Komatsu PC240LC-11E0,PC240NLC-11E0 Hydraulic Excavator Shop Manual PDF

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Komatsu PC240LC-11E0,PC240NLC-11E0 Hydraulic Excavator Shop Manual UENBM00660 – PDF DOWNLOAD

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Komatsu PC240LC-11E0,PC240NLC-11E0 Hydraulic Excavator Shop Manual UENBM00660 – PDF DOWNLOAD

Language : English
Pages : 2854
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC240LC-11E0,PC240NLC-11E0 Hydraulic Excavator Shop Manual UENBM00660 – PDF DOWNLOAD

• SERIAL NUMBERS K75001-K75273

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 . 152
FUNCTION OF BATTERY DISCONNECT SWITCH . 152
ENGINE SYSTEM . 153
LAYOUT DRAWING OF ENGINE SYSTEM . 153
SPECIFICATIONS OF ENGINE SYSTEM . 154
FUNCTION OF ENGINE SYSTEM . 154
ENGINE CONTROL SYSTEM . 155
ENGINE CONTROL SYSTEM DIAGRAM . 155
FUNCTION OF ENGINE CONTROL SYSTEM . 156
AUTO-DECELERATION SYSTEM 158
AUTO-DECELERATION SYSTEM DIAGRAM 158
FUNCTION OF AUTO-DECELERATION SYSTEM 158
OPERATION OF AUTO-DECELERATION SYSTEM . 159
ENGINE AUTOMATIC WARM-UP SYSTEM . 160
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 160
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 161
OVERHEAT PREVENTION SYSTEM 162
OVERHEAT PREVENTION SYSTEM DIAGRAM 162
FUNCTION OF OVERHEAT PREVENTION SYSTEM 163
TURBOCHARGER PROTECTION SYSTEM 165
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 165
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 166
AUTOMATIC IDLE STOP SYSTEM 167
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 167
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 167
COMPONENT PARTS OF ENGINE SYSTEM 170
VGT . 170
EGR SYSTEM 174
EGR VALVE . 176
EGR COOLER 178
KCCV SYSTEM . 179
KCCV VENTILATOR . 181
KDPF 183
COOLING SYSTEM 188
LAYOUT DRAWING OF COOLING SYSTEM 188
SPECIFICATIONS OF COOLING SYSTEM 189
CONTROL SYSTEM 190
LAYOUT DRAWING OF CONTROL SYSTEM 190
MACHINE MONITOR SYSTEM 193
MACHINE MONITOR SYSTEM DIAGRAM 193
KomVision SYSTEM 194
LAYOUT DRAWING OF KOMVISION SYSTEM 194
KomVision SYSTEM DIAGRAM 196
FUNCTION OF KomVision SYSTEM 196
KOMTRAX SYSTEM 198
KOMTRAX SYSTEM DIAGRAM 198
FUNCTION OF KOMTRAX SYSTEM 198
PPC LEVERS 199
LH PPC LEVER 199
RH PPC LEVER 200
AUTOMATIC GREASE SYSTEM . 201
OUTLINE OF AUTO GREASE SYSTEM . 201
COMPONENT PARTS OF CONTROL SYSTEM . 216
MACHINE MONITOR . 216
KomVision CONTROLLER 229
KomVision CAMERA 233
KOMTRAX TERMINAL 233
PUMP CONTROLLER . 236
RESISTOR FOR PC-EPC VALVE . 240
CAN TERMINATING RESISTOR 240
PPC OIL PRESSURE SWITCH . 241
ENGINE CONTROLLER . 242
FUEL CONTROL DIAL . 248
SENSOR 250
STRUCTURE OF AMBIENT PRESSURE SENSOR 250
FUNCTION OF AMBIENT PRESSURE SENSOR . 250
STRUCTURE OF ENGINE OIL PRESSURE SWITCH . 250
FUNCTION OF ENGINE OIL PRESSURE SWITCH 251
STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR . 251
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR 251
STRUCTURE OF COOLANT TEMPERATURE SENSOR . 252
FUNCTION OF COOLANT TEMPERATURE SENSOR 252
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR . 252
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR 253
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR . 253
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR 253
STRUCTURE OF COMMON RAIL PRESSURE SENSOR 254
FUNCTION OF COMMON RAIL PRESSURE SENSOR . 254
STRUCTURE OF EGR VALVE LIFT SENSOR 254
FUNCTION OF EGR VALVE LIFT SENSOR . 254
STRUCTURE OF VGT SPEED SENSOR . 255
FUNCTION OF KVGT SPEED SENSOR . 255
STRUCTURE OF KVGT POSITION SENSOR . 255
FUNCTION OF KVGT POSITION SENSOR 256
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR . 256
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR 257
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR . 257
STRUCTURE OF CRANKCASE PRESSURE SENSOR 257
FUNCTION OF CRANKCASE PRESSURE SENSOR . 258
STRUCTURE OF ENGINE OIL LEVEL SENSOR 258
STRUCTURE OF AIR CLEANER CLOGGING SENSOR 258
FUNCTION OF AIR CLEANER CLOGGING SENSOR . 259
STRUCTURE OF WATER-IN-FUEL SENSOR . 259
FUNCTION OF WATER-IN-FUEL SENSOR 259
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 259
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 260
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH . 260
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 260
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 261
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 261
STRUCTURE OF OVERLOAD CAUTION SENSOR 261
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 261
FUNCTION OF OVERLOAD CAUTION SENSOR . 261
HYDRAULIC SYSTEM 262
LAYOUT DRAWING OF HYDRAULIC SYSTEM 262
CLSS 268
STRUCTURE OF CLSS . 268
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 270
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 271
PRESSURE COMPENSATION CONTROL . 284
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 287
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 287
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 288
PUMP AND VALVE CONTROL SYSTEM . 293
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 293
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 294
COMPONENT PARTS OF HYDRAULIC SYSTEM . 296
HYDRAULIC TANK 296
MAIN PUMP . 298
PC-EPC VALVE 322
PILOT OIL FILTER 324
CONTROL VALVE . 324
WORK EQUIPMENT SYSTEM . 381
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 381
STRUCTURE OF VALVE CONTROL 386
ONE-TOUCH POWER MAXIMIZING SYSTEM . 388
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 388
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 389
PPC LOCK SYSTEM . 390
PPC LOCK SYSTEM DIAGRAM . 390
FUNCTION OF PPC LOCK SYSTEM . 390
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 391
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 391
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 391
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 392
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 393
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 393
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 395
TOOL CONTROL SYSTEM . 396
TOOL CONTROL SYSTEM DIAGRAM . 396
FUNCTION OF TOOL CONTROL SYSTEM . 397
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 398
WORK EQUIPMENT AND SWING PPC VALVE 398
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 403
SOLENOID VALVE 409
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 412
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 414
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE . 417
2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE . 419
ATTACHMENT BYPASS SOLENOID VALVE 422
ATT EPC VALVE ASSEMBLY 424
PILOT CIRCUIT ACCUMULATOR . 425
ATTACHMENT CIRCUIT ACCUMULATOR 426
SWING SYSTEM 427
LAYOUT DRAWING OF SWING SYSTEM 427
SWING CONTROL SYSTEM DIAGRAM 431
FUNCTION OF SWING CONTROL SYSTEM 431
COMPONENT PARTS OF SWING SYSTEM . 435
SWING MOTOR . 435
SWING MACHINERY . 447
SWING CIRCLE 448
TRAVEL SYSTEM . 450
LAYOUT DRAWING OF TRAVEL SYSTEM . 450
TRAVEL CONTROL SYSTEM DIAGRAM . 454
FUNCTION OF TRAVEL CONTROL SYSTEM . 454
COMPONENT PARTS OF TRAVEL SYSTEM 456
TRAVEL MOTOR 456
FINAL DRIVE . 468
TRAVEL PPC VALVE 470
CENTER SWIVEL JOINT . 475
UNDERCARRIAGE AND FRAME . 477
LAYOUT DRAWING OF UNDERCARRIAGE . 477
SPECIFICATIONS OF UNDERCARRIAGE . 478
WORK EQUIPMENT 479
STRUCTURE OF WORK EQUIPMENT . 479
FUNCTION OF WORK EQUIPMENT 480
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 481
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 481
BUCKET CLEARANCE ADJUSTMENT SHIM 482
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 482
CAB AND ITS ATTACHMENTS . 483
ROPS CAB 483
STRUCTURE OF ROPS CAB . 483
FUNCTION OF ROPS CAB 483
CAB MOUNT . 484
STRUCTURE OF CAB MOUNT 484
FUNCTION OF CAB MOUNT . 484
CAB TIPPING STOPPER . 485
STRUCTURE OF CAB TIPPING STOPPER 485
FUNCTION OF CAB TIPPING STOPPER . 485
20 STANDARD VALUE TABLE . 487
CONTENTS 488
ABBREVIATION LIST . 489
STANDARD VALUE TABLE FOR ENGINE . 495
STANDARD VALUE TABLE FOR ENGINE: PC240LC-11E0, PC240NLC-11E0 495
STANDARD VALUE TABLE FOR MACHINE 499
STANDARD VALUE TABLE FOR MACHINE: PC240LC-11E0, PC240NLC-11E0 . 499
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 513
STANDARD VALUE TABLE FOR ELECTRICAL . 517
STANDARD VALUE TABLE FOR ELECTRICAL . 517
30 TESTING AND ADJUSTING 527
CONTENTS 528
ABBREVIATION LIST . 531
RELATED INFORMATION ON TESTING AND ADJUSTING 537
TOOLS FOR TESTING AND ADJUSTING . 537
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 544
ENGINE AND COOLING SYSTEM . 546
TEST ENGINE SPEED . 546
METHOD FOR TESTING ENGINE SPEED . 546
TEST BOOST PRESSURE . 549
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 549
METHOD FOR TESTING BOOST PRESSURE . 550
TEST EXHAUST GAS COLOR 551
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 551
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 552
TEST AND ADJUST VALVE CLEARANCE . 554
METHOD FOR TESTING VALVE CLEARANCE 554
METHOD FOR ADJUSTING VALVE CLEARANCE 555
TEST COMPRESSION PRESSURE . 557
METHOD FOR TESTING COMPRESSION PRESSURE . 557
TEST BLOWBY PRESSURE 562
METHOD FOR TESTING BLOWBY PRESSURE 562
TEST ENGINE OIL PRESSURE 564
METHOD FOR TESTING ENGINE OIL PRESSURE 564
TEST EGR VALVE AND VGT OIL PRESSURE . 565
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 565
TEST FUEL PRESSURE 567
METHOD FOR TESTING FUEL PRESSURE 568
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 573
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 574
BLEEDING AIR FROM FUEL SYSTEM . 580
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 580
TEST FUEL CIRCUIT FOR LEAKAGE . 581
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 581
HANDLE CYLINDER CUT-OUT MODE OPERATION 583
HANDLE NO-INJECTION CRANKING OPERATION 584
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 585
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 585
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 585
TEST FAN BELT AND ALTERNATOR BELT . 587
METHOD FOR TESTING FAN BELT AND ALTERNATOR BELT . 587
TEST AUTO-TENSIONER . 588
METHOD FOR TESTING AUTO-TENSIONER . 588
REPLACING FAN BELT 589
METHOD FOR REPLACING FAN BELT . 589
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 590
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 590
TEST SCR RELATED FUNCTIONS 591
TEST AdBlue/DEF PUMP RAISED PRESSURE 594
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 597
TEST AdBlue/DEF LINE HEATER RELAY 1 . 601
TEST AdBlue/DEF LINE HEATER RELAY 2 . 604
TEST AdBlue/DEF PUMP HEATER RELAY . 606
TEST AdBlue/DEF TANK HEATER VALVE . 609
TEST DENITRATION EFFICIENCY OF SCR 612
CLEAN AdBlue/DEF TANK . 616
METHOD FOR CLEANING AdBlue/DEF TANK . 616
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 620
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 620
POWER TRAIN . 622
TEST SWING CIRCLE BEARING CLEARANCE . 622
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 622
UNDERCARRIAGE AND FRAME . 623
TEST AND ADJUST TRACK TENSION . 623
METHOD FOR TESTING TRACK TENSION 623
METHOD FOR ADJUSTING TRACK TENSION 623
HYDRAULIC SYSTEM 625
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 625
