBIENT PRESSURE SENSOR......................................................................................... 265 STRUCTURE OF ENGINE OIL PRESSURE SWITCH..................................................................................... 265 FUNCTION OF ENGINE OIL PRESSURE SWITCH...................................................................................... 266 STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR................................................................. 266 FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR.................................................................. 266 STRUCTURE OF COOLANT TEMPERATURE SENSOR..................................................................................... 267 FUNCTION OF COOLANT TEMPERATURE SENSOR...................................................................................... 267 STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR................................................................................... 267 FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR.................................................................................... 268 STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR................................................................................... 268 FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR.................................................................................... 268 STRUCTURE OF COMMON RAIL PRESSURE SENSOR.................................................................................... 269 FUNCTION OF COMMON RAIL PRESSURE SENSOR..................................................................................... 269 STRUCTURE OF EGR VALVE LIFT SENSOR.......................................................................................... 269 FUNCTION OF EGR VALVE LIFT SENSOR........................................................................................... 269 STRUCTURE OF VGT SPEED SENSOR............................................................................................... 270 FUNCTION OF KVGT SPEED SENSOR............................................................................................... 270 STRUCTURE OF KVGT POSITION SENSOR........................................................................................... 270 FUNCTION OF KVGT POSITION SENSOR............................................................................................ 271 STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR........................................................................... 271 STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR.......................................................... 272 FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR........................................................... 272 STRUCTURE OF CRANKCASE PRESSURE SENSOR...................................................................................... 272 FUNCTION OF CRANKCASE PRESSURE SENSOR....................................................................................... 273 STRUCTURE OF ENGINE OIL LEVEL SENSOR........................................................................................ 273 STRUCTURE OF AIR CLEANER CLOGGING SENSOR.................................................................................... 273 FUNCTION OF AIR CLEANER CLOGGING SENSOR..................................................................................... 274 STRUCTURE OF WATER-IN-FUEL SENSOR........................................................................................... 274 FUNCTION OF WATER-IN-FUEL SENSOR............................................................................................ 274 STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH...................................................................... 274 SPECIFICATIONS - QUICK COUPLER LOW PRESSURE WARNING SWITCH.................................................................. 275 FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH....................................................................... 275 STRUCTURE OF AUTO GREASE PRESSURE SWITCH.................................................................................... 275 SPECIFICATIONS - AUTO GREASE PRESSURE SWITCH................................................................................ 276 FUNCTION OF AUTO GREASE PRESSURE SWITCH..................................................................................... 276 STRUCTURE OF OVERLOAD CAUTION SENSOR........................................................................................ 276 SPECIFICATIONS - OVERLOAD CAUTION SENSOR.................................................................................... 276 FUNCTION OF OVERLOAD CAUTION SENSOR......................................................................................... 276 HYDRAULIC SYSTEM.................................................................................................................... 277 LAYOUT DRAWING OF HYDRAULIC SYSTEM.............................................................................................. 277 CLSS............................................................................................................................ 283 STRUCTURE OF CLSS........................................................................................................... 283 OPERATION OF UNLOAD VALVE AND LS PRESSURE................................................................................... 285 PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL................................................................................... 286 PRESSURE COMPENSATION CONTROL............................................................................................... 299 ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................................... 302 ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM............................................................................. 302 FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................... 303 PUMP AND VALVE CONTROL SYSTEM................................................................................................... 308 PUMP AND VALVE CONTROL SYSTEM DIAGRAM....................................................................................... 308 FUNCTION OF PUMP AND VALVE CONTROL SYSTEM................................................................................... 309 COMPONENT PARTS OF HYDRAULIC SYSTEM............................................................................................. 311 HYDRAULIC TANK.............................................................................................................. 311 MAIN PUMP................................................................................................................... 313 PC-EPC VALVE................................................................................................................ 337 PILOT OIL FILTER............................................................................................................ 339 CONTROL VALVE............................................................................................................... 339 WORK EQUIPMENT SYSTEM............................................................................................................... 396 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM......................................................................................... 396 STRUCTURE OF VALVE CONTROL...................................................................................................... 401 ONE-TOUCH POWER MAXIMIZING SYSTEM............................................................................................... 403 ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM................................................................................... 403 FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM............................................................................... 404 PPC LOCK SYSTEM................................................................................................................. 405 PPC LOCK SYSTEM DIAGRAM..................................................................................................... 405 FUNCTION OF PPC LOCK SYSTEM................................................................................................. 405 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................................. 406 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM..................................................................... 406 FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................. 406 OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................ 407 OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT......................................................................................... 408 ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM................................................................................. 408 FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT......................................................................... 410 TOOL CONTROL SYSTEM............................................................................................................. 411 TOOL CONTROL SYSTEM DIAGRAM................................................................................................. 411 FUNCTION OF TOOL CONTROL SYSTEM............................................................................................. 412 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM........................................................................................ 413 WORK EQUIPMENT AND SWING PPC VALVE.......................................................................................... 413 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE).............................................................................. 418 SOLENOID VALVE.............................................................................................................. 424 ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)....................................................................... 427 ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)........................................................................ 429 1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE................................................................................... 432 2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE................................................................................... 434 ATTACHMENT BYPASS SOLENOID VALVE............................................................................................ 437 ATT EPC VALVE ASSEMBLY...................................................................................................... 439 PILOT CIRCUIT ACCUMULATOR................................................................................................... 440 ATTACHMENT CIRCUIT ACCUMULATOR.............................................................................................. 441 SWING SYSTEM........................................................................................................................ 442 LAYOUT DRAWING OF SWING SYSTEM.................................................................................................. 442 SWING CONTROL SYSTEM DIAGRAM.................................................................................................... 446 FUNCTION OF SWING CONTROL SYSTEM............................................................................................ 446 COMPONENT PARTS OF SWING SYSTEM................................................................................................. 450 SWING MOTOR................................................................................................................. 450 SWING MACHINERY............................................................................................................. 462 SWING CIRCLE................................................................................................................ 463 TRAVEL SYSTEM....................................................................................................................... 465 LAYOUT DRAWING OF TRAVEL SYSTEM................................................................................................. 465 TRAVEL CONTROL SYSTEM DIAGRAM................................................................................................... 469 FUNCTION OF TRAVEL CONTROL SYSTEM........................................................................................... 469 COMPONENT PARTS OF TRAVEL SYSTEM................................................................................................ 471 TRAVEL MOTOR................................................................................................................ 471 FINAL DRIVE................................................................................................................. 483 TRAVEL PPC VALVE............................................................................................................ 485 CENTER SWIVEL JOINT......................................................................................................... 490 UNDERCARRIAGE AND FRAME............................................................................................................. 492 LAYOUT DRAWING OF UNDERCARRIAGE................................................................................................. 492 SPECIFICATIONS OF UNDERCARRIAGE............................................................................................. 493 WORK EQUIPMENT...................................................................................................................... 494 STRUCTURE OF WORK EQUIPMENT..................................................................................................... 494 FUNCTION OF WORK EQUIPMENT...................................................................................................... 495 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM........................................................................................ 496 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM........................................................................ 496 BUCKET CLEARANCE ADJUSTMENT SHIM................................................................................................ 497 FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM................................................................................ 497 CAB AND ITS ATTACHMENTS............................................................................................................. 498 ROPS CAB........................................................................................................................ 498 STRUCTURE OF ROPS CAB....................................................................................................... 498 FUNCTION OF ROPS CAB........................................................................................................ 498 CAB MOUNT....................................................................................................................... 499 STRUCTURE OF CAB MOUNT...................................................................................................... 499 FUNCTION OF CAB MOUNT....................................................................................................... 499 CAB TIPPING STOPPER............................................................................................................. 500 STRUCTURE OF CAB TIPPING STOPPER............................................................................................ 500 FUNCTION OF CAB TIPPING STOPPER............................................................................................. 500 20 STANDARD VALUE TABLE................................................................................................................. 501 CONTENTS............................................................................................................................ 502 ABBREVIATION LIST................................................................................................................... 503 STANDARD VALUE TABLE FOR ENGINE..................................................................................................... 509 STANDARD VALUE TABLE FOR ENGINE: PC240LC-11E0, PC240NLC-11E0.................................................................... 509 STANDARD VALUE TABLE FOR MACHINE.................................................................................................... 513 STANDARD VALUE TABLE FOR MACHINE: PC240LC-11E0, PC240NLC-11E0................................................................... 513 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE......................................................................... 527 STANDARD VALUE TABLE FOR ELECTRICAL................................................................................................. 531 STANDARD VALUE TABLE FOR ELECTRICAL............................................................................................. 531 30 TESTING AND ADJUSTING................................................................................................................ 541 CONTENTS............................................................................................................................ 542 ABBREVIATION LIST................................................................................................................... 545 RELATED INFORMATION ON TESTING AND ADJUSTING........................................................................................ 551 TOOLS FOR TESTING AND ADJUSTING................................................................................................. 551 SKETCH OF TOOLS FOR TESTING AND ADJUSTING....................................................................................... 558 ENGINE AND COOLING SYSTEM........................................................................................................... 560 TEST ENGINE SPEED............................................................................................................... 560 METHOD FOR TESTING ENGINE SPEED............................................................................................. 560 TEST BOOST PRESSURE............................................................................................................. 563 METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR........................................................................ 563 METHOD FOR TESTING BOOST PRESSURE........................................................................................... 564 TEST EXHAUST GAS COLOR.......................................................................................................... 565 METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER................................................................. 565 METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER......................................................................... 566 TEST AND ADJUST VALVE CLEARANCE................................................................................................. 568 METHOD FOR TESTING VALVE CLEARANCE.......................................................................................... 568 METHOD FOR ADJUSTING VALVE CLEARANCE........................................................................................ 569 TEST COMPRESSION PRESSURE....................................................................................................... 571 METHOD FOR TESTING COMPRESSION PRESSURE..................................................................................... 571 TEST BLOWBY PRESSURE............................................................................................................ 576 METHOD FOR TESTING BLOWBY PRESSURE.......................................................................................... 576 TEST ENGINE OIL PRESSURE........................................................................................................ 578 METHOD FOR TESTING ENGINE OIL PRESSURE...................................................................................... 578 TEST EGR VALVE AND VGT OIL PRESSURE............................................................................................. 