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK . 625
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT . 625
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 631
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 632
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 638
TEST OIL PRESSURE OF CONTROL CIRCUIT 641
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 641
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 643
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 643
TEST PC-EPC VALVE OUTLET PRESSURE . 644
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 645
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 647
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 647
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 648
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 651
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 652
METHOD FOR ADJUSTING LS VALVE . 653
TEST OUTLET PRESSURE OF SOLENOID VALVE 654
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 654
OPERATING CONDITION OF SOLENOID VALVE . 655
TEST PPC VALVE OUTLET PRESSURE 658
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 658
TEST ATTACHMENT CIRCUIT OIL PRESSURE 660
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 660
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 662
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 662
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 663
TEST PUMP SWASH PLATE SENSOR 665
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 665
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 666
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 666
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 666
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 667
TEST OIL LEAKAGE 668
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 668
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 668
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 669
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 670
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 670
BLEED AIR FROM HYDRAULIC CIRCUIT 671
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 673
CAB AND ITS ATTACHMENTS . 675
TEST CAB TIPPING STOPPER 675
METHOD FOR TESTING CAB TIPPING STOPPER 675
METHOD FOR ADJUSTING MIRRORS 676
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 676
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 677
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 678
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 679
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 680
ELECTRICAL SYSTEM . 682
ELECTRICAL SYSTEM . 683
SET AND OPERATE MACHINE MONITOR . 683
OPERATOR MODE . 686
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 687
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 687
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 688
CHECKING FUNCTION OF SERVICE METER 688
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 688
SERVICE MODE 691
SERVICE MODE 691
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 693
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 699
ABNORMALITY RECORD MENU . 710
METHOD FOR CONFIRMING MAINTENANCE RECORD 715
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 716
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 720
DEFAULT MENU 721
DIAGNOSTIC TESTS MENU . 732
ADJUSTMENT MENU . 742
METHOD FOR PERFORMING NO-INJECTION CRANKING . 776
KOMTRAX SETTINGS MENU . 777
METHOD FOR DISPLAYING SERVICE MESSAGE . 779
METHOD FOR STARTING UP KOMTRAX TERMINAL . 781
ADJUST REARVIEW CAMERA ANGLE 786
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 786
ADJUST KomVision CAMERA ANGLE . 789
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 790
ADJUST KomVision RELATED ITEMS 794
SETTING OF KomVision (MAIN SETTING) . 794
SETTING OF KomVision (CAMERA SETTING) . 796
SETTING OF KomVision (CAMERA CALIBRATION) . 798
KomVision screen – Check 12 m visibility 811
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 814
HANDLE BATTERY DISCONNECT SWITCH 815
TEST DIODES . 816
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 816
METHOD FOR TESTING DIODE USING ANALOG TESTER 816
Pm CLINIC . 817
Pm CLINIC SERVICE . 817
Pm CLINIC CHECK SHEET . 821
40 TROUBLESHOOTING 831
CONTENTS 832
ABBREVIATION LIST . 843
RELATED INFORMATION ON TROUBLESHOOTING 849
GENERAL TROUBLESHOOTING POINTS 849
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 850
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 862
CHECKS BEFORE TROUBLESHOOTING . 864
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 866
WALK-AROUND CHECK . 866
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 868
CHECK FUEL LEVEL AND TYPE . 868
CHECK IMPURE INGREDIENT IN FUEL . 868
CHECK FUEL PREFILTER 869
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 869
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 870
CHECK MAIN FILTER . 871
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 873
CHECK COOLANT LEVEL (RESERVOIR TANK) 874
CHECK CLOGGING OF AIR CLEANER . 874
OUTER ELEMENT – CLEAN . 875
ELEMENTS – REPLACE 877
CHECK HYDRAULIC OIL LEVEL . 878
CHECK HYDRAULIC OIL STRAINER 879
CHECK HYDRAULIC FILTER 880
CHECK OIL LEVEL IN SWING MACHINERY CASE . 881
CHECK OIL LEVEL IN DAMPER CASE 882
CHECK OIL LEVEL IN FINAL DRIVE CASE . 882
BLEED AIR FROM FUEL SYSTEM 883
BLEED AIR FROM HYDRAULIC SYSTEM . 883
ELECTRICAL EQUIPMENT – CHECK METHOD . 883
AUTOMATIC GREASE SYSTEM . 891
FINDING MALFUNCTIONS 891
MALFUNCTION FINDING PROCEDURES 893
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM . 895
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 905
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 908
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 912
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 914
CONNECTOR LIST AND LAYOUT . 917
CONNECTOR CONTACT IDENTIFICATION 930
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 970
FUSE LOCATION TABLE . 976
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 978
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 982
FAILURE CODE TABLE 984
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .1002
FAILURE CODE [879AKA] .1002
FAILURE CODE [879AKB] .1003
FAILURE CODE [879BKA] .1004
FAILURE CODE [879BKB] .1006
FAILURE CODE [879CKA] .1008
FAILURE CODE [879CKB] .1009
FAILURE CODE [879DKZ] .1010
FAILURE CODE [879EMC] .1012
FAILURE CODE [879FMC] .1013
FAILURE CODE [879GKX] .1014
FAILURE CODE [989L00] .1016
FAILURE CODE [989M00] .1017
FAILURE CODE [989N00] .1018
FAILURE CODE [A1U0N3] .1019
FAILURE CODE [A1U0N4] .1021
FAILURE CODE [A900FR] .1023
FAILURE CODE [A900N6] .1024
FAILURE CODE [A900NY] .1025
FAILURE CODE [AA10NX] .1026
FAILURE CODE [AB00KE] .1028
FAILURE CODE [AQ10N3] .1031
FAILURE CODE [AS00N3] .1033
FAILURE CODE [AS00R2] .1035
FAILURE CODE [AS00R3] .1036
FAILURE CODE [AS00R4] .1037
FAILURE CODE [AS00R5] .1038
FAILURE CODE [AS00R6] .1039
FAILURE CODE [AS00ZK] .1040
FAILURE CODE [AS10KM] .1041
FAILURE CODE [AS10NR] .1042
FAILURE CODE [AS10NT] .1043
FAILURE CODE [B@BAZG] .1044
FAILURE CODE [B@BAZK] .1045
FAILURE CODE [B@BCNS] .1047
FAILURE CODE [B@BCQA] .1048
FAILURE CODE [B@BCZK] .1050
FAILURE CODE [B@HANS] .1052
FAILURE CODE [CA115] 1053
FAILURE CODE [CA122] 1054
FAILURE CODE [CA123] 1056
FAILURE CODE [CA131] 1058
FAILURE CODE [CA132] 1060
FAILURE CODE [CA144] 1062
FAILURE CODE [CA145] 1064
FAILURE CODE [CA153] 1066
FAILURE CODE [CA154] 1069
FAILURE CODE [CA187] 1071
FAILURE CODE [CA221] 1073
FAILURE CODE [CA222] 1075
FAILURE CODE [CA227] 1077
FAILURE CODE [CA234] 1078
FAILURE CODE [CA238] 1079
FAILURE CODE [CA239] 1081
FAILURE CODE [CA249] 1083
FAILURE CODE [CA256] 1085
FAILURE CODE [CA271] 1087
FAILURE CODE [CA272] 1089
FAILURE CODE [CA322] 1091
FAILURE CODE [CA323] 1093
FAILURE CODE [CA324] 1095
FAILURE CODE [CA325] 1097
FAILURE CODE [CA331] 1099
FAILURE CODE [CA332] 1101
FAILURE CODE [CA343] 1103
FAILURE CODE [CA351] 1104
FAILURE CODE [CA352] 1105
FAILURE CODE [CA356] 1108
FAILURE CODE [CA357] 1110
FAILURE CODE [CA386] 1112
FAILURE CODE [CA428] 1113
FAILURE CODE [CA429] 1115
FAILURE CODE [CA435] 1117
FAILURE CODE [CA441] 1119
FAILURE CODE [CA442] 1121
FAILURE CODE [CA449] 1122
FAILURE CODE [CA451] 1123
FAILURE CODE [CA452] 1125
FAILURE CODE [CA488] 1127
FAILURE CODE [CA515] 1128
FAILURE CODE [CA516] 1130
FAILURE CODE [CA553] 1132
FAILURE CODE [CA555] 1133
FAILURE CODE [CA556] 1134
FAILURE CODE [CA559] 1135
FAILURE CODE [CA595] 1138
FAILURE CODE [CA687] 1139
FAILURE CODE [CA689] 1141
FAILURE CODE [CA691] 1144
FAILURE CODE [CA692] 1146
FAILURE CODE [CA697] 1148
FAILURE CODE [CA698] 1149
FAILURE CODE [CA731] 1150
FAILURE CODE [CA778] 1152
FAILURE CODE [CA1117] .1157
FAILURE CODE [CA1664] .1158
FAILURE CODE [CA1669] .1160
FAILURE CODE [CA1673] .1161
FAILURE CODE [CA1677] .1162
FAILURE CODE [CA1678] .1163
FAILURE CODE [CA1682] .1164
FAILURE CODE [CA1683] .1166
FAILURE CODE [CA1684] .1168
FAILURE CODE [CA1686] .1170
FAILURE CODE [CA1691] .1171
FAILURE CODE [CA1694] .1174
FAILURE CODE [CA1695] .1177
FAILURE CODE [CA1696] .1178
FAILURE CODE [CA1712] .1180
FAILURE CODE [CA1713] .1183
FAILURE CODE [CA1714] .1185
FAILURE CODE [CA1715] .1186
FAILURE CODE [CA1776] .1187
FAILURE CODE [CA1777] .1190
FAILURE CODE [CA1843] .1193
FAILURE CODE [CA1844] .1195
FAILURE CODE [CA1879] .1198
FAILURE CODE [CA1881] .1200
FAILURE CODE [CA1883] .1202
FAILURE CODE [CA1885] .1205
FAILURE CODE [CA1887] .1207
FAILURE CODE [CA1921] .1209
FAILURE CODE [CA1922] .1212
FAILURE CODE [CA1942] .1217
FAILURE CODE [CA1993] .1218
FAILURE CODE [CA2185] .1221
FAILURE CODE [CA2186] .1222
FAILURE CODE [CA2249] .1224
FAILURE CODE [CA2271] .1225
FAILURE CODE [CA2272] .1228
FAILURE CODE [CA2288] .1231
FAILURE CODE [CA2311] .1232
FAILURE CODE [CA2349] .1233
FAILURE CODE [CA2353] .1236
FAILURE CODE [CA2357] .1238
FAILURE CODE [CA2381] .1239
FAILURE CODE [CA2382] .1242
FAILURE CODE [CA2383] .1245
FAILURE CODE [CA2386] .1248
FAILURE CODE [CA2387] .1250
FAILURE CODE [CA2555] .1251
FAILURE CODE [CA2556] .1254
FAILURE CODE [CA2637] .1257
FAILURE CODE [CA2639] .1259
FAILURE CODE [CA2771] .1262
FAILURE CODE [CA2777] .1268
FAILURE CODE [CA2976] .1271
FAILURE CODE [CA3133] .1273
FAILURE CODE [CA3134] .1276
FAILURE CODE [CA3135] .1278
FAILURE CODE [CA3142] .1281
FAILURE CODE [CA3143] .1282
FAILURE CODE [CA3144] .1283
FAILURE CODE [CA3146] .1285
FAILURE CODE [CA3147] .1286
FAILURE CODE [CA3148] .1287
FAILURE CODE [CA3151] .1289
FAILURE CODE [CA3165] .1295
FAILURE CODE [CA3229] .1297
FAILURE CODE [CA3231] .1299
FAILURE CODE [CA3232] .1301
FAILURE CODE [CA3235] .1305
FAILURE CODE [CA3239] .1307
FAILURE CODE [CA3241] .1310
FAILURE CODE [CA3242] .1313
FAILURE CODE [CA3251] .1316
FAILURE CODE [CA3253] .1318
FAILURE CODE [CA3254] .1321
FAILURE CODE [CA3255] .1324
FAILURE CODE [CA3256] .1328
FAILURE CODE [CA3311] .1330
FAILURE CODE [CA3312] .1332
FAILURE CODE [CA3313] .1335
FAILURE CODE [CA3314] .1336
FAILURE CODE [CA3315] .1337
FAILURE CODE [CA3316] .1339
FAILURE CODE [CA3317] .1340
FAILURE CODE [CA3318] .1341