579 METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE........................................................................... 579 TEST FUEL PRESSURE.............................................................................................................. 581 METHOD FOR TESTING FUEL PRESSURE............................................................................................ 582 TEST FUEL DISCHARGE, RETURN AND LEAKAGE......................................................................................... 587 METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE....................................................................... 588 BLEEDING AIR FROM FUEL SYSTEM................................................................................................... 594 METHOD FOR BLEEDING AIR FROM FUEL SYSTEM.................................................................................... 594 TEST FUEL CIRCUIT FOR LEAKAGE................................................................................................... 595 METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE................................................................................. 595 HANDLE CYLINDER CUT-OUT MODE OPERATION.......................................................................................... 597 HANDLE NO-INJECTION CRANKING OPERATION.......................................................................................... 598 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION......................................................................... 599 METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT......................................................................... 599 METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT........................................................................ 599 TEST FAN BELT AND ALTERNATOR BELT............................................................................................... 601 METHOD FOR TESTING FAN BELT AND ALTERNATOR BELT............................................................................. 601 TEST AUTO-TENSIONER............................................................................................................. 602 METHOD FOR TESTING AUTO-TENSIONER........................................................................................... 602 REPLACING FAN BELT.............................................................................................................. 603 METHOD FOR REPLACING FAN BELT............................................................................................... 603 WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER.................................................................. 604 METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER................................................. 604 TEST SCR RELATED FUNCTIONS...................................................................................................... 605 TEST AdBlue/DEF PUMP RAISED PRESSURE........................................................................................ 608 TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR.............................................................................. 611 TEST AdBlue/DEF LINE HEATER RELAY 1......................................................................................... 615 TEST AdBlue/DEF LINE HEATER RELAY 2......................................................................................... 618 TEST AdBlue/DEF PUMP HEATER RELAY........................................................................................... 620 TEST AdBlue/DEF TANK HEATER VALVE........................................................................................... 623 TEST DENITRATION EFFICIENCY OF SCR.......................................................................................... 626 CLEAN AdBlue/DEF TANK........................................................................................................... 630 METHOD FOR CLEANING AdBlue/DEF TANK......................................................................................... 630 BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK............................................................................... 634 METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK............................................................. 634 POWER TRAIN......................................................................................................................... 636 TEST SWING CIRCLE BEARING CLEARANCE............................................................................................. 636 METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE........................................................................... 636 UNDERCARRIAGE AND FRAME............................................................................................................. 637 TEST AND ADJUST TRACK TENSION................................................................................................... 637 METHOD FOR TESTING TRACK TENSION............................................................................................ 637 METHOD FOR ADJUSTING TRACK TENSION.......................................................................................... 637 HYDRAULIC SYSTEM.................................................................................................................... 639 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM................................................................................ 639 METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK................................................................. 639 METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT....................................................... 639 TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS...................................................... 645 METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS............................................... 646 METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS............................................. 652 TEST OIL PRESSURE OF CONTROL CIRCUIT............................................................................................ 655 METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT.......................................................................... 655 TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT......................................................................... 657 TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)................................................................. 657 TEST PC-EPC VALVE OUTLET PRESSURE........................................................................................... 658 METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT................................................................ 659 TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT......................................................................... 661 METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR.............................................................. 661 METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL................................................................. 662 METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)................................................... 665 METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE............................................................................. 666 METHOD FOR ADJUSTING LS VALVE............................................................................................... 667 TEST OUTLET PRESSURE OF SOLENOID VALVE.......................................................................................... 668 METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE........................................................................ 668 OPERATING CONDITION OF SOLENOID VALVE....................................................................................... 669 TEST PPC VALVE OUTLET PRESSURE.................................................................................................. 672 METHOD FOR TESTING PPC VALVE OUTLET PRESSURE................................................................................ 672 TEST ATTACHMENT CIRCUIT OIL PRESSURE............................................................................................ 674 METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE.......................................................................... 674 ADJUST WORK EQUIPMENT AND SWING PPC VALVES...................................................................................... 676 METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES............................................................ 676 MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE............................................................. 677 TEST PUMP SWASH PLATE SENSOR.................................................................................................... 679 METHOD FOR TESTING PUMP SWASH PLATE SENSOR.................................................................................. 679 TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT........................................................................ 680 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER................................... 680 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER........................................................ 680 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE........................................................... 681 TEST OIL LEAKAGE................................................................................................................ 682 METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER........................................................................... 682 METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER............................................................................ 682 METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER......................................................................... 683 METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR............................................................................. 684 METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR............................................................................ 684 BLEED AIR FROM HYDRAULIC CIRCUIT................................................................................................ 685 METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT.............................................................................. 687 CAB AND ITS ATTACHMENTS............................................................................................................. 689 TEST CAB TIPPING STOPPER........................................................................................................ 689 METHOD FOR TESTING CAB TIPPING STOPPER...................................................................................... 689 METHOD FOR ADJUSTING MIRRORS.................................................................................................... 690 PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A)....................................................................... 690 PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A)................................................... 691 PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B)...................................................................... 692 PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B).................................................. 693 PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C)....................................................................... 694 ELECTRICAL SYSTEM................................................................................................................... 696 ELECTRICAL SYSTEM................................................................................................................... 697 SET AND OPERATE MACHINE MONITOR................................................................................................. 697 OPERATOR MODE............................................................................................................... 700 DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN................................................................. 701 DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN.................................................................... 701 CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)........................................................................... 702 CHECKING FUNCTION OF SERVICE METER.......................................................................................... 702 METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD................................................................... 702 SERVICE MODE................................................................................................................ 705 SERVICE MODE................................................................................................................ 705 METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION...................................................................... 707 METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION...................................................................... 713 ABNORMALITY RECORD MENU..................................................................................................... 724 METHOD FOR CONFIRMING MAINTENANCE RECORD.................................................................................... 729 METHOD FOR OPERATING MAINTENANCE MODE SETTING............................................................................... 730 METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING............................................................................. 734 DEFAULT MENU................................................................................................................ 735 DIAGNOSTIC TESTS MENU....................................................................................................... 746 ADJUSTMENT MENU............................................................................................................. 756 METHOD FOR PERFORMING NO-INJECTION CRANKING................................................................................. 790 KOMTRAX SETTINGS MENU....................................................................................................... 791 METHOD FOR DISPLAYING SERVICE MESSAGE....................................................................................... 793 METHOD FOR STARTING UP KOMTRAX SYSTEM........................................................................................... 795 ADJUST REARVIEW CAMERA ANGLE.................................................................................................... 800 METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE.................................................................................. 800 ADJUST KomVision CAMERA ANGLE................................................................................................... 803 METHOD FOR ADJUSTING KomVision CAMERA ANGLE................................................................................. 804 ADJUST KomVision RELATED ITEMS.................................................................................................. 808 SETTING OF KomVision (MAIN SETTING)......................................................................................... 808 SETTING OF KomVision (CAMERA SETTING)....................................................................................... 810 SETTING OF KomVision (CAMERA CALIBRATION)................................................................................... 812 KomVision screen - Check 12 m visibility.................................................................................... 825 HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER..................................................................................... 828 HANDLE BATTERY DISCONNECT SWITCH................................................................................................ 829 TEST DIODES..................................................................................................................... 830 METHOD FOR TESTING DIODE USING DIGITAL TESTER............................................................................... 830 METHOD FOR TESTING DIODE USING ANALOG TESTER................................................................................ 830 Pm CLINIC........................................................................................................................... 831 Pm CLINIC SERVICE............................................................................................................... 831 Pm CLINIC CHECK SHEET....................................................................................................... 835 40 TROUBLESHOOTING...................................................................................................................... 845 CONTENTS............................................................................................................................ 846 ABBREVIATION LIST................................................................................................................... 857 RELATED INFORMATION ON TROUBLESHOOTING.............................................................................................. 863 GENERAL TROUBLESHOOTING POINTS.................................................................................................. 863 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM...................................................................................... 864 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................... 876 CHECKS BEFORE TROUBLESHOOTING................................................................................................... 878 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING..................................................................................... 880 WALK-AROUND CHECK........................................................................................................... 880 TESTING IN ACCORDANCE WITH TESTING PROCEDURE.................................................................................... 882 CHECK FUEL LEVEL AND TYPE................................................................................................... 882 CHECK IMPURE INGREDIENT IN FUEL............................................................................................. 882 CHECK FUEL PREFILTER........................................................................................................ 883 WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT.......................................................................... 883 METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE............................................................................... 884 CHECK MAIN FILTER........................................................................................................... 885 CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN).............................................................................. 887 CHECK COOLANT LEVEL (RESERVOIR TANK)........................................................................................ 888 CHECK CLOGGING OF AIR CLEANER............................................................................................... 888 OUTER ELEMENT - CLEAN....................................................................................................... 889 ELEMENTS - REPLACE.......................................................................................................... 891 CHECK HYDRAULIC OIL LEVEL................................................................................................... 892 CHECK HYDRAULIC OIL STRAINER................................................................................................ 893 CHECK HYDRAULIC FILTER...................................................................................................... 894 CHECK OIL LEVEL IN SWING MACHINERY CASE..................................................................................... 895 CHECK OIL LEVEL IN DAMPER CASE.............................................................................................. 896 CHECK OIL LEVEL IN FINAL DRIVE CASE......................................................................................... 896 BLEED AIR FROM FUEL SYSTEM.................................................................................................. 897 BLEED AIR FROM HYDRAULIC SYSTEM............................................................................................. 897 ELECTRICAL EQUIPMENT - CHECK METHOD......................................................................................... 897 AUTOMATIC GREASE SYSTEM......................................................................................................... 905 FINDING MALFUNCTIONS........................................................................................................ 905 MALFUNCTION FINDING PROCEDURES.............................................................................................. 909 PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM................................................................................... 911 PROCEDURE FOR TESTING AND TROUBLESHOOTING....................................................................................... 924 SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS................................................................................. 927 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.................................................................................. 931 TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM............................................. 933 CONNECTOR LIST AND LAYOUT....................................................................................................... 936 CONNECTOR CONTACT IDENTIFICATION................................................................................................ 949 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE......................................................................................... 989 FUSE LOCATION TABLE............................................................................................................. 995 PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)..................................................................... 997 PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]).....................................1001 FAILURE CODES TABLE.............................................................................................................1003 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)...................................................................................1021 FAILURE CODE [879AKA]...........................................................................................................1021 FAILURE CODE [879AKB]...........................................................................................................1022 FAILURE CODE [879BKA]...........................................................................................................1023 FAILURE CODE [879BKB]...........................................................................................................1025 FAILURE CODE [879CKA]...........................................................................................................1027 FAILURE CODE [879CKB]...........................................................................................................1028 FAILURE CODE [879DKZ]...........................................................................................................1029 FAILURE CODE [879EMC]...........................................................................................................1031 FAILURE CODE [879FMC]...........................................................................................................1032 FAILURE CODE [879GKX]...........................................................................................................1033 FAILURE CODE [989L00]...........................................................................................................1035 FAILURE CODE [989M00]...........................................................................................................1036 FAILURE CODE [989N00]...........................................................................................................1037 FAILURE CODE [A1U0N3]...........................................................................................................1038 FAILURE CODE [A1U0N4]...........................................................................................................1040 FAILURE CODE [A900FR]...........................................................................................................1042 FAILURE CODE [A900N6]...........................................................................................................1043 FAILURE CODE [A900NY]...........................................................................................................1044 FAILURE CODE [AA10NX]...........................................................................................................1045 FAILURE CODE [AB00KE]...........................................................................................................1047 FAILURE CODE [AQ10N3]...........................................................................................................1050 FAILURE CODE [AS00N3]...........................................................................................................1052 FAILURE CODE [AS00R2]...........................................................................................................1054 FAILURE CODE [AS00R3]...........................................................................................................1055 FAILURE CODE [AS00R4]...........................................................................................................1056 FAILURE CODE [AS00R5]...........................................................................................................1057 FAILURE CODE [AS00R6]...........................................................................................................1058 FAILURE CODE [AS00ZK]...........................................................................................................1059 FAILURE CODE [AS10KM]...........................................................................................................1060 FAILURE CODE [AS10NR]...........................................................................................................1061 FAILURE CODE [AS10NT]...........................................................................................................1062 FAILURE CODE [B@BAZG]...........................................................................................................1063 FAILURE CODE [B@BAZK]...........................................................................................................1064 FAILURE CODE [B@BCNS]...........................................................................................................1066 FAILURE CODE [B@BCQA]...........................................................................................................1067 FAILURE CODE [B@BCZK]...........................................................................................................1069 FAILURE CODE [B@HANS]...........................................................................................................1071 FAILURE CODE [CA115]............................................................................................................1072 FAILURE CODE [CA122]............................................................................................................1073 FAILURE CODE [CA123]............................................................................................................1075 FAILURE CODE [CA131]............................................................................................................1077 FAILURE CODE [CA132]............................................................................................................1079 FAILURE CODE [CA144]............................................................................................................1081 FAILURE CODE [CA145]............................................................................................................1083 FAILURE CODE [CA153]............................................................................................................1085 FAILURE CODE [CA154]............................................................................................................1088 FAILURE CODE [CA187]............................................................................................................1090 FAILURE CODE [CA221]............................................................................................................1092 FAILURE CODE [CA222]............................................................................................................1094 FAILURE CODE [CA227]............................................................................................................1096 FAILURE CODE [CA234]............................................................................................................1097 FAILURE CODE [CA238]............................................................................................................1098 FAILURE CODE [CA239]............................................................................................................1100 FAILURE CODE [CA249]............................................................................................................1102 FAILURE CODE [CA256]............................................................................................................1104 FAILURE CODE [CA271]............................................................................................................1106 FAILURE CODE [CA272]............................................................................................................1108 FAILURE CODE [CA322]............................................................................................................1110 FAILURE CODE [CA323]............................................................................................................1112 FAILURE CODE [CA324]............................................................................................................1114 FAILURE CODE [CA325]............................................................................................................1116 FAILURE CODE [CA331]............................................................................................................1118 FAILURE CODE [CA332]............................................................................................................1120 FAILURE CODE [CA343]............................................................................................................1122 FAILURE CODE [CA351]............................................................................................................1123 FAILURE CODE [CA352]............................................................................................................1124 FAILURE CODE [CA356]............................................................................................................1127 FAILURE CODE [CA357]............................................................................................................1129 FAILURE CODE [CA386]............................................................................................................1131 FAILURE CODE [CA428]............................................................................................................1132 FAILURE CODE [CA429]............................................................................................................1134 FAILURE CODE [CA435]............................................................................................................1136 FAILURE CODE [CA441]............................................................................................................1138 FAILURE CODE [CA442]............................................................................................................1140 FAILURE CODE [CA449]............................................................................................................1141 FAILURE CODE [CA451]............................................................................................................1142 FAILURE CODE [CA452]............................................................................................................1144 FAILURE CODE [CA488]............................................................................................................1146 FAILURE CODE [CA515]............................................................................................................1147 FAILURE CODE [CA516]............................................................................................................1149 FAILURE CODE [CA553]............................................................................................................1151 FAILURE CODE [CA555]............................................................................................................1152 FAILURE CODE [CA556]............................................................................................................1153 FAILURE CODE [CA559]............................................................................................................1154 FAILURE CODE [CA595]............................................................................................................1157 FAILURE CODE [CA687]............................................................................................................1158 FAILURE CODE [CA689]............................................................................................................1160 FAILURE CODE [CA691]............................................................................................................1163 FAILURE CODE [CA692]............................................................................................................1165 FAILURE CODE [CA697]............................................................................................................1167 FAILURE CODE [CA698]............................................................................................................1168 FAILURE CODE [CA731]............................................................................................................1169 FAILURE CODE [CA778]............................................................................................................1171 FAILURE CODE [CA1117]...........................................................................................................1176 FAILURE CODE [CA1664]...........................................................................................................1177 FAILURE CODE [CA1669]...........................................................................................................1179 FAILURE CODE [CA1673]...........................................................................................................1180 FAILURE CODE [CA1677]...........................................................................................................1181 FAILURE CODE [CA1678]...........................................................................................................1182 FAILURE CODE [CA1682]...........................................................................................................1183 FAILURE CODE [CA1683]...........................................................................................................1185 FAILURE CODE [CA1684]...........................................................................................................1187 FAILURE CODE [CA1686]...........................................................................................................1189 FAILURE CODE [CA1691]...........................................................................................................1190 FAILURE CODE [CA1694]...........................................................................................................1193 FAILURE CODE [CA1695]...........................................................................................................1196 FAILURE CODE [CA1696]...........................................................................................................1197 FAILURE CODE [CA1712]...........................................................................................................1199 FAILURE CODE [CA1713]...........................................................................................................1202 FAILURE CODE [CA1714]...........................................................................................................1204 FAILURE CODE [CA1715]...........................................................................................................1205 FAILURE CODE [CA1776]...........................................................................................................1206 FAILURE CODE [CA1777]...........................................................................................................1209 FAILURE CODE [CA1843]...........................................................................................................1212 FAILURE CODE [CA1844]...........................................................................................................1214 FAILURE CODE [CA1879]...........................................................................................................1217 FAILURE CODE [CA1881]...........................................................................................................1219 FAILURE CODE [CA1883]...........................................................................................................1221 FAILURE CODE [CA1885]...........................................................................................................1224 FAILURE CODE [CA1887]...........................................................................................................1226 FAILURE CODE [CA1921]...........................................................................................................1228 FAILURE CODE [CA1922]...........................................................................................................1231 FAILURE CODE [CA1942]...........................................................................................................1236 FAILURE CODE [CA1993]...........................................................................................................1237 FAILURE CODE [CA2185]...........................................................................................................1240 FAILURE CODE [CA2186]...........................................................................................................1241 FAILURE CODE [CA2249]...........................................................................................................1243 FAILURE CODE [CA2271]...........................................................................................................1244 FAILURE CODE [CA2272]...........................................................................................................1247 FAILURE CODE [CA2288]...........................................................................................................1250 FAILURE CODE [CA2311]...........................................................................................................1251 FAILURE CODE [CA2349]...........................................................................................................1252 FAILURE CODE [CA2353]...........................................................................................................1255 FAILURE CODE [CA2357]...........................................................................................................1257 FAILURE CODE [CA2381]...........................................................................................................1258 FAILURE CODE [CA2382]...........................................................................................................1261 FAILURE CODE [CA2383]...........................................................................................................1264 FAILURE CODE [CA2386]...........................................................................................................1267 FAILURE CODE [CA2387]...........................................................................................................1269 FAILURE CODE [CA2555]...........................................................................................................1270 