FAILURE CODE [CA3319] .1343
FAILURE CODE [CA3321] .1344
FAILURE CODE [CA3322] .1346
FAILURE CODE [CA3419] .1348
FAILURE CODE [CA3421] .1350
FAILURE CODE [CA3497] .1352
FAILURE CODE [CA3498] .1353
FAILURE CODE [CA3543] .1354
FAILURE CODE [CA3545] .1361
FAILURE CODE [CA3547] .1363
FAILURE CODE [CA3558] .1364
FAILURE CODE [CA3559] .1366
FAILURE CODE [CA3562] .1368
FAILURE CODE [CA3563] .1370
FAILURE CODE [CA3567] .1373
FAILURE CODE [CA3568] .1376
FAILURE CODE [CA3571] .1380
FAILURE CODE [CA3572] .1382
FAILURE CODE [CA3574] .1384
FAILURE CODE [CA3575] .1386
FAILURE CODE [CA3577] .1388
FAILURE CODE [CA3578] .1390
FAILURE CODE [CA3582] .1392
FAILURE CODE [CA3583] .1398
FAILURE CODE [CA3596] .1400
FAILURE CODE [CA3649] .1402
FAILURE CODE [CA3681] .1404
FAILURE CODE [CA3682] .1409
FAILURE CODE [CA3713] .1415
FAILURE CODE [CA3717] .1418
FAILURE CODE [CA3718] .1419
FAILURE CODE [CA3725] .1420
FAILURE CODE [CA3741] .1423
FAILURE CODE [CA3748] .1424
FAILURE CODE [CA3751] .1426
FAILURE CODE [CA3755] .1428
FAILURE CODE [CA3866] .1430
FAILURE CODE [CA3867] .1434
FAILURE CODE [CA3868] .1437
FAILURE CODE [CA3899] .1441
FAILURE CODE [CA3911] .1443
FAILURE CODE [CA3912] .1447
FAILURE CODE [CA3932] .1449
FAILURE CODE [CA3933] .1451
FAILURE CODE [CA3934] .1453
FAILURE CODE [CA3935] .1456
FAILURE CODE [CA3936] .1458
FAILURE CODE [CA4151] .1460
FAILURE CODE [CA4152] .1464
FAILURE CODE [CA4155] .1468
FAILURE CODE [CA4156] .1470
FAILURE CODE [CA4157] .1473
FAILURE CODE [CA4158] .1475
FAILURE CODE [CA4159] .1476
FAILURE CODE [CA4161] .1477
FAILURE CODE [CA4162] .1480
FAILURE CODE [CA4163] .1483
FAILURE CODE [CA4164] .1484
FAILURE CODE [CA4165] .1486
FAILURE CODE [CA4166] .1488
FAILURE CODE [CA4168] .1489
FAILURE CODE [CA4169] .1492
FAILURE CODE [CA4171] .1494
FAILURE CODE [CA4249] .1497
FAILURE CODE [CA4251] .1499
FAILURE CODE [CA4259] .1501
FAILURE CODE [CA4261] .1504
FAILURE CODE [CA4277] .1507
FAILURE CODE [CA4281] .1511
FAILURE CODE [CA4459] .1514
FAILURE CODE [CA4461] .1517
FAILURE CODE [CA4658] .1520
FAILURE CODE [CA4731] .1524
FAILURE CODE [CA4732] .1525
FAILURE CODE [CA4739] .1526
FAILURE CODE [CA4768] .1527
FAILURE CODE [CA4769] .1529
FAILURE CODE [CA4842] .1532
FAILURE CODE [CA4952] .1536
FAILURE CODE [CA5115] .1538
FAILURE CODE [CA5179] .1541
FAILURE CODE [CA5181] .1543
FAILURE CODE [CA5383] .1545
FAILURE CODE [D110KB] .1547
FAILURE CODE [D19JKZ] .1549
FAILURE CODE [D811MC] .1552
FAILURE CODE [D862KA] .1553
FAILURE CODE [D8ALKA] .1554
FAILURE CODE [D8ALKB] .1556
FAILURE CODE [D8AQKR] .1558
FAILURE CODE [D8G1KT] .1560
FAILURE CODE [D8G6KT] .1561
FAILURE CODE [DA20MC] .1562
FAILURE CODE [DA22KK] .1563
FAILURE CODE [DA25KP] .1566
FAILURE CODE [DA26KP] .1569
FAILURE CODE [DA29KQ] .1572
FAILURE CODE [DA2LKA] .1574
FAILURE CODE [DA2LKB] .1576
FAILURE CODE [DA2QKR] .1578
FAILURE CODE [DA2RKR] .1581
FAILURE CODE [DAF0KM] .1582
FAILURE CODE [DAF0MB] .1583
FAILURE CODE [DAF0MC] .1584
FAILURE CODE [DAF8KB] .1585
FAILURE CODE [DAF9KQ] .1587
FAILURE CODE [DAFGMC] .1588
FAILURE CODE [DAFLKA] .1589
FAILURE CODE [DAFLKB] .1591
FAILURE CODE [DAFQKR] .1593
FAILURE CODE [DAZ9KQ] .1594
FAILURE CODE [DAZQKR] .1595
FAILURE CODE [DB2QKR] .1600
FAILURE CODE [DB2RKR] .1605
FAILURE CODE [DBP0KM] .1610
FAILURE CODE [DBP0KT] .1611
FAILURE CODE [DBP5KB] .1612
FAILURE CODE [DBP5KY] .1615
FAILURE CODE [DBPQKR] .1618
FAILURE CODE [DDNRKA] .1623
FAILURE CODE [DDNRKY] .1625
FAILURE CODE [DDNS00] .1627
FAILURE CODE [DFB1KZ] .1629
FAILURE CODE [DFB2KZ] .1631
FAILURE CODE [DFB3L8] .1633
FAILURE CODE [DFB4L8] .1635
FAILURE CODE [DFB5KZ] .1637
FAILURE CODE [DFB6KZ] .1639
FAILURE CODE [DGH2KA] .1641
FAILURE CODE [DGH2KB] .1643
FAILURE CODE [DHA4KA] .1645
FAILURE CODE [DHAAMA] .1647
FAILURE CODE [DHACMA] .1649
FAILURE CODE [DHPAMA] .1651
FAILURE CODE [DHPBMA] .1654
FAILURE CODE [DHS3MA] .1657
FAILURE CODE [DHS4MA] .1660
FAILURE CODE [DHS8MA] .1663
FAILURE CODE [DHS9MA] .1666
FAILURE CODE [DHSAMA] .1669
FAILURE CODE [DHSBMA] .1672
FAILURE CODE [DHSCMA] .1675
FAILURE CODE [DHSDMA] .1678
FAILURE CODE [DHSFMA] .1681
FAILURE CODE [DHSGMA] .1684
FAILURE CODE [DHSHMA] .1687
FAILURE CODE [DHSJMA] .1690
FAILURE CODE [DHX1MA] .1693
FAILURE CODE [DHZAMA] .1696
FAILURE CODE [DHZCL8] .1700
FAILURE CODE [DKR0MA] .1701
FAILURE CODE [DKR1MA] .1704
FAILURE CODE [DKULKA] .1707
FAILURE CODE [DKULKB] .1709
FAILURE CODE [DKULKY] .1711
FAILURE CODE [DR10KA] .1713
FAILURE CODE [DR12KA] .1716
FAILURE CODE [DR20KA] .1718
FAILURE CODE [DR21KX] .1720
FAILURE CODE [DR30KA] .1722
FAILURE CODE [DR31KX] .1724
FAILURE CODE [DR40KA] .1726
FAILURE CODE [DUMBKA] .1728
FAILURE CODE [DUMBKB] .1730
FAILURE CODE [DV00KA] .1732
FAILURE CODE [DV00KB] .1733
FAILURE CODE [DV20KB] .1734
FAILURE CODE [DW43KA] .1736
FAILURE CODE [DW43KB] .1738
FAILURE CODE [DW43KY] .1740
FAILURE CODE [DW45KA] .1742
FAILURE CODE [DW45KB] .1745
FAILURE CODE [DW45KY] .1748
FAILURE CODE [DW4CKY] .1750
FAILURE CODE [DW91KA] .1752
FAILURE CODE [DW91KB] .1754
FAILURE CODE [DW91KY] .1756
FAILURE CODE [DWA2KA] .1758
FAILURE CODE [DWA2KB] .1760
FAILURE CODE [DWA2KY] .1762
FAILURE CODE [DWK0KA] .1764
FAILURE CODE [DWK0KB] .1766
FAILURE CODE [DWK0KY] .1768
FAILURE CODE [DWK2KA] .1770
FAILURE CODE [DWK2KB] .1772
FAILURE CODE [DWK2KY] .1774
FAILURE CODE [DWK8KA] .1776
FAILURE CODE [DWK8KB] .1778
FAILURE CODE [DWK8KY] .1780
FAILURE CODE [DWPUKA] .1782
FAILURE CODE [DWPUKB] .1784
FAILURE CODE [DXA8KA] .1786
FAILURE CODE [DXA8KB] .1788
FAILURE CODE [DXA9KA] .1790
FAILURE CODE [DXA9KB] .1792
FAILURE CODE [DXE0KA] .1794
FAILURE CODE [DXE0KB] .1795
FAILURE CODE [DXE4KA] .1797
FAILURE CODE [DXE4KB] .1799
FAILURE CODE [DXE4KY] .1801
FAILURE CODE [DXE5KA] .1803
FAILURE CODE [DXE5KB] .1805
FAILURE CODE [DXE6KA] .1807
FAILURE CODE [DXE6KB] .1809
FAILURE CODE [DXE7KA] .1811
FAILURE CODE [DXE7KB] .1813
FAILURE CODE [DXE7KY] .1815
FAILURE CODE [DXE8KA] .1817
FAILURE CODE [DXE8KB] .1819
FAILURE CODE [DXE8KY] .1821
FAILURE CODE [DXE9KA] .1823
FAILURE CODE [DXE9KB] .1825
FAILURE CODE [DXE9KY] .1827
FAILURE CODE [DXEAKA] .1829
FAILURE CODE [DXEAKB] .1831
FAILURE CODE [DXEAKY] .1833
FAILURE CODE [DXEKKA] .1835
FAILURE CODE [DXEKKB] .1837
FAILURE CODE [DXEKKY] .1839
FAILURE CODE [DXELKA] .1841
FAILURE CODE [DXELKB] .1843
FAILURE CODE [DXELKY] .1845
FAILURE CODE [DY20KA] .1847
FAILURE CODE [DY20MA] .1849
FAILURE CODE [DY2CKB] .1851
FAILURE CODE [DY2DKB] .1854
FAILURE CODE [DY2EKB] .1856
FAILURE CODE [F313KA] .1858
FAILURE CODE [F313KB] .1860
FAILURE CODE [F318KB] .1863
FAILURE CODE [F318KY] .1866
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1868
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1868
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1874
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1877
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1879
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1881
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1884
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1885
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1886
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1887
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1888
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1889
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1890
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1891
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1892
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1893
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1894
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1895
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1897
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1898
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1899
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1900
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1902
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1903
E-24 FUNCTION SWITCH DOES NOT OPERATE .1904
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1905
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1906
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1907
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1908
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1909
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1910
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1911
E-32 ALARM BUZZER CANNOT BE CANCELED 1913
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1914
E-34 SERVICE MODE CANNOT BE SELECTED 1915
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1916
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1919
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1921
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1924
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1926
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1929
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1930
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1932
E-43 HORN DOES NOT SOUND 1933
E-44 HORN DOES NOT STOP SOUNDING 1936
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1938
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1939
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1941
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1942
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1943
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1944
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1945
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1946
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1947
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1948
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1949
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1950
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1952
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1953
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1954
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1954
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1955
FAILURE MODE AND CAUSE TABLE 1957
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1966
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1967
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1970
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1971
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1972
H-6 SPEED OR POWER OF BOOM IS LOW .1974
H-7 ARM SPEED OR POWER IS LOW .1978
H-8 BUCKET SPEED OR POWER IS LOW 1983
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1986
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1987
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1989
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .1991
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .1992
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1993
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1994
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1995
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .1996
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1997