FAILURE CODE [CA2556]...........................................................................................................1273 FAILURE CODE [CA2637]...........................................................................................................1276 FAILURE CODE [CA2639]...........................................................................................................1278 FAILURE CODE [CA2771]...........................................................................................................1281 FAILURE CODE [CA2777]...........................................................................................................1287 FAILURE CODE [CA2976]...........................................................................................................1290 FAILURE CODE [CA3133]...........................................................................................................1292 FAILURE CODE [CA3134]...........................................................................................................1295 FAILURE CODE [CA3135]...........................................................................................................1297 FAILURE CODE [CA3142]...........................................................................................................1300 FAILURE CODE [CA3143]...........................................................................................................1301 FAILURE CODE [CA3144]...........................................................................................................1302 FAILURE CODE [CA3146]...........................................................................................................1304 FAILURE CODE [CA3147]...........................................................................................................1305 FAILURE CODE [CA3148]...........................................................................................................1306 FAILURE CODE [CA3151]...........................................................................................................1308 FAILURE CODE [CA3165]...........................................................................................................1314 FAILURE CODE [CA3229]...........................................................................................................1316 FAILURE CODE [CA3231]...........................................................................................................1318 FAILURE CODE [CA3232]...........................................................................................................1320 FAILURE CODE [CA3235]...........................................................................................................1324 FAILURE CODE [CA3239]...........................................................................................................1326 FAILURE CODE [CA3241]...........................................................................................................1329 FAILURE CODE [CA3242]...........................................................................................................1332 FAILURE CODE [CA3251]...........................................................................................................1335 FAILURE CODE [CA3253]...........................................................................................................1337 FAILURE CODE [CA3254]...........................................................................................................1340 FAILURE CODE [CA3255]...........................................................................................................1343 FAILURE CODE [CA3256]...........................................................................................................1347 FAILURE CODE [CA3311]...........................................................................................................1349 FAILURE CODE [CA3312]...........................................................................................................1351 FAILURE CODE [CA3313]...........................................................................................................1354 FAILURE CODE [CA3314]...........................................................................................................1355 FAILURE CODE [CA3315]...........................................................................................................1356 FAILURE CODE [CA3316]...........................................................................................................1358 FAILURE CODE [CA3317]...........................................................................................................1359 FAILURE CODE [CA3318]...........................................................................................................1360 FAILURE CODE [CA3319]...........................................................................................................1362 FAILURE CODE [CA3321]...........................................................................................................1363 FAILURE CODE [CA3322]...........................................................................................................1365 FAILURE CODE [CA3419]...........................................................................................................1367 FAILURE CODE [CA3421]...........................................................................................................1369 FAILURE CODE [CA3497]...........................................................................................................1371 FAILURE CODE [CA3498]...........................................................................................................1372 FAILURE CODE [CA3543]...........................................................................................................1373 FAILURE CODE [CA3545]...........................................................................................................1380 FAILURE CODE [CA3547]...........................................................................................................1382 FAILURE CODE [CA3558]...........................................................................................................1383 FAILURE CODE [CA3559]...........................................................................................................1385 FAILURE CODE [CA3562]...........................................................................................................1387 FAILURE CODE [CA3563]...........................................................................................................1389 FAILURE CODE [CA3567]...........................................................................................................1392 FAILURE CODE [CA3568]...........................................................................................................1395 FAILURE CODE [CA3571]...........................................................................................................1399 FAILURE CODE [CA3572]...........................................................................................................1401 FAILURE CODE [CA3574]...........................................................................................................1403 FAILURE CODE [CA3575]...........................................................................................................1405 FAILURE CODE [CA3577]...........................................................................................................1407 FAILURE CODE [CA3578]...........................................................................................................1409 FAILURE CODE [CA3582]...........................................................................................................1411 FAILURE CODE [CA3583]...........................................................................................................1417 FAILURE CODE [CA3596]...........................................................................................................1419 FAILURE CODE [CA3649]...........................................................................................................1421 FAILURE CODE [CA3681]...........................................................................................................1423 FAILURE CODE [CA3682]...........................................................................................................1428 FAILURE CODE [CA3713]...........................................................................................................1434 FAILURE CODE [CA3717]...........................................................................................................1437 FAILURE CODE [CA3718]...........................................................................................................1438 FAILURE CODE [CA3725]...........................................................................................................1439 FAILURE CODE [CA3741]...........................................................................................................1442 FAILURE CODE [CA3748]...........................................................................................................1443 FAILURE CODE [CA3751]...........................................................................................................1445 FAILURE CODE [CA3755]...........................................................................................................1447 FAILURE CODE [CA3866]...........................................................................................................1449 FAILURE CODE [CA3867]...........................................................................................................1453 FAILURE CODE [CA3868]...........................................................................................................1456 FAILURE CODE [CA3899]...........................................................................................................1460 FAILURE CODE [CA3911]...........................................................................................................1462 FAILURE CODE [CA3912]...........................................................................................................1466 FAILURE CODE [CA3932]...........................................................................................................1468 FAILURE CODE [CA3933]...........................................................................................................1470 FAILURE CODE [CA3934]...........................................................................................................1472 FAILURE CODE [CA3935]...........................................................................................................1475 FAILURE CODE [CA3936]...........................................................................................................1477 FAILURE CODE [CA4151]...........................................................................................................1479 FAILURE CODE [CA4152]...........................................................................................................1483 FAILURE CODE [CA4155]...........................................................................................................1487 FAILURE CODE [CA4156]...........................................................................................................1489 FAILURE CODE [CA4157]...........................................................................................................1491 FAILURE CODE [CA4158]...........................................................................................................1493 FAILURE CODE [CA4159]...........................................................................................................1494 FAILURE CODE [CA4161]...........................................................................................................1495 FAILURE CODE [CA4162]...........................................................................................................1498 FAILURE CODE [CA4163]...........................................................................................................1501 FAILURE CODE [CA4164]...........................................................................................................1502 FAILURE CODE [CA4165]...........................................................................................................1504 FAILURE CODE [CA4166]...........................................................................................................1506 FAILURE CODE [CA4168]...........................................................................................................1507 FAILURE CODE [CA4169]...........................................................................................................1510 FAILURE CODE [CA4171]...........................................................................................................1512 FAILURE CODE [CA4249]...........................................................................................................1515 FAILURE CODE [CA4251]...........................................................................................................1517 FAILURE CODE [CA4259]...........................................................................................................1519 FAILURE CODE [CA4261]...........................................................................................................1522 FAILURE CODE [CA4277]...........................................................................................................1525 FAILURE CODE [CA4281]...........................................................................................................1529 FAILURE CODE [CA4459]...........................................................................................................1532 FAILURE CODE [CA4461]...........................................................................................................1535 FAILURE CODE [CA4658]...........................................................................................................1538 FAILURE CODE [CA4731]...........................................................................................................1542 FAILURE CODE [CA4732]...........................................................................................................1543 FAILURE CODE [CA4739]...........................................................................................................1544 FAILURE CODE [CA4768]...........................................................................................................1545 FAILURE CODE [CA4769]...........................................................................................................1547 FAILURE CODE [CA4842]...........................................................................................................1550 FAILURE CODE [CA4952]...........................................................................................................1554 FAILURE CODE [CA5115]...........................................................................................................1556 FAILURE CODE [CA5179]...........................................................................................................1559 FAILURE CODE [CA5181]...........................................................................................................1561 FAILURE CODE [CA5383]...........................................................................................................1563 FAILURE CODE [D110KB]...........................................................................................................1565 FAILURE CODE [D19JKZ]...........................................................................................................1567 FAILURE CODE [D811MC]...........................................................................................................1570 FAILURE CODE [D862KA]...........................................................................................................1571 FAILURE CODE [D8ALKA]...........................................................................................................1573 FAILURE CODE [D8ALKB]...........................................................................................................1576 FAILURE CODE [D8AQKR]...........................................................................................................1578 FAILURE CODE [D8G1KT]...........................................................................................................1580 FAILURE CODE [D8G6KT]...........................................................................................................1581 FAILURE CODE [DA20MC]...........................................................................................................1582 FAILURE CODE [DA22KK]...........................................................................................................1583 FAILURE CODE [DA25KP]...........................................................................................................1586 FAILURE CODE [DA26KP]...........................................................................................................1589 FAILURE CODE [DA29KQ]...........................................................................................................1592 FAILURE CODE [DA2LKA]...........................................................................................................1594 FAILURE CODE [DA2LKB]...........................................................................................................1597 FAILURE CODE [DA2QKR]...........................................................................................................1599 FAILURE CODE [DA2RKR]...........................................................................................................1608 FAILURE CODE [DAF0KM]...........................................................................................................1609 FAILURE CODE [DAF0MB]...........................................................................................................1610 FAILURE CODE [DAF0MC]...........................................................................................................1611 FAILURE CODE [DAF8KB]...........................................................................................................1612 FAILURE CODE [DAF9KQ]...........................................................................................................1614 FAILURE CODE [DAFGMC]...........................................................................................................1615 FAILURE CODE [DAFLKA]...........................................................................................................1616 FAILURE CODE [DAFLKB]...........................................................................................................1619 FAILURE CODE [DAFQKR]...........................................................................................................1621 FAILURE CODE [DAZ9KQ]...........................................................................................................1629 FAILURE CODE [DAZQKR]...........................................................................................................1630 FAILURE CODE [DB2QKR]...........................................................................................................1637 FAILURE CODE [DB2RKR]...........................................................................................................1645 FAILURE CODE [DBP0KM]...........................................................................................................1650 FAILURE CODE [DBP0KT]...........................................................................................................1651 FAILURE CODE [DBP5KB]...........................................................................................................1652 FAILURE CODE [DBP5KY]...........................................................................................................1655 FAILURE CODE [DBPQKR]...........................................................................................................1658 FAILURE CODE [DDNRKA]...........................................................................................................1666 FAILURE CODE [DDNRKY]...........................................................................................................1668 