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1998
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1999
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .2000
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .2002
H-23 TRAVEL SPEED IS LOW 2005
H-24 ONE OF TRACKS DOES NOT RUN .2007
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2008
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 2009
H-27 SWINGS ONLY IN ONE DIRECTION .2010
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .2011
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 2012
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 2013
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 2014
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .2015
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .2016
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .2017
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2018
H-36 Quick coupler cylinder will not extend .2019
H-37 Quick coupler cylinder will not retract (but buzzer doesnot sound) .2021
H-38 Buzzer does not sound (but quick coupler cylinder doesretract) .2023
H-39 Quick coupler cylinder extends and retracts slowly .2025
TROUBLESHOOTING OF ENGINE (S-MODE) 2026
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .2026
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2027
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2028
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2029
S-4 ENGINE STARTABILITY IS POOR .2031
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2033
S-6 ENGINE STOPS DURING OPERATION .2035
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2037
S-8 ENGINE LACKS POWER 2038
S-9 KDPF GETS CLOGGED IN A SHORT TIME .2040
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2042
S-11 OIL BECOMES CONTAMINATED QUICKLY .2043
S-12 FUEL CONSUMPTION IS EXCESSIVE 2044
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2045
S-14 OIL PRESSURE DROPS .2046
S-15 FUEL MIXES INTO ENGINE OIL .2048
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2049
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2050
S-18 UNUSUAL NOISE IS HEARD .2051
S-19 VIBRATION IS EXCESSIVE .2052
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .2053
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2054
S-22 ACTIVE REGENERATION TAKES TIME .2056
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2057
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2058
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2060
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2061
50 DISASSEMBLY AND ASSEMBLY .2063
CONTENTS 2064
ABBREVIATION LIST .2069
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2075
HOW TO READ THIS MANUAL .2075
COATING MATERIALS LIST 2077
SPECIAL TOOLS LIST 2082
SKETCHES OF SPECIAL TOOLS .2094
ENGINE AND COOLING SYSTEM .2100
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2100
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2100
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2103
REMOVE AND INSTALL INJECTOR ASSEMBLY 2107
METHOD FOR REMOVING INJECTOR ASSEMBLY .2107
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2112
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2120
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2121
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2130
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2146
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2146
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2147
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2150
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2150
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2153
REMOVE AND INSTALL STARTER ASSEMBLY .2158
METHOD FOR REMOVING STARTER ASSEMBLY 2158
METHOD FOR INSTALLING STARTER ASSEMBLY 2160
REMOVE AND INSTALL ALTERNATOR BELT 2162
METHOD FOR REMOVING ALTERNATOR BELT .2162
METHOD FOR INSTALLING ALTERNATOR BELT .2164
REMOVE AND INSTALL RADIATOR ASSEMBLY 2166
METHOD FOR REMOVING RADIATOR ASSEMBLY .2166
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2168
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2170
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2170
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2173
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2176
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2176
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2177
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2179
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2180
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2188
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2199
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2199
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2202
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2206
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2206
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2207
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2210
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2210
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2211
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2212
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2212
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2214
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2220
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2220
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2224
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2230
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2230
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2235
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2241
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2241
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2246
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2252
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2252
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2252
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2259
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2259
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2259
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2261
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2261
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2263
REMOVE AND INSTALL KDPF ASSEMBLY 2266
METHOD FOR REMOVING KDPF ASSEMBLY .2266
METHOD FOR INSTALLING KDPF ASSEMBLY .2268
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2270
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2271
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2274
REMOVE AND INSTALL SCR ASSEMBLY .2279
METHOD FOR REMOVING SCR ASSEMBLY 2279
METHOD FOR INSTALLING SCR ASSEMBLY 2281
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2283
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2283
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2289
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2295
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2295
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2301
REMOVE AND INSTALL KCCV ASSEMBLY 2308
METHOD FOR REMOVING KCCV ASSEMBLY .2308
METHOD FOR INSTALLING KCCV ASSEMBLY .2311
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2315
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2315
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2320
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2325
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2325
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2327
REMOVE AND INSTALL AdBlue/DEF PUMP 2329
METHOD FOR REMOVING AdBlue/DEF PUMP .2329
METHOD FOR INSTALLING AdBlue/DEF PUMP .2331
REMOVE AND INSTALL AdBlue/DEF HOSE 2334
METHOD FOR REMOVING AdBlue/DEF HOSE .2334
METHOD FOR INSTALLING AdBlue/DEF HOSE .2342
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2348
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2348
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2349
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2351
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2351
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2353
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2356
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2356
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2357
POWER TRAIN .2358
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2358
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2358
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2359
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2361
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2361
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2365
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2374
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2374
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2377
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2380
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2380
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2384
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2391
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2391
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2391
UNDERCARRIAGE AND FRAME .2393
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2393
METHOD FOR SEPARATING TRACK ASSEMBLY 2393
METHOD FOR INSTALLING TRACK ASSEMBLY 2395
REMOVE AND INSTALL SPROCKET .2398
METHOD FOR REMOVING SPROCKET 2398
METHOD FOR INSTALLING SPROCKET 2398
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2400
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2400
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2401
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2402
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2402
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2403
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2407
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2408
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2409
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2410
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2411
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2412
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2414
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2414
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2416
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2418
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2418
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2420
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2423
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2423
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2426
HYDRAULIC SYSTEM 2430
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2430
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2430
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2432
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2435