FAILURE CODE [DDNS00]...........................................................................................................1670 FAILURE CODE [DFB1KZ]...........................................................................................................1672 FAILURE CODE [DFB2KZ]...........................................................................................................1674 FAILURE CODE [DFB3L8]...........................................................................................................1676 FAILURE CODE [DFB4L8]...........................................................................................................1678 FAILURE CODE [DFB5KZ]...........................................................................................................1680 FAILURE CODE [DFB6KZ]...........................................................................................................1682 FAILURE CODE [DGH2KA]...........................................................................................................1684 FAILURE CODE [DGH2KB]...........................................................................................................1686 FAILURE CODE [DHA4KA]...........................................................................................................1688 FAILURE CODE [DHAAMA]...........................................................................................................1690 FAILURE CODE [DHACMA]...........................................................................................................1692 FAILURE CODE [DHPAMA]...........................................................................................................1694 FAILURE CODE [DHPBMA]...........................................................................................................1697 FAILURE CODE [DHS3MA]...........................................................................................................1700 FAILURE CODE [DHS4MA]...........................................................................................................1703 FAILURE CODE [DHS8MA]...........................................................................................................1706 FAILURE CODE [DHS9MA]...........................................................................................................1709 FAILURE CODE [DHSAMA]...........................................................................................................1712 FAILURE CODE [DHSBMA]...........................................................................................................1715 FAILURE CODE [DHSCMA]...........................................................................................................1718 FAILURE CODE [DHSDMA]...........................................................................................................1721 FAILURE CODE [DHSFMA]...........................................................................................................1724 FAILURE CODE [DHSGMA]...........................................................................................................1727 FAILURE CODE [DHSHMA]...........................................................................................................1730 FAILURE CODE [DHSJMA]...........................................................................................................1733 FAILURE CODE [DHX1MA]...........................................................................................................1736 FAILURE CODE [DHZAMA]...........................................................................................................1739 FAILURE CODE [DHZCL8]...........................................................................................................1743 FAILURE CODE [DKR0MA]...........................................................................................................1744 FAILURE CODE [DKR1MA]...........................................................................................................1747 FAILURE CODE [DKULKA]...........................................................................................................1750 FAILURE CODE [DKULKB]...........................................................................................................1752 FAILURE CODE [DKULKY]...........................................................................................................1754 FAILURE CODE [DR10KA]...........................................................................................................1756 FAILURE CODE [DR12KA]...........................................................................................................1759 FAILURE CODE [DR20KA]...........................................................................................................1761 FAILURE CODE [DR21KX]...........................................................................................................1763 FAILURE CODE [DR30KA]...........................................................................................................1765 FAILURE CODE [DR31KX]...........................................................................................................1767 FAILURE CODE [DR40KA]...........................................................................................................1769 FAILURE CODE [DUMBKA]...........................................................................................................1771 FAILURE CODE [DUMBKB]...........................................................................................................1774 FAILURE CODE [DV00KA]...........................................................................................................1776 FAILURE CODE [DV00KB]...........................................................................................................1777 FAILURE CODE [DV20KB]...........................................................................................................1778 FAILURE CODE [DW43KA]...........................................................................................................1780 FAILURE CODE [DW43KB]...........................................................................................................1782 FAILURE CODE [DW43KY]...........................................................................................................1784 FAILURE CODE [DW45KA]...........................................................................................................1786 FAILURE CODE [DW45KB]...........................................................................................................1789 FAILURE CODE [DW45KY]...........................................................................................................1792 FAILURE CODE [DW4CKY]...........................................................................................................1794 FAILURE CODE [DW91KA]...........................................................................................................1796 FAILURE CODE [DW91KB]...........................................................................................................1798 FAILURE CODE [DW91KY]...........................................................................................................1800 FAILURE CODE [DWA2KA]...........................................................................................................1802 FAILURE CODE [DWA2KB]...........................................................................................................1804 FAILURE CODE [DWA2KY]...........................................................................................................1806 FAILURE CODE [DWK0KA]...........................................................................................................1808 FAILURE CODE [DWK0KB]...........................................................................................................1810 FAILURE CODE [DWK0KY]...........................................................................................................1812 FAILURE CODE [DWK2KA]...........................................................................................................1814 FAILURE CODE [DWK2KB]...........................................................................................................1816 FAILURE CODE [DWK2KY]...........................................................................................................1818 FAILURE CODE [DWK8KA]...........................................................................................................1820 FAILURE CODE [DWK8KB]...........................................................................................................1822 FAILURE CODE [DWK8KY]...........................................................................................................1824 FAILURE CODE [DWPUKA]...........................................................................................................1826 FAILURE CODE [DWPUKB]...........................................................................................................1828 FAILURE CODE [DXA8KA]...........................................................................................................1830 FAILURE CODE [DXA8KB]...........................................................................................................1832 FAILURE CODE [DXA9KA]...........................................................................................................1834 FAILURE CODE [DXA9KB]...........................................................................................................1836 FAILURE CODE [DXE0KA]...........................................................................................................1838 FAILURE CODE [DXE0KB]...........................................................................................................1839 FAILURE CODE [DXE4KA]...........................................................................................................1841 FAILURE CODE [DXE4KB]...........................................................................................................1843 FAILURE CODE [DXE4KY]...........................................................................................................1845 FAILURE CODE [DXE5KA]...........................................................................................................1847 FAILURE CODE [DXE5KB]...........................................................................................................1849 FAILURE CODE [DXE6KA]...........................................................................................................1851 FAILURE CODE [DXE6KB]...........................................................................................................1853 FAILURE CODE [DXE7KA]...........................................................................................................1855 FAILURE CODE [DXE7KB]...........................................................................................................1857 FAILURE CODE [DXE7KY]...........................................................................................................1859 FAILURE CODE [DXE8KA]...........................................................................................................1861 FAILURE CODE [DXE8KB]...........................................................................................................1863 FAILURE CODE [DXE8KY]...........................................................................................................1865 FAILURE CODE [DXE9KA]...........................................................................................................1867 FAILURE CODE [DXE9KB]...........................................................................................................1869 FAILURE CODE [DXE9KY]...........................................................................................................1871 FAILURE CODE [DXEAKA]...........................................................................................................1873 FAILURE CODE [DXEAKB]...........................................................................................................1875 FAILURE CODE [DXEAKY]...........................................................................................................1877 FAILURE CODE [DXEKKA]...........................................................................................................1879 FAILURE CODE [DXEKKB]...........................................................................................................1881 FAILURE CODE [DXEKKY]...........................................................................................................1883 FAILURE CODE [DXELKA]...........................................................................................................1885 FAILURE CODE [DXELKB]...........................................................................................................1887 FAILURE CODE [DXELKY]...........................................................................................................1889 FAILURE CODE [DY20KA]...........................................................................................................1891 FAILURE CODE [DY20MA]...........................................................................................................1893 FAILURE CODE [DY2CKB]...........................................................................................................1895 FAILURE CODE [DY2DKB]...........................................................................................................1898 FAILURE CODE [DY2EKB]...........................................................................................................1900 FAILURE CODE [F313KA]...........................................................................................................1902 FAILURE CODE [F313KB]...........................................................................................................1904 FAILURE CODE [F318KB]...........................................................................................................1907 FAILURE CODE [F318KY]...........................................................................................................1910 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).......................................................................................1912 E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)...............................................................................1912 E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK......................................................................................1918 E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK...................................................................................1921 E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP...........................................................1923 E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING.............................................1925 E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW..........1928 E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW....1929 E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING...............................................1930 E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING................................................1931 E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING...................................................1932 E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..............................................................1933 E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING................................................................1934 E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...........................................................1935 E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING................................................1936 E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.......................................................1937 E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.................................................1938 E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM...................................................................1939 E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL.......................................................................1941 E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM.............................................1942 E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE........................................1943 E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM..............................................1944 E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE.............................................1946 E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED.....................................................................1947 E-24 FUNCTION SWITCH DOES NOT OPERATE...........................................................................................1948 E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)...................................................................1949 E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF....................1950 E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER....................................................................1951 E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED.......................................1952 E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED..........................................1953 E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE.................................................1954 E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE................................................1955 E-32 ALARM BUZZER CANNOT BE CANCELED............................................................................................1957 E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION...................................................1958 E-34 SERVICE MODE CANNOT BE SELECTED............................................................................................1959 E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE............................................................1960 E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK.............................................................1963 E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING.............................................1965 E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE.............................1968 E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR.......................1970 E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED.......................................................................1973 E-41 ALARM DOES NOT SOUND DURING TRAVEL.........................................................................................1974 E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED......................................................................1976 E-43 HORN DOES NOT SOUND........................................................................................................1977 E-44 HORN DOES NOT STOP SOUNDING................................................................................................1980 E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF...................................................1982 E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE...........................................................1983 E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE......................................................1985 E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION....................................................1986 E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION....................................................1987 E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.......................................................1988 E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................................1989 E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...................................................1990 E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...................................................1991 E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.........................................................1992 E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................................1993 