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2436
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2437
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2438
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2438
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2441
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2445
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2445
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2448
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2452
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2452
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2459
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2467
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2467
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2469
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2473
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2473
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2473
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2475
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2475
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2476
REMOVE AND INSTALL QUICK COUPLER VALVE 2478
WORK EQUIPMENT 2480
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2480
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2480
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2484
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2490
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2490
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2493
CAB AND ITS ATTACHMENTS .2499
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2499
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2499
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2505
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2512
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2514
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2514
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2524
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2524
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2527
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2533
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2533
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2540
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2547
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2547
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2553
REMOVE AND INSTALL OPERATOR’S SEAT 2560
METHOD FOR REMOVING OPERATOR’S SEAT .2560
METHOD FOR INSTALLING OPERATOR’S SEAT .2562
REMOVE AND INSTALL SEAT BELT 2565
METHOD FOR REMOVING SEAT BELT .2565
METHOD FOR INSTALLING SEAT BELT .2566
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2567
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2567
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2572
ELECTRICAL SYSTEM .2581
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2581
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2581
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2583
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2584
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2584
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2588
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2593
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2593
METHOD FOR INSTALLING KomVision CONTROLLER 2594
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2596
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2596
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2599
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2602
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2602
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2603
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2604
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2604
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2605
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2606
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2606
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2607
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2609
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2609
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2611
REMOVE AND INSTALL KomVision CAMERA .2614
METHOD FOR REMOVING KomVision CAMERA 2614
METHOD FOR INSTALLING KomVision CAMERA 2617
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2620
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2620
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2623
60 MAINTENANCE STANDARD .2627
CONTENTS 2628
ABBREVIATION LIST .2629
ENGINE AND COOLING SYSTEM .2635
MAINTENANCE STANDARD OF ENGINE MOUNT 2635
MAINTENANCE STANDARD OF COOLING SYSTEM 2636
POWER TRAIN .2637
MAINTENANCE STANDARD OF SWING CIRCLE 2637
MAINTENANCE STANDARD OF SWING MACHINERY .2638
MAINTENANCE STANDARD OF FINAL DRIVE .2640
MAINTENANCE STANDARD OF SPROCKET 2642
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2643
UNDERCARRIAGE AND FRAME .2645
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2645
MAINTENANCE STANDARD OF IDLER .2647
MAINTENANCE STANDARD OF TRACK ROLLER 2649
MAINTENANCE STANDARD OF CARRIER ROLLER 2650
MAINTENANCE STANDARD OF TRACK SHOE 2651
MAINTENANCE STANDARD OF TRIPLE SHOE .2654
MAINTENANCE STANDARD OF SWAMP SHOE 2655
MAINTENANCE STANDARD OF ROAD LINER 2656
HYDRAULIC SYSTEM 2657
MAINTENANCE STANDARD OF HYDRAULIC TANK 2657
MAINTENANCE STANDARD OF MAIN PUMP .2658
MAINTENANCE STANDARD OF LS-EPC VALVE 2659
MAINTENANCE STANDARD OF PC-EPC VALVE 2660
MAINTENANCE STANDARD OF SWING MOTOR .2661
MAINTENANCE STANDARD OF TRAVEL MOTOR 2664
MAINTENANCE STANDARD OF CONTROL VALVE .2667
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2677
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2680
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2683
MAINTENANCE STANDARD OF EPC VALVE .2684
MAINTENANCE STANDARD OF SOLENOID VALVE 2686
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 2687
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2689
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2690
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2691
WORK EQUIPMENT 2692
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2692
DIMENSION OF ARM 2697
DIMENSIONS OF BUCKET 2699
MAINTENANCE STANDARD OF BOOM CYLINDER .2701
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2702
MAINTENANCE STANDARD OF ARM CYLINDER 2703
MAINTENANCE STANDARD OF BUCKET CYLINDER .2704
80 APPENDIX .2705
CONTENTS 2706
ABBREVIATION LIST .2708
AIR CONDITIONER SYSTEM 2714
PRECAUTIONS FOR REFRIGERANT .2714
AIR CONDITIONER COMPONENT .2715
SPECIFICATIONS OF AIR CONDITIONER .2717
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2718
OUTLINE OF REFRIGERATION CYCLE 2719
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2721
AIR CONDITIONER UNIT 2721
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2721
FUNCTION OF AIR CONDITIONER UNIT 2723
COMPONENT PARTS OF AIR CONDITIONER UNIT .2725
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2726
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2726
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2726
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2726
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2727
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2727
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2727
FUNCTION OF DUAL PRESSURE SWITCH 2728
AIR CONDITIONER CONTROLLER 2729
STRUCTURE OF AIR CONDITIONER CONTROLLER .2729
COMPRESSOR 2730
STRUCTURE OF COMPRESSOR .2730
SPECIFICATIONS OF COMPRESSOR 2730
FUNCTION OF COMPRESSOR 2730
CONDENSER .2731
STRUCTURE OF CONDENSER 2731
SPECIFICATIONS OF CONDENSER .2731
FUNCTION OF CONDENSER .2731
SENSORS FOR AIR CONDITIONER SYSTEM 2733
STRUCTURE OF SUNLIGHT SENSOR 2733
FUNCTION OF SUNLIGHT SENSOR .2733
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2733
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2733
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2735
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2737
AIR CONDITIONER SYSTEM DIAGRAM 2739
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2740
FUNCTION OF AIR CONDITIONER CONTROLLER 2741
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2742
TESTING AIR LEAKAGE (DUCT) 2746
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2746
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2748
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2749
TEST VENT (MODE) CHANGEOVER .2750
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2750
TESTING FRESH/RECIRC AIR CHANGEOVER .2752
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2752
TEST SUNLIGHT SENSOR 2753
METHOD FOR TESTING SUNLIGHT SENSOR 2753
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2754
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2754
TEST RELAYS .2755
METHOD FOR TESTING RELAYS .2755
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2756
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2757
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2760
FAILURE CODE [879AKA] .2762
FAILURE CODE [879AKB] .2763
FAILURE CODE [879BKA] .2764
FAILURE CODE [879BKB] .2766
FAILURE CODE [879CKA] .2768
FAILURE CODE [879CKB] .2769
FAILURE CODE [879DKZ] .2770
FAILURE CODE [879EMC] .2772
FAILURE CODE [879FMC] .2773
FAILURE CODE [879GKX] .2774
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2776
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2778
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2781
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2783
TROUBLESHOOTING USING GAUGE PRESSURE 2785
CONNECTION OF SERVICE TOOL 2788
METHOD FOR CONNECTING SERVICE TOOL 2788
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2790
HANDLE COMPRESSOR OIL .2792
METHOD FOR REPLACING DESICCANT 2794
90 CIRCUIT DIAGRAMS .2797
CONTENTS 2798
ABBREVIATION LIST .2799
HYDRAULIC CIRCUIT DIAGRAM .2805
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2805
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2809
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2811
ELECTRICAL CIRCUIT DIAGRAM 2813
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2813
ELECTRICAL CIRCUIT DIAGRAM (1/9) 2817
ELECTRICAL CIRCUIT DIAGRAM (2/9) 2819
ELECTRICAL CIRCUIT DIAGRAM (3/9) 2821
ELECTRICAL CIRCUIT DIAGRAM (4/9) 2823
ELECTRICAL CIRCUIT DIAGRAM (5/9) 2825
ELECTRICAL CIRCUIT DIAGRAM (6/9) 2827
ELECTRICAL CIRCUIT DIAGRAM (7/9) 2829
ELECTRICAL CIRCUIT DIAGRAM (8/9) 2831
ELECTRICAL CIRCUIT DIAGRAM (9/9) 2833
INDEX 2835 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 . 152
FUNCTION OF BATTERY DISCONNECT SWITCH . 152
ENGINE SYSTEM . 153
LAYOUT DRAWING OF ENGINE SYSTEM . 153
SPECIFICATIONS OF ENGINE SYSTEM . 154
FUNCTION OF ENGINE SYSTEM . 154
ENGINE CONTROL SYSTEM . 155
ENGINE CONTROL SYSTEM DIAGRAM . 155
FUNCTION OF ENGINE CONTROL SYSTEM . 156
AUTO-DECELERATION SYSTEM 158
AUTO-DECELERATION SYSTEM DIAGRAM 158
FUNCTION OF AUTO-DECELERATION SYSTEM 158