E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.......................................................1994 E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED.............................................................................1996 E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY...................................................................................1997 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE).......................................................................1998 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE).........................................................................1998 SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS................................................................................1999 FAILURE MODE AND CAUSE TABLE....................................................................................................2001 H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK............................................................................2010 H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER...................................................................2011 H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR................................................................................2014 H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP...........................................................................2015 H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS..................................................................................2016 H-6 SPEED OR POWER OF BOOM IS LOW...............................................................................................2018 H-7 ARM SPEED OR POWER IS LOW...................................................................................................2022 H-8 BUCKET SPEED OR POWER IS LOW................................................................................................2027 H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION............................................................................2030 H-10 HYDRAULIC DRIFT OF BOOM IS LARGE...........................................................................................2031 H-11 HYDRAULIC DRIFT OF ARM IS LARGE............................................................................................2033 H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE.........................................................................................2035 H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES...........................................2036 H-14 TIME LAG OF WORK EQUIPMENT IS LARGE........................................................................................2037 H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE.......................................................................2038 H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED.......................................................................................2039 H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED...........................................................................2040 H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER........................................2041 H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY......................................................2042 H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW....................................................2043 H-21 MACHINE DOES NOT TRAVEL STRAIGHT...........................................................................................2044 H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW.......................................................................2046 H-23 TRAVEL SPEED IS LOW........................................................................................................2049 H-24 ONE OF TRACKS DOES NOT RUN.................................................................................................2051 H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST..........................................................2052 H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT..................................................................2053 H-27 SWINGS ONLY IN ONE DIRECTION...............................................................................................2054 H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)...............................................2055 H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION........................................2056 H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)..........................................2057 H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)......................2058 H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING.........................................................................2059 H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING...........................................................2060 H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED).....................................................2061 H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)....................................................2062 H-36 Quick coupler cylinder will not extend.....................................................................................2063 H-37 Quick coupler cylinder will not retract (but buzzer doesnot sound).........................................................2065 H-38 Buzzer does not sound (but quick coupler cylinder doesretract).............................................................2067 H-39 Quick coupler cylinder extends and retracts slowly.........................................................................2069 TROUBLESHOOTING OF ENGINE (S-MODE)..................................................................................................2070 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE).........................................................................2070 S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION......................................................2071 S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT..................................................................................2072 S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)..............................2073 S-4 ENGINE STARTABILITY IS POOR.................................................................................................2075 S-5 ENGINE DOES NOT PICK UP SMOOTHLY............................................................................................2077 S-6 ENGINE STOPS DURING OPERATION...............................................................................................2079 S-7 ENGINE RUNS ROUGH OR IS UNSTABLE............................................................................................2081 S-8 ENGINE LACKS POWER..........................................................................................................2082 S-9 KDPF GETS CLOGGED IN A SHORT TIME...........................................................................................2084 S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE........................................................................................2086 S-11 OIL BECOMES CONTAMINATED QUICKLY...........................................................................................2087 S-12 FUEL CONSUMPTION IS EXCESSIVE..............................................................................................2088 S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)......................................................2089 S-14 OIL PRESSURE DROPS.........................................................................................................2090 S-15 FUEL MIXES INTO ENGINE OIL.................................................................................................2092 S-16 WATER MIXES INTO ENGINE OIL (MILKY)........................................................................................2093 S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)...........................................................................2094 S-18 UNUSUAL NOISE IS HEARD.....................................................................................................2095 S-19 VIBRATION IS EXCESSIVE.....................................................................................................2096 S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT.......................................................................................2097 S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY.................................................................................2098 S-22 ACTIVE REGENERATION TAKES TIME.............................................................................................2100 S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION........................................................................2101 S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE........................................................................................2102 S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)...................................................................................2104 S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)..................................................................2105 50 DISASSEMBLY AND ASSEMBLY.............................................................................................................2107 CONTENTS............................................................................................................................2108 ABBREVIATION LIST...................................................................................................................2113 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY.....................................................................................2119 HOW TO READ THIS MANUAL.........................................................................................................2119 COATING MATERIALS LIST..........................................................................................................2121 SPECIAL TOOLS LIST..............................................................................................................2126 SKETCHES OF SPECIAL TOOLS.......................................................................................................2138 ENGINE AND COOLING SYSTEM...........................................................................................................2144 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY.........................................................................................2144 METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY....................................................................................2144 METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY..................................................................................2147 REMOVE AND INSTALL INJECTOR ASSEMBLY............................................................................................2151 METHOD FOR REMOVING INJECTOR ASSEMBLY.......................................................................................2151 METHOD FOR INSTALLING INJECTOR ASSEMBLY.....................................................................................2156 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY.......................................................................................2164 METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY..................................................................................2165 METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY................................................................................2174 REMOVE AND INSTALL EGR VALVE ASSEMBLY...........................................................................................2190 METHOD FOR REMOVING EGR VALVE ASSEMBLY......................................................................................2190 METHOD FOR INSTALLING EGR VALVE ASSEMBLY....................................................................................2191 REMOVE AND INSTALL EGR COOLER ASSEMBLY..........................................................................................2194 METHOD FOR REMOVING EGR COOLER ASSEMBLY.....................................................................................2194 METHOD FOR INSTALLING EGR COOLER ASSEMBLY...................................................................................2197 REMOVE AND INSTALL STARTER ASSEMBLY.............................................................................................2202 METHOD FOR REMOVING STARTER ASSEMBLY........................................................................................2202 METHOD FOR INSTALLING STARTER ASSEMBLY......................................................................................2204 REMOVE AND INSTALL ALTERNATOR BELT..............................................................................................2206 METHOD FOR REMOVING ALTERNATOR BELT.........................................................................................2206 METHOD FOR INSTALLING ALTERNATOR BELT.......................................................................................2208 REMOVE AND INSTALL RADIATOR ASSEMBLY............................................................................................2210 METHOD FOR REMOVING RADIATOR ASSEMBLY.......................................................................................2210 METHOD FOR INSTALLING RADIATOR ASSEMBLY.....................................................................................2212 REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY................................................................................2214 METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY...........................................................................2214 METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY.........................................................................2217 REMOVE AND INSTALL AFTERCOOLER ASSEMBLY.........................................................................................2220 METHOD FOR REMOVING AFTERCOOLER ASSEMBLY....................................................................................2220 METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY..................................................................................2221 REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY................................................................................2223 METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY...........................................................................2224 METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY.........................................................................2232 REMOVE AND INSTALL ENGINE FRONT OIL SEAL........................................................................................2243 METHOD FOR REMOVING ENGINE FRONT OIL SEAL...................................................................................2243 METHOD FOR INSTALLING ENGINE FRONT OIL SEAL.................................................................................2246 REMOVE AND INSTALL ENGINE REAR OIL SEAL.........................................................................................2250 METHOD FOR REMOVING ENGINE REAR OIL SEAL....................................................................................2250 METHOD FOR INSTALLING ENGINE REAR OIL SEAL..................................................................................2251 REMOVE AND INSTALL FUEL COOLER ASSEMBLY.........................................................................................2254 METHOD FOR REMOVING FUEL COOLER ASSEMBLY....................................................................................2254 METHOD FOR INSTALLING FUEL COOLER ASSEMBLY..................................................................................2255 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY.........................................................................................2256 METHOD FOR REMOVING ENGINE HOOD ASSEMBLY....................................................................................2256 METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY..................................................................................2258 REMOVE AND INSTALL FUEL TANK ASSEMBLY...........................................................................................2264 METHOD FOR REMOVING FUEL TANK ASSEMBLY......................................................................................2264 METHOD FOR INSTALLING FUEL TANK ASSEMBLY....................................................................................2268 REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY.....................................................................................2274 METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY................................................................................2274 METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY..............................................................................2279 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY.......................................................................2285 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY..................................................................2285 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY................................................................2290 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR.......................................................................................2296 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR..................................................................................2296 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR................................................................................2296 REMOVE AND INSTALL AdBlue/DEF TANK STRAINER.....................................................................................2303 METHOD FOR REMOVING AdBlue/DEF TANK STRAINER................................................................................2303 METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER..............................................................................2303 REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER...........................................................................2305 METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER......................................................................2305 METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER....................................................................2307 REMOVE AND INSTALL KDPF ASSEMBLY................................................................................................2310 METHOD FOR REMOVING KDPF ASSEMBLY...........................................................................................2310 METHOD FOR INSTALLING KDPF ASSEMBLY.........................................................................................2312 DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY.......................................................................................2314 METHOD FOR DISASSEMBLING KDPF ASSEMBLY......................................................................................2315 METHOD FOR ASSEMBLING KDPF ASSEMBLY.........................................................................................2318 REMOVE AND INSTALL SCR ASSEMBLY.................................................................................................2323 METHOD FOR REMOVING SCR ASSEMBLY............................................................................................2323 METHOD FOR INSTALLING SCR ASSEMBLY..........................................................................................2325 REMOVE AND INSTALL KDPF, SCR ASSEMBLY...........................................................................................2327 METHOD FOR REMOVING KDPF, SCR ASSEMBLY......................................................................................2327 METHOD FOR INSTALLING KDPF, SCR ASSEMBLY....................................................................................2333 REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET...................................................................................2339 METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET..............................................................................2339 METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET............................................................................2345 REMOVE AND INSTALL KCCV ASSEMBLY................................................................................................2352 METHOD FOR REMOVING KCCV ASSEMBLY...........................................................................................2352 METHOD FOR INSTALLING KCCV ASSEMBLY.........................................................................................2355 REMOVE AND INSTALL AdBlue/DEF MIXING TUBE.......................................................................................2359 METHOD FOR REMOVING AdBlue/DEF MIXING TUBE..................................................................................2359 METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE................................................................................2364 REMOVE AND INSTALL AdBlue/DEF INJECTOR..........................................................................................2369 METHOD FOR REMOVING AdBlue/DEF INJECTOR.....................................................................................2369 METHOD FOR INSTALLING AdBlue/DEF INJECTOR...................................................................................2371 REMOVE AND INSTALL AdBlue/DEF PUMP..............................................................................................2373 METHOD FOR REMOVING AdBlue/DEF PUMP.........................................................................................2373 METHOD FOR INSTALLING AdBlue/DEF PUMP.......................................................................................2375 REMOVE AND INSTALL AdBlue/DEF HOSE..............................................................................................2378 METHOD FOR REMOVING AdBlue/DEF HOSE.........................................................................................2378 METHOD FOR INSTALLING AdBlue/DEF HOSE.......................................................................................2386 REMOVE AND INSTALL AIR CLEANER ASSEMBLY.........................................................................................2392 METHOD FOR REMOVING AIR CLEANER ASSEMBLY....................................................................................2392 METHOD FOR INSTALLING AIR CLEANER ASSEMBLY..................................................................................2393 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY..........................................................................2395 METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY.....................................................................2395 METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY...................................................................2397 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...........................................................................2400 METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY......................................................................2400 METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY....................................................................2401 POWER TRAIN.........................................................................................................................2402 REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY........................................................................2402 METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...................................................................2402 METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY.................................................................2403 DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY...................................................................................2405 METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY...............................................................................2405 METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY..................................................................................2409 REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY.....................................................................2418 METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY................................................................2418 METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY..............................................................2421 DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY...............................................................................2424 METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY...........................................................................2424 METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY..............................................................................2428 REMOVE AND INSTALL SWING CIRCLE ASSEMBLY........................................................................................2435 METHOD FOR REMOVING SWING CIRCLE ASSEMBLY...................................................................................2435 METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY.................................................................................2435 UNDERCARRIAGE AND FRAME.............................................................................................................2437 SEPARATION AND CONNECTION OF TRACK ASSEMBLY.....................................................................................2437 METHOD FOR SEPARATING TRACK ASSEMBLY........................................................................................2437 METHOD FOR INSTALLING TRACK ASSEMBLY........................................................................................2439 REMOVE AND INSTALL SPROCKET.....................................................................................................2442 METHOD FOR REMOVING SPROCKET................................................................................................2442 METHOD FOR INSTALLING SPROCKET..............................................................................................2442 REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY.............................................................................2444 METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY........................................................................2444 METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY......................................................................2445 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY.........................................................................................2446 METHOD FOR DISASSEMBLING IDLER ASSEMBLY.....................................................................................2446 METHOD FOR ASSEMBLING IDLER ASSEMBLY........................................................................................2447 DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY..............................................................................2451 METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY.............................................................................2452 METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY................................................................................2453 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY..................................................................................2454 METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY..............................................................................2455 METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY.................................................................................2456 DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY.................................................................................2458 METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY............................................................................2458 METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY...............................................................................2460 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY.....................................................................................2462 METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY................................................................................2462 METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY..............................................................................2464 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY.......................................................................................2467 METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY..................................................................................2467 METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY................................................................................2470 HYDRAULIC SYSTEM....................................................................................................................2474 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY.................................................................................2474 METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY............................................................................2474 METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY..........................................................................2476 DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY...........................................................................2479 METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY.......................................................................2480 METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY..........................................................................2481 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY......................................................................................2482 METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY.................................................................................2482 METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY...............................................................................2485 REMOVE AND INSTALL MAIN PUMP ASSEMBLY...........................................................................................2489 METHOD FOR REMOVING MAIN PUMP ASSEMBLY......................................................................................2489 METHOD FOR INSTALLING MAIN PUMP ASSEMBLY....................................................................................2492 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY.......................................................................................2496 METHOD FOR REMOVING CONTROL VALVE ASSEMBLY..................................................................................2496 METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY................................................................................2503 DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY.................................................................................2511 METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING..................................................................2511 METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY................................................................................2513 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY......................................................................2517 METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY..................................................................2517 METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY.....................................................................2517 DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY..............................................................................2519 METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY..........................................................................2519 METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY.............................................................................2520 REMOVE AND INSTALL QUICK COUPLER VALVE..........................................................................................2522 WORK EQUIPMENT......................................................................................................................2524 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY......................................................................................2524 METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY.................................................................................2524 METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY...............................................................................2528 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY.......................................................................2534 METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY...................................................................2534 METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY......................................................................2537 CAB AND ITS ATTACHMENTS.............................................................................................................2543 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY......................................................................................2543 METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY.................................................................................2543 METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY...............................................................................2549 REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)...........................................................................2556 METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY.................................................................................2558 METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY...............................................................................2558 REMOVE AND INSTALL FRONT WINDOW ASSEMBLY........................................................................................2568 METHOD FOR REMOVING FRONT WINDOW ASSEMBLY...................................................................................2568 METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY.................................................................................2571 REMOVE AND INSTALL FLOOR FRAME ASSEMBLY.........................................................................................2577 METHOD FOR REMOVING FLOOR FRAME ASSEMBLY....................................................................................2577 METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY..................................................................................2584 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY................................................................................2591 METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY...........................................................................2591 METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY.........................................................................2597 REMOVE AND INSTALL OPERATOR'S SEAT..............................................................................................2604 METHOD FOR REMOVING OPERATOR'S SEAT.........................................................................................2604 METHOD FOR INSTALLING OPERATOR'S SEAT.......................................................................................2606 REMOVE AND INSTALL SEAT BELT....................................................................................................2609 METHOD FOR REMOVING SEAT BELT...............................................................................................2609 METHOD FOR INSTALLING SEAT BELT.............................................................................................2610 REMOVE AND INSTALL FRONT WIPER ASSEMBLY.........................................................................................2611 METHOD FOR REMOVING FRONT WIPER ASSEMBLY....................................................................................2611 METHOD FOR INSTALLING FRONT WIPER ASSEMBLY..................................................................................2616 ELECTRICAL SYSTEM...................................................................................................................2625 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...................................................................................2625 METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY..............................................................................2625 METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY............................................................................2627 REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY.....................................................................................2628 METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY................................................................................2628 METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY..............................................................................2632 REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY................................................................................2637 METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY...........................................................................2637 METHOD FOR INSTALLING KomVision CONTROLLER..................................................................................2638 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY.....................................................................................2640 METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY................................................................................2640 METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY..............................................................................2643 REMOVE AND INSTALL PUMP SWASH PLATE SENSOR......................................................................................2646 METHOD FOR REMOVING PUMP SWASH PLATE SENSOR.................................................................................2646 METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR...............................................................................2647 REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR.........................................................................2648 METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR....................................................................2648 METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR..................................................................2649 REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR...............................................................................2650 METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR..........................................................................2650 METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR........................................................................2651 REMOVE AND INSTALL SCR TEMPERATURE SENSOR.......................................................................................2653 METHOD FOR REMOVING SCR TEMPERATURE SENSOR..................................................................................2653 METHOD FOR INSTALLING SCR TEMPERATURE SENSOR................................................................................2655 REMOVE AND INSTALL KomVision CAMERA.............................................................................................2658 METHOD FOR REMOVING KomVision CAMERA........................................................................................2658 METHOD FOR INSTALLING KomVision CAMERA......................................................................................2661 