OPERATION OF AUTO-DECELERATION SYSTEM . 159
ENGINE AUTOMATIC WARM-UP SYSTEM . 160
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 160
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 161
OVERHEAT PREVENTION SYSTEM 162
OVERHEAT PREVENTION SYSTEM DIAGRAM 162
FUNCTION OF OVERHEAT PREVENTION SYSTEM 163
TURBOCHARGER PROTECTION SYSTEM 165
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 165
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 166
AUTOMATIC IDLE STOP SYSTEM 167
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 167
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 167
COMPONENT PARTS OF ENGINE SYSTEM 170
VGT . 170
EGR SYSTEM 174
EGR VALVE . 176
EGR COOLER 178
KCCV SYSTEM . 179
KCCV VENTILATOR . 181
KDPF 183
COOLING SYSTEM 188
LAYOUT DRAWING OF COOLING SYSTEM 188
SPECIFICATIONS OF COOLING SYSTEM 189
CONTROL SYSTEM 190
LAYOUT DRAWING OF CONTROL SYSTEM 190
MACHINE MONITOR SYSTEM 193
MACHINE MONITOR SYSTEM DIAGRAM 193
KomVision SYSTEM 194
LAYOUT DRAWING OF KOMVISION SYSTEM 194
KomVision SYSTEM DIAGRAM 196
FUNCTION OF KomVision SYSTEM 196
KOMTRAX SYSTEM 198
KOMTRAX SYSTEM DIAGRAM 198
FUNCTION OF KOMTRAX SYSTEM 198
PPC LEVERS 199
LH PPC LEVER 199
RH PPC LEVER 200
AUTOMATIC GREASE SYSTEM . 201
OUTLINE OF AUTO GREASE SYSTEM . 201
COMPONENT PARTS OF CONTROL SYSTEM . 216
MACHINE MONITOR . 216
KomVision CONTROLLER 229
KomVision CAMERA 233
KOMTRAX TERMINAL 233
PUMP CONTROLLER . 236
RESISTOR FOR PC-EPC VALVE . 240
CAN TERMINATING RESISTOR 240
PPC OIL PRESSURE SWITCH . 241
ENGINE CONTROLLER . 242
FUEL CONTROL DIAL . 248
SENSOR 250
STRUCTURE OF AMBIENT PRESSURE SENSOR 250
FUNCTION OF AMBIENT PRESSURE SENSOR . 250
STRUCTURE OF ENGINE OIL PRESSURE SWITCH . 250
FUNCTION OF ENGINE OIL PRESSURE SWITCH 251
STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR . 251
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR 251
STRUCTURE OF COOLANT TEMPERATURE SENSOR . 252
FUNCTION OF COOLANT TEMPERATURE SENSOR 252
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR . 252
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR 253
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR . 253
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR 253
STRUCTURE OF COMMON RAIL PRESSURE SENSOR 254
FUNCTION OF COMMON RAIL PRESSURE SENSOR . 254
STRUCTURE OF EGR VALVE LIFT SENSOR 254
FUNCTION OF EGR VALVE LIFT SENSOR . 254
STRUCTURE OF VGT SPEED SENSOR . 255
FUNCTION OF KVGT SPEED SENSOR . 255
STRUCTURE OF KVGT POSITION SENSOR . 255
FUNCTION OF KVGT POSITION SENSOR 256
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR . 256
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR 257
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR . 257
STRUCTURE OF CRANKCASE PRESSURE SENSOR 257
FUNCTION OF CRANKCASE PRESSURE SENSOR . 258
STRUCTURE OF ENGINE OIL LEVEL SENSOR 258
STRUCTURE OF AIR CLEANER CLOGGING SENSOR 258
FUNCTION OF AIR CLEANER CLOGGING SENSOR . 259
STRUCTURE OF WATER-IN-FUEL SENSOR . 259
FUNCTION OF WATER-IN-FUEL SENSOR 259
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 259
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 260
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH . 260
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 260
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 261
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 261
STRUCTURE OF OVERLOAD CAUTION SENSOR 261
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 261
FUNCTION OF OVERLOAD CAUTION SENSOR . 261
HYDRAULIC SYSTEM 262
LAYOUT DRAWING OF HYDRAULIC SYSTEM 262
CLSS 268
STRUCTURE OF CLSS . 268
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 270
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 271
PRESSURE COMPENSATION CONTROL . 284
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 287
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 287
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 288
PUMP AND VALVE CONTROL SYSTEM . 293
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 293
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 294
COMPONENT PARTS OF HYDRAULIC SYSTEM . 296
HYDRAULIC TANK 296
MAIN PUMP . 298
PC-EPC VALVE 322
PILOT OIL FILTER 324
CONTROL VALVE . 324
WORK EQUIPMENT SYSTEM . 381
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 381
STRUCTURE OF VALVE CONTROL 386
ONE-TOUCH POWER MAXIMIZING SYSTEM . 388
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 388
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 389
PPC LOCK SYSTEM . 390
PPC LOCK SYSTEM DIAGRAM . 390
FUNCTION OF PPC LOCK SYSTEM . 390
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 391
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 391
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 391
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 392
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 393
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 393
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 395
TOOL CONTROL SYSTEM . 396
TOOL CONTROL SYSTEM DIAGRAM . 396
FUNCTION OF TOOL CONTROL SYSTEM . 397
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 398
WORK EQUIPMENT AND SWING PPC VALVE 398
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 403
SOLENOID VALVE 409
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 412
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 414
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE . 417
2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE . 419
ATTACHMENT BYPASS SOLENOID VALVE 422
ATT EPC VALVE ASSEMBLY 424
PILOT CIRCUIT ACCUMULATOR . 425
ATTACHMENT CIRCUIT ACCUMULATOR 426
SWING SYSTEM 427
LAYOUT DRAWING OF SWING SYSTEM 427
SWING CONTROL SYSTEM DIAGRAM 431
FUNCTION OF SWING CONTROL SYSTEM 431
COMPONENT PARTS OF SWING SYSTEM . 435
SWING MOTOR . 435
SWING MACHINERY . 447
SWING CIRCLE 448
TRAVEL SYSTEM . 450
LAYOUT DRAWING OF TRAVEL SYSTEM . 450
TRAVEL CONTROL SYSTEM DIAGRAM . 454
FUNCTION OF TRAVEL CONTROL SYSTEM . 454
COMPONENT PARTS OF TRAVEL SYSTEM 456
TRAVEL MOTOR 456
FINAL DRIVE . 468
TRAVEL PPC VALVE 470
CENTER SWIVEL JOINT . 475
UNDERCARRIAGE AND FRAME . 477
LAYOUT DRAWING OF UNDERCARRIAGE . 477
SPECIFICATIONS OF UNDERCARRIAGE . 478
WORK EQUIPMENT 479
STRUCTURE OF WORK EQUIPMENT . 479
FUNCTION OF WORK EQUIPMENT 480
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 481
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 481
BUCKET CLEARANCE ADJUSTMENT SHIM 482
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 482
CAB AND ITS ATTACHMENTS . 483
ROPS CAB 483
STRUCTURE OF ROPS CAB . 483
FUNCTION OF ROPS CAB 483
CAB MOUNT . 484
STRUCTURE OF CAB MOUNT 484
FUNCTION OF CAB MOUNT . 484
CAB TIPPING STOPPER . 485
STRUCTURE OF CAB TIPPING STOPPER 485
FUNCTION OF CAB TIPPING STOPPER . 485
20 STANDARD VALUE TABLE . 487
CONTENTS 488
ABBREVIATION LIST . 489
STANDARD VALUE TABLE FOR ENGINE . 495
STANDARD VALUE TABLE FOR ENGINE: PC240LC-11E0, PC240NLC-11E0 495
STANDARD VALUE TABLE FOR MACHINE 499
STANDARD VALUE TABLE FOR MACHINE: PC240LC-11E0, PC240NLC-11E0 . 499
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 513
STANDARD VALUE TABLE FOR ELECTRICAL . 517
STANDARD VALUE TABLE FOR ELECTRICAL . 517
30 TESTING AND ADJUSTING 527
CONTENTS 528
ABBREVIATION LIST . 531
RELATED INFORMATION ON TESTING AND ADJUSTING 537
TOOLS FOR TESTING AND ADJUSTING . 537
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 544
ENGINE AND COOLING SYSTEM . 546
TEST ENGINE SPEED . 546
METHOD FOR TESTING ENGINE SPEED . 546
TEST BOOST PRESSURE . 549
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 549
METHOD FOR TESTING BOOST PRESSURE . 550
TEST EXHAUST GAS COLOR 551
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 551
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 552
TEST AND ADJUST VALVE CLEARANCE . 554
METHOD FOR TESTING VALVE CLEARANCE 554
METHOD FOR ADJUSTING VALVE CLEARANCE 555
TEST COMPRESSION PRESSURE . 557
METHOD FOR TESTING COMPRESSION PRESSURE . 557
TEST BLOWBY PRESSURE 562
METHOD FOR TESTING BLOWBY PRESSURE 562
TEST ENGINE OIL PRESSURE 564
METHOD FOR TESTING ENGINE OIL PRESSURE 564
TEST EGR VALVE AND VGT OIL PRESSURE . 565
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 565
TEST FUEL PRESSURE 567
METHOD FOR TESTING FUEL PRESSURE 568
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 573
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 574
BLEEDING AIR FROM FUEL SYSTEM . 580
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 580
TEST FUEL CIRCUIT FOR LEAKAGE . 581
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 581
HANDLE CYLINDER CUT-OUT MODE OPERATION 583
HANDLE NO-INJECTION CRANKING OPERATION 584
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 585
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 585
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 585
TEST FAN BELT AND ALTERNATOR BELT . 587
METHOD FOR TESTING FAN BELT AND ALTERNATOR BELT . 587
TEST AUTO-TENSIONER . 588
METHOD FOR TESTING AUTO-TENSIONER . 588
REPLACING FAN BELT 589
METHOD FOR REPLACING FAN BELT . 589
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 590
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 590
TEST SCR RELATED FUNCTIONS 591
TEST AdBlue/DEF PUMP RAISED PRESSURE 594
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 597
TEST AdBlue/DEF LINE HEATER RELAY 1 . 601
TEST AdBlue/DEF LINE HEATER RELAY 2 . 604
TEST AdBlue/DEF PUMP HEATER RELAY . 606
TEST AdBlue/DEF TANK HEATER VALVE . 609
TEST DENITRATION EFFICIENCY OF SCR 612
CLEAN AdBlue/DEF TANK . 616
METHOD FOR CLEANING AdBlue/DEF TANK . 616
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 620
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 620
POWER TRAIN . 622
TEST SWING CIRCLE BEARING CLEARANCE . 622
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 622
UNDERCARRIAGE AND FRAME . 623
TEST AND ADJUST TRACK TENSION . 623
METHOD FOR TESTING TRACK TENSION 623
METHOD FOR ADJUSTING TRACK TENSION 623
HYDRAULIC SYSTEM 625
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 625
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK . 625
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT . 625
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 631
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 632
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 638
TEST OIL PRESSURE OF CONTROL CIRCUIT 641
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 641
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 643
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 643
TEST PC-EPC VALVE OUTLET PRESSURE . 644
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 645
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 647
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 647
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 648
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 651
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 652
METHOD FOR ADJUSTING LS VALVE . 653
TEST OUTLET PRESSURE OF SOLENOID VALVE 654
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 654
OPERATING CONDITION OF SOLENOID VALVE . 655
TEST PPC VALVE OUTLET PRESSURE 658
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 658
TEST ATTACHMENT CIRCUIT OIL PRESSURE 660
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 660
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 662
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 662
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 663
TEST PUMP SWASH PLATE SENSOR 665
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 665
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 666
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 666
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 666
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 667
TEST OIL LEAKAGE 668
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 668
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 668
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 669
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 670
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 670
BLEED AIR FROM HYDRAULIC CIRCUIT 671
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 673
CAB AND ITS ATTACHMENTS . 675
TEST CAB TIPPING STOPPER 675
METHOD FOR TESTING CAB TIPPING STOPPER 675
METHOD FOR ADJUSTING MIRRORS 676
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 676
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 677
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 678
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 679
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 680
ELECTRICAL SYSTEM . 682
ELECTRICAL SYSTEM . 683
SET AND OPERATE MACHINE MONITOR . 683
OPERATOR MODE . 686
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 687
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 687
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 688
CHECKING FUNCTION OF SERVICE METER 688
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 688
SERVICE MODE 691
SERVICE MODE 691
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 693
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 699
ABNORMALITY RECORD MENU . 710
METHOD FOR CONFIRMING MAINTENANCE RECORD 715
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 716
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 720
DEFAULT MENU 721
DIAGNOSTIC TESTS MENU . 732
ADJUSTMENT MENU . 742
METHOD FOR PERFORMING NO-INJECTION CRANKING . 776
KOMTRAX SETTINGS MENU . 777
METHOD FOR DISPLAYING SERVICE MESSAGE . 779
METHOD FOR STARTING UP KOMTRAX TERMINAL . 781
ADJUST REARVIEW CAMERA ANGLE 786
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 786
ADJUST KomVision CAMERA ANGLE . 789
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 790
ADJUST KomVision RELATED ITEMS 794
SETTING OF KomVision (MAIN SETTING) . 794
SETTING OF KomVision (CAMERA SETTING) . 796
SETTING OF KomVision (CAMERA CALIBRATION) . 798
KomVision screen – Check 12 m visibility 811
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 814
HANDLE BATTERY DISCONNECT SWITCH 815
TEST DIODES . 816
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 816
METHOD FOR TESTING DIODE USING ANALOG TESTER 816
Pm CLINIC . 817
Pm CLINIC SERVICE . 817
Pm CLINIC CHECK SHEET . 821
40 TROUBLESHOOTING 831
CONTENTS 832
ABBREVIATION LIST . 843
RELATED INFORMATION ON TROUBLESHOOTING 849
GENERAL TROUBLESHOOTING POINTS 849
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 850
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 862
CHECKS BEFORE TROUBLESHOOTING . 864
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 866
WALK-AROUND CHECK . 866
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 868
CHECK FUEL LEVEL AND TYPE . 868
CHECK IMPURE INGREDIENT IN FUEL . 868
CHECK FUEL PREFILTER 869
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 869
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 870
CHECK MAIN FILTER . 871
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 873
CHECK COOLANT LEVEL (RESERVOIR TANK) 874
CHECK CLOGGING OF AIR CLEANER . 874
OUTER ELEMENT – CLEAN . 875
ELEMENTS – REPLACE 877
CHECK HYDRAULIC OIL LEVEL . 878
CHECK HYDRAULIC OIL STRAINER 879
CHECK HYDRAULIC FILTER 880
CHECK OIL LEVEL IN SWING MACHINERY CASE . 881
CHECK OIL LEVEL IN DAMPER CASE 882
CHECK OIL LEVEL IN FINAL DRIVE CASE . 882
BLEED AIR FROM FUEL SYSTEM 883
BLEED AIR FROM HYDRAULIC SYSTEM . 883
ELECTRICAL EQUIPMENT – CHECK METHOD . 883
AUTOMATIC GREASE SYSTEM . 891
FINDING MALFUNCTIONS 891
MALFUNCTION FINDING PROCEDURES 893
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM . 895
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 905
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 908
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 912
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 914
CONNECTOR LIST AND LAYOUT . 917
CONNECTOR CONTACT IDENTIFICATION 930
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 970
FUSE LOCATION TABLE . 976
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 978
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 982
FAILURE CODE TABLE 984
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .1002
FAILURE CODE [879AKA] .1002
FAILURE CODE [879AKB] .1003
FAILURE CODE [879BKA] .1004
FAILURE CODE [879BKB] .1006
FAILURE CODE [879CKA] .1008
FAILURE CODE [879CKB] .1009
FAILURE CODE [879DKZ] .1010
FAILURE CODE [879EMC] .1012
FAILURE CODE [879FMC] .1013
FAILURE CODE [879GKX] .1014
FAILURE CODE [989L00] .1016
FAILURE CODE [989M00] .1017
FAILURE CODE [989N00] .1018
FAILURE CODE [A1U0N3] .1019
FAILURE CODE [A1U0N4] .1021
FAILURE CODE [A900FR] .1023
FAILURE CODE [A900N6] .1024
FAILURE CODE [A900NY] .1025
FAILURE CODE [AA10NX] .1026
FAILURE CODE [AB00KE] .1028
FAILURE CODE [AQ10N3] .1031
FAILURE CODE [AS00N3] .1033
FAILURE CODE [AS00R2] .1035
FAILURE CODE [AS00R3] .1036
FAILURE CODE [AS00R4] .1037
FAILURE CODE [AS00R5] .1038
FAILURE CODE [AS00R6] .1039
FAILURE CODE [AS00ZK] .1040
FAILURE CODE [AS10KM] .1041
FAILURE CODE [AS10NR] .1042
FAILURE CODE [AS10NT] .1043
FAILURE CODE [B@BAZG] .1044
FAILURE CODE [B@BAZK] .1045
FAILURE CODE [B@BCNS] .1047
FAILURE CODE [B@BCQA] .1048
FAILURE CODE [B@BCZK] .1050
FAILURE CODE [B@HANS] .1052
FAILURE CODE [CA115] 1053
FAILURE CODE [CA122] 1054
FAILURE CODE [CA123] 1056
FAILURE CODE [CA131] 1058
FAILURE CODE [CA132] 1060
FAILURE CODE [CA144] 1062
FAILURE CODE [CA145] 1064
FAILURE CODE [CA153] 1066
FAILURE CODE [CA154] 1069
FAILURE CODE [CA187] 1071
FAILURE CODE [CA221] 1073
FAILURE CODE [CA222] 1075
FAILURE CODE [CA227] 1077
FAILURE CODE [CA234] 1078
FAILURE CODE [CA238] 1079
FAILURE CODE [CA239] 1081
FAILURE CODE [CA249] 1083
FAILURE CODE [CA256] 1085
FAILURE CODE [CA271] 1087
FAILURE CODE [CA272] 1089
FAILURE CODE [CA322] 1091
FAILURE CODE [CA323] 1093
FAILURE CODE [CA324] 1095
FAILURE CODE [CA325] 1097
FAILURE CODE [CA331] 1099
FAILURE CODE [CA332] 1101
FAILURE CODE [CA343] 1103
FAILURE CODE [CA351] 1104
FAILURE CODE [CA352] 1105
FAILURE CODE [CA356] 1108
FAILURE CODE [CA357] 1110
FAILURE CODE [CA386] 1112
FAILURE CODE [CA428] 1113
FAILURE CODE [CA429] 1115
FAILURE CODE [CA435] 1117
FAILURE CODE [CA441] 1119
FAILURE CODE [CA442] 1121
FAILURE CODE [CA449] 1122
FAILURE CODE [CA451] 1123
FAILURE CODE [CA452] 1125
FAILURE CODE [CA488] 1127
FAILURE CODE [CA515] 1128
FAILURE CODE [CA516] 1130
FAILURE CODE [CA553] 1132
FAILURE CODE [CA555] 1133
FAILURE CODE [CA556] 1134
FAILURE CODE [CA559] 1135
FAILURE CODE [CA595] 1138
FAILURE CODE [CA687] 1139
FAILURE CODE [CA689] 1141
FAILURE CODE [CA691] 1144
FAILURE CODE [CA692] 1146
FAILURE CODE [CA697] 1148
FAILURE CODE [CA698] 1149
FAILURE CODE [CA731] 1150
FAILURE CODE [CA778] 1152
FAILURE CODE [CA1117] .1157
FAILURE CODE [CA1664] .1158
FAILURE CODE [CA1669] .1160
FAILURE CODE [CA1673] .1161
FAILURE CODE [CA1677] .1162
FAILURE CODE [CA1678] .1163
FAILURE CODE [CA1682] .1164
FAILURE CODE [CA1683] .1166
FAILURE CODE [CA1684] .1168
FAILURE CODE [CA1686] .1170
FAILURE CODE [CA1691] .1171
FAILURE CODE [CA1694] .1174
FAILURE CODE [CA1695] .1177
FAILURE CODE [CA1696] .1178
FAILURE CODE [CA1712] .1180
FAILURE CODE [CA1713] .1183
FAILURE CODE [CA1714] .1185
FAILURE CODE [CA1715] .1186
FAILURE CODE [CA1776] .1187
FAILURE CODE [CA1777] .1190
FAILURE CODE [CA1843] .1193
FAILURE CODE [CA1844] .1195
FAILURE CODE [CA1879] .1198
FAILURE CODE [CA1881] .1200
FAILURE CODE [CA1883] .1202
FAILURE CODE [CA1885] .1205
FAILURE CODE [CA1887] .1207
FAILURE CODE [CA1921] .1209
FAILURE CODE [CA1922] .1212
FAILURE CODE [CA1942] .1217
FAILURE CODE [CA1993] .1218
FAILURE CODE [CA2185] .1221
FAILURE CODE [CA2186] .1222
FAILURE CODE [CA2249] .1224
FAILURE CODE [CA2271] .1225
FAILURE CODE [CA2272] .1228
FAILURE CODE [CA2288] .1231
FAILURE CODE [CA2311] .1232
FAILURE CODE [CA2349] .1233
FAILURE CODE [CA2353] .1236
FAILURE CODE [CA2357] .1238
FAILURE CODE [CA2381] .1239
FAILURE CODE [CA2382] .1242
FAILURE CODE [CA2383] .1245
FAILURE CODE [CA2386] .1248
FAILURE CODE [CA2387] .1250
FAILURE CODE [CA2555] .1251
FAILURE CODE [CA2556] .1254
FAILURE CODE [CA2637] .1257
FAILURE CODE [CA2639] .1259
FAILURE CODE [CA2771] .1262
FAILURE CODE [CA2777] .1268
FAILURE CODE [CA2976] .1271
FAILURE CODE [CA3133] .1273
FAILURE CODE [CA3134] .1276
FAILURE CODE [CA3135] .1278
FAILURE CODE [CA3142] .1281
FAILURE CODE [CA3143] .1282
FAILURE CODE [CA3144] .1283
FAILURE CODE [CA3146] .1285
FAILURE CODE [CA3147] .1286
FAILURE CODE [CA3148] .1287
FAILURE CODE [CA3151] .1289
FAILURE CODE [CA3165] .1295
FAILURE CODE [CA3229] .1297
FAILURE CODE [CA3231] .1299
FAILURE CODE [CA3232] .1301
FAILURE CODE [CA3235] .1305
FAILURE CODE [CA3239] .1307
FAILURE CODE [CA3241] .1310
FAILURE CODE [CA3242] .1313
FAILURE CODE [CA3251] .1316
FAILURE CODE [CA3253] .1318
FAILURE CODE [CA3254] .1321
FAILURE CODE [CA3255] .1324
FAILURE CODE [CA3256] .1328
FAILURE CODE [CA3311] .1330
FAILURE CODE [CA3312] .1332
FAILURE CODE [CA3313] .1335
FAILURE CODE [CA3314] .1336
FAILURE CODE [CA3315] .1337
FAILURE CODE [CA3316] .1339
FAILURE CODE [CA3317] .1340
FAILURE CODE [CA3318] .1341
FAILURE CODE [CA3319] .1343
FAILURE CODE [CA3321] .1344
FAILURE CODE [CA3322] .1346
FAILURE CODE [CA3419] .1348
FAILURE CODE [CA3421] .1350
FAILURE CODE [CA3497] .1352
FAILURE CODE [CA3498] .1353
FAILURE CODE [CA3543] .1354
FAILURE CODE [CA3545] .1361
FAILURE CODE [CA3547] .1363
FAILURE CODE [CA3558] .1364
FAILURE CODE [CA3559] .1366
FAILURE CODE [CA3562] .1368
FAILURE CODE [CA3563] .1370
FAILURE CODE [CA3567] .1373
FAILURE CODE [CA3568] .1376
FAILURE CODE [CA3571] .1380
FAILURE CODE [CA3572] .1382
FAILURE CODE [CA3574] .1384
FAILURE CODE [CA3575] .1386
FAILURE CODE [CA3577] .1388
FAILURE CODE [CA3578] .1390
FAILURE CODE [CA3582] .1392
FAILURE CODE [CA3583] .1398
FAILURE CODE [CA3596] .1400
FAILURE CODE [CA3649] .1402
FAILURE CODE [CA3681] .1404
FAILURE CODE [CA3682] .1409
FAILURE CODE [CA3713] .1415
FAILURE CODE [CA3717] .1418
FAILURE CODE [CA3718] .1419
FAILURE CODE [CA3725] .1420
FAILURE CODE [CA3741] .1423
FAILURE CODE [CA3748] .1424
FAILURE CODE [CA3751] .1426
FAILURE CODE [CA3755] .1428
FAILURE CODE [CA3866] .1430