REMOVE AND INSTALL KomVision CAMERA.............................................................................................2664 METHOD FOR REMOVING KomVision CAMERA........................................................................................2664 METHOD FOR INSTALLING KomVision CAMERA......................................................................................2667 REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY.........................................................................2670 METHOD FOR REMOVING GATEWAY FUNCTION CONTROLLER ASSEMBLY....................................................................2670 METHOD FOR INSTALLING GATEWAY FUNCTION CONTROLLER ASSEMBLY..................................................................2675 REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS........................................................................2680 METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS...................................................................2680 METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS.................................................................2688 REMOVE AND INSTALL COMMUNICATION TERMINAL.......................................................................................2697 METHOD FOR REMOVING COMMUNICATION TERMINAL..................................................................................2697 METHOD FOR INSTALLING COMMUNICATION TERMINAL................................................................................2699 60 MAINTENANCE STANDARD.................................................................................................................2703 CONTENTS............................................................................................................................2704 ABBREVIATION LIST...................................................................................................................2705 ENGINE AND COOLING SYSTEM...........................................................................................................2711 MAINTENANCE STANDARD OF ENGINE MOUNT............................................................................................2711 MAINTENANCE STANDARD OF COOLING SYSTEM..........................................................................................2712 POWER TRAIN.........................................................................................................................2713 MAINTENANCE STANDARD OF SWING CIRCLE............................................................................................2713 MAINTENANCE STANDARD OF SWING MACHINERY.........................................................................................2714 MAINTENANCE STANDARD OF FINAL DRIVE.............................................................................................2716 MAINTENANCE STANDARD OF SPROCKET................................................................................................2718 MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING...............................................................2719 UNDERCARRIAGE AND FRAME.............................................................................................................2721 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION...........................................................................2721 MAINTENANCE STANDARD OF IDLER...................................................................................................2723 MAINTENANCE STANDARD OF TRACK ROLLER............................................................................................2725 MAINTENANCE STANDARD OF CARRIER ROLLER..........................................................................................2726 MAINTENANCE STANDARD OF TRACK SHOE..............................................................................................2727 MAINTENANCE STANDARD OF TRIPLE SHOE.............................................................................................2730 MAINTENANCE STANDARD OF SWAMP SHOE..............................................................................................2731 MAINTENANCE STANDARD OF ROAD LINER..............................................................................................2732 HYDRAULIC SYSTEM....................................................................................................................2733 MAINTENANCE STANDARD OF HYDRAULIC TANK..........................................................................................2733 MAINTENANCE STANDARD OF MAIN PUMP...............................................................................................2734 MAINTENANCE STANDARD OF LS-EPC VALVE............................................................................................2735 MAINTENANCE STANDARD OF PC-EPC VALVE............................................................................................2736 MAINTENANCE STANDARD OF SWING MOTOR.............................................................................................2737 MAINTENANCE STANDARD OF TRAVEL MOTOR............................................................................................2740 MAINTENANCE STANDARD OF CONTROL VALVE...........................................................................................2743 MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE......................................................................2753 MAINTENANCE STANDARD OF TRAVEL PPC VALVE........................................................................................2756 MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)..........................................................2759 MAINTENANCE STANDARD OF EPC VALVE...........................................................................................2760 MAINTENANCE STANDARD OF SOLENOID VALVE..........................................................................................2762 MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE........................................................................2763 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)...................................................2765 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)....................................................2766 MAINTENANCE STANDARD OF CENTER SWIVEL JOINT.....................................................................................2767 WORK EQUIPMENT......................................................................................................................2768 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE..................................................................................2768 DIMENSION OF ARM............................................................................................................2773 DIMENSIONS OF BUCKET........................................................................................................2775 MAINTENANCE STANDARD OF BOOM CYLINDER...........................................................................................2777 MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON)...................................................................2778 MAINTENANCE STANDARD OF ARM CYLINDER............................................................................................2779 MAINTENANCE STANDARD OF BUCKET CYLINDER.........................................................................................2780 80 APPENDIX.............................................................................................................................2781 CONTENTS............................................................................................................................2782 ABBREVIATION LIST...................................................................................................................2784 AIR CONDITIONER SYSTEM..............................................................................................................2790 PRECAUTIONS FOR REFRIGERANT.....................................................................................................2790 AIR CONDITIONER COMPONENT.......................................................................................................2791 SPECIFICATIONS OF AIR CONDITIONER...............................................................................................2793 CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE...............................................................................2794 OUTLINE OF REFRIGERATION CYCLE..................................................................................................2795 COMPONENT PARTS OF AIR CONDITIONER SYSTEM...........................................................................................2797 AIR CONDITIONER UNIT............................................................................................................2797 CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT...............................................................................2797 FUNCTION OF AIR CONDITIONER UNIT............................................................................................2799 COMPONENT PARTS OF AIR CONDITIONER UNIT.........................................................................................2801 FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT....................................................................2802 FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT...................................................................2802 FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT.................................................2802 FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT...................................................................2802 STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT..............................................................2803 FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...............................................................2803 OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...................................................................2803 FUNCTION OF DUAL PRESSURE SWITCH............................................................................................2804 AIR CONDITIONER CONTROLLER......................................................................................................2805 STRUCTURE OF AIR CONDITIONER CONTROLLER.....................................................................................2805 COMPRESSOR......................................................................................................................2806 STRUCTURE OF COMPRESSOR.....................................................................................................2806 SPECIFICATIONS OF COMPRESSOR................................................................................................2806 FUNCTION OF COMPRESSOR......................................................................................................2806 CONDENSER.......................................................................................................................2807 STRUCTURE OF CONDENSER......................................................................................................2807 SPECIFICATIONS OF CONDENSER.................................................................................................2807 FUNCTION OF CONDENSER.......................................................................................................2807 SENSORS FOR AIR CONDITIONER SYSTEM..............................................................................................2809 STRUCTURE OF SUNLIGHT SENSOR................................................................................................2809 FUNCTION OF SUNLIGHT SENSOR.................................................................................................2809 STRUCTURE OF AMBIENT TEMPERATURE SENSOR.....................................................................................2809 FUNCTION OF AMBIENT TEMPERATURE SENSOR......................................................................................2809 EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER.........................................................2811 CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER...............................................................2813 AIR CONDITIONER SYSTEM DIAGRAM......................................................................................................2815 INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER..........................................................................2816 FUNCTION OF AIR CONDITIONER CONTROLLER......................................................................................2817 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS.......................................................2818 TESTING AIR LEAKAGE (DUCT)..........................................................................................................2822 METHOD FOR TESTING AIR LEAKAGE (DUCT)...........................................................................................2822 TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION...............................................................................2824 HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR..................................2825 TEST VENT (MODE) CHANGEOVER.........................................................................................................2826 METHOD FOR TESTING VENT (MODE) CHANGEOVER.......................................................................................2826 TESTING FRESH/RECIRC AIR CHANGEOVER.................................................................................................2828 METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER..................................................................................2828 TEST SUNLIGHT SENSOR................................................................................................................2829 METHOD FOR TESTING SUNLIGHT SENSOR..............................................................................................2829 TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT.........................................................................................2830 METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT.......................................................................2830 TEST RELAYS.........................................................................................................................2831 METHOD FOR TESTING RELAYS.......................................................................................................2831 AIR CONDITIONER TROUBLESHOOTING CHART 1.............................................................................................2832 AIR CONDITIONER TROUBLESHOOTING CHART 2.............................................................................................2833 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE......................................................................................2836 FAILURE CODE [879AKA]...............................................................................................................2838 FAILURE CODE [879AKB]...............................................................................................................2839 FAILURE CODE [879BKA]...............................................................................................................2840 FAILURE CODE [879BKB]...............................................................................................................2842 FAILURE CODE [879CKA]...............................................................................................................2844 FAILURE CODE [879CKB]...............................................................................................................2845 FAILURE CODE [879DKZ]...............................................................................................................2846 FAILURE CODE [879EMC]...............................................................................................................2848 FAILURE CODE [879FMC]...............................................................................................................2849 FAILURE CODE [879GKX]...............................................................................................................2850 A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)......................................................2852 A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED).......................................................2854 A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)..............................................2857 A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER.................................................................................2859 TROUBLESHOOTING USING GAUGE PRESSURE................................................................................................2861 CONNECTION OF SERVICE TOOL..........................................................................................................2864 METHOD FOR CONNECTING SERVICE TOOL..............................................................................................2864 PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS.............................................2866 HANDLE COMPRESSOR OIL...............................................................................................................2868 METHOD FOR REPLACING DESICCANT......................................................................................................2870 90 CIRCUIT DIAGRAMS.....................................................................................................................2873 CONTENTS............................................................................................................................2874 ABBREVIATION LIST...................................................................................................................2875 HYDRAULIC CIRCUIT DIAGRAM...........................................................................................................2881 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM.......................................................................................2881 HYDRAULIC CIRCUIT DIAGRAM (1/2).................................................................................................2885 HYDRAULIC CIRCUIT DIAGRAM (2/2).................................................................................................2887 ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................2889 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM......................................................................................2889 ELECTRICAL CIRCUIT DIAGRAM (1/10)...............................................................................................2893 ELECTRICAL CIRCUIT DIAGRAM (2/10)...............................................................................................2895 ELECTRICAL CIRCUIT DIAGRAM (3/10)...............................................................................................2897 ELECTRICAL CIRCUIT DIAGRAM (4/10)...............................................................................................2899 ELECTRICAL CIRCUIT DIAGRAM (5/10)...............................................................................................2901 ELECTRICAL CIRCUIT DIAGRAM (6/10)...............................................................................................2903 ELECTRICAL CIRCUIT DIAGRAM (7/10)...............................................................................................2905 ELECTRICAL CIRCUIT DIAGRAM (8/10)...............................................................................................2907 ELECTRICAL CIRCUIT DIAGRAM (9/10)...............................................................................................2909 ELECTRICAL CIRCUIT DIAGRAM (10/10)..............................................................................................2911 INDEX....................................................................................................................................2913
DESCRIPTION:
KOMATSU PC240LC-11E0 PC240NLC-11E0 SHOP MANUAL UENBM00473 – PDF DOWNLOAD
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.
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