FAILURE CODE [CA3867] .1434
FAILURE CODE [CA3868] .1437
FAILURE CODE [CA3899] .1441
FAILURE CODE [CA3911] .1443
FAILURE CODE [CA3912] .1447
FAILURE CODE [CA3932] .1449
FAILURE CODE [CA3933] .1451
FAILURE CODE [CA3934] .1453
FAILURE CODE [CA3935] .1456
FAILURE CODE [CA3936] .1458
FAILURE CODE [CA4151] .1460
FAILURE CODE [CA4152] .1464
FAILURE CODE [CA4155] .1468
FAILURE CODE [CA4156] .1470
FAILURE CODE [CA4157] .1473
FAILURE CODE [CA4158] .1475
FAILURE CODE [CA4159] .1476
FAILURE CODE [CA4161] .1477
FAILURE CODE [CA4162] .1480
FAILURE CODE [CA4163] .1483
FAILURE CODE [CA4164] .1484
FAILURE CODE [CA4165] .1486
FAILURE CODE [CA4166] .1488
FAILURE CODE [CA4168] .1489
FAILURE CODE [CA4169] .1492
FAILURE CODE [CA4171] .1494
FAILURE CODE [CA4249] .1497
FAILURE CODE [CA4251] .1499
FAILURE CODE [CA4259] .1501
FAILURE CODE [CA4261] .1504
FAILURE CODE [CA4277] .1507
FAILURE CODE [CA4281] .1511
FAILURE CODE [CA4459] .1514
FAILURE CODE [CA4461] .1517
FAILURE CODE [CA4658] .1520
FAILURE CODE [CA4731] .1524
FAILURE CODE [CA4732] .1525
FAILURE CODE [CA4739] .1526
FAILURE CODE [CA4768] .1527
FAILURE CODE [CA4769] .1529
FAILURE CODE [CA4842] .1532
FAILURE CODE [CA4952] .1536
FAILURE CODE [CA5115] .1538
FAILURE CODE [CA5179] .1541
FAILURE CODE [CA5181] .1543
FAILURE CODE [CA5383] .1545
FAILURE CODE [D110KB] .1547
FAILURE CODE [D19JKZ] .1549
FAILURE CODE [D811MC] .1552
FAILURE CODE [D862KA] .1553
FAILURE CODE [D8ALKA] .1554
FAILURE CODE [D8ALKB] .1556
FAILURE CODE [D8AQKR] .1558
FAILURE CODE [D8G1KT] .1560
FAILURE CODE [D8G6KT] .1561
FAILURE CODE [DA20MC] .1562
FAILURE CODE [DA22KK] .1563
FAILURE CODE [DA25KP] .1566
FAILURE CODE [DA26KP] .1569
FAILURE CODE [DA29KQ] .1572
FAILURE CODE [DA2LKA] .1574
FAILURE CODE [DA2LKB] .1576
FAILURE CODE [DA2QKR] .1578
FAILURE CODE [DA2RKR] .1581
FAILURE CODE [DAF0KM] .1582
FAILURE CODE [DAF0MB] .1583
FAILURE CODE [DAF0MC] .1584
FAILURE CODE [DAF8KB] .1585
FAILURE CODE [DAF9KQ] .1587
FAILURE CODE [DAFGMC] .1588
FAILURE CODE [DAFLKA] .1589
FAILURE CODE [DAFLKB] .1591
FAILURE CODE [DAFQKR] .1593
FAILURE CODE [DAZ9KQ] .1594
FAILURE CODE [DAZQKR] .1595
FAILURE CODE [DB2QKR] .1600
FAILURE CODE [DB2RKR] .1605
FAILURE CODE [DBP0KM] .1610
FAILURE CODE [DBP0KT] .1611
FAILURE CODE [DBP5KB] .1612
FAILURE CODE [DBP5KY] .1615
FAILURE CODE [DBPQKR] .1618
FAILURE CODE [DDNRKA] .1623
FAILURE CODE [DDNRKY] .1625
FAILURE CODE [DDNS00] .1627
FAILURE CODE [DFB1KZ] .1629
FAILURE CODE [DFB2KZ] .1631
FAILURE CODE [DFB3L8] .1633
FAILURE CODE [DFB4L8] .1635
FAILURE CODE [DFB5KZ] .1637
FAILURE CODE [DFB6KZ] .1639
FAILURE CODE [DGH2KA] .1641
FAILURE CODE [DGH2KB] .1643
FAILURE CODE [DHA4KA] .1645
FAILURE CODE [DHAAMA] .1647
FAILURE CODE [DHACMA] .1649
FAILURE CODE [DHPAMA] .1651
FAILURE CODE [DHPBMA] .1654
FAILURE CODE [DHS3MA] .1657
FAILURE CODE [DHS4MA] .1660
FAILURE CODE [DHS8MA] .1663
FAILURE CODE [DHS9MA] .1666
FAILURE CODE [DHSAMA] .1669
FAILURE CODE [DHSBMA] .1672
FAILURE CODE [DHSCMA] .1675
FAILURE CODE [DHSDMA] .1678
FAILURE CODE [DHSFMA] .1681
FAILURE CODE [DHSGMA] .1684
FAILURE CODE [DHSHMA] .1687
FAILURE CODE [DHSJMA] .1690
FAILURE CODE [DHX1MA] .1693
FAILURE CODE [DHZAMA] .1696
FAILURE CODE [DHZCL8] .1700
FAILURE CODE [DKR0MA] .1701
FAILURE CODE [DKR1MA] .1704
FAILURE CODE [DKULKA] .1707
FAILURE CODE [DKULKB] .1709
FAILURE CODE [DKULKY] .1711
FAILURE CODE [DR10KA] .1713
FAILURE CODE [DR12KA] .1716
FAILURE CODE [DR20KA] .1718
FAILURE CODE [DR21KX] .1720
FAILURE CODE [DR30KA] .1722
FAILURE CODE [DR31KX] .1724
FAILURE CODE [DR40KA] .1726
FAILURE CODE [DUMBKA] .1728
FAILURE CODE [DUMBKB] .1730
FAILURE CODE [DV00KA] .1732
FAILURE CODE [DV00KB] .1733
FAILURE CODE [DV20KB] .1734
FAILURE CODE [DW43KA] .1736
FAILURE CODE [DW43KB] .1738
FAILURE CODE [DW43KY] .1740
FAILURE CODE [DW45KA] .1742
FAILURE CODE [DW45KB] .1745
FAILURE CODE [DW45KY] .1748
FAILURE CODE [DW4CKY] .1750
FAILURE CODE [DW91KA] .1752
FAILURE CODE [DW91KB] .1754
FAILURE CODE [DW91KY] .1756
FAILURE CODE [DWA2KA] .1758
FAILURE CODE [DWA2KB] .1760
FAILURE CODE [DWA2KY] .1762
FAILURE CODE [DWK0KA] .1764
FAILURE CODE [DWK0KB] .1766
FAILURE CODE [DWK0KY] .1768
FAILURE CODE [DWK2KA] .1770
FAILURE CODE [DWK2KB] .1772
FAILURE CODE [DWK2KY] .1774
FAILURE CODE [DWK8KA] .1776
FAILURE CODE [DWK8KB] .1778
FAILURE CODE [DWK8KY] .1780
FAILURE CODE [DWPUKA] .1782
FAILURE CODE [DWPUKB] .1784
FAILURE CODE [DXA8KA] .1786
FAILURE CODE [DXA8KB] .1788
FAILURE CODE [DXA9KA] .1790
FAILURE CODE [DXA9KB] .1792
FAILURE CODE [DXE0KA] .1794
FAILURE CODE [DXE0KB] .1795
FAILURE CODE [DXE4KA] .1797
FAILURE CODE [DXE4KB] .1799
FAILURE CODE [DXE4KY] .1801
FAILURE CODE [DXE5KA] .1803
FAILURE CODE [DXE5KB] .1805
FAILURE CODE [DXE6KA] .1807
FAILURE CODE [DXE6KB] .1809
FAILURE CODE [DXE7KA] .1811
FAILURE CODE [DXE7KB] .1813
FAILURE CODE [DXE7KY] .1815
FAILURE CODE [DXE8KA] .1817
FAILURE CODE [DXE8KB] .1819
FAILURE CODE [DXE8KY] .1821
FAILURE CODE [DXE9KA] .1823
FAILURE CODE [DXE9KB] .1825
FAILURE CODE [DXE9KY] .1827
FAILURE CODE [DXEAKA] .1829
FAILURE CODE [DXEAKB] .1831
FAILURE CODE [DXEAKY] .1833
FAILURE CODE [DXEKKA] .1835
FAILURE CODE [DXEKKB] .1837
FAILURE CODE [DXEKKY] .1839
FAILURE CODE [DXELKA] .1841
FAILURE CODE [DXELKB] .1843
FAILURE CODE [DXELKY] .1845
FAILURE CODE [DY20KA] .1847
FAILURE CODE [DY20MA] .1849
FAILURE CODE [DY2CKB] .1851
FAILURE CODE [DY2DKB] .1854
FAILURE CODE [DY2EKB] .1856
FAILURE CODE [F313KA] .1858
FAILURE CODE [F313KB] .1860
FAILURE CODE [F318KB] .1863
FAILURE CODE [F318KY] .1866
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1868
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1868
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1874
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1877
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1879
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1881
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1884
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1885
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1886
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1887
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1888
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1889
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1890
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1891
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1892
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1893
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1894
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1895
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1897
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1898
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1899
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1900
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1902
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1903
E-24 FUNCTION SWITCH DOES NOT OPERATE .1904
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1905
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1906
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1907
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1908
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1909
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1910
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1911
E-32 ALARM BUZZER CANNOT BE CANCELED 1913
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1914
E-34 SERVICE MODE CANNOT BE SELECTED 1915
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1916
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1919
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1921
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1924
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1926
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1929
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1930
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1932
E-43 HORN DOES NOT SOUND 1933
E-44 HORN DOES NOT STOP SOUNDING 1936
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1938
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1939
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1941
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1942
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1943
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1944
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1945
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1946
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1947
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1948
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1949
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1950
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1952
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1953
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1954
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1954
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1955
FAILURE MODE AND CAUSE TABLE 1957
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1966
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1967
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1970
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1971
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1972
H-6 SPEED OR POWER OF BOOM IS LOW .1974
H-7 ARM SPEED OR POWER IS LOW .1978
H-8 BUCKET SPEED OR POWER IS LOW 1983
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1986
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1987
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1989
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .1991
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .1992
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1993
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1994
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1995
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .1996
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1997
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1998
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1999
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .2000
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .2002
H-23 TRAVEL SPEED IS LOW 2005
H-24 ONE OF TRACKS DOES NOT RUN .2007
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2008
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 2009
H-27 SWINGS ONLY IN ONE DIRECTION .2010
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .2011
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 2012
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 2013
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 2014
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .2015
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .2016
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .2017
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2018
H-36 Quick coupler cylinder will not extend .2019
H-37 Quick coupler cylinder will not retract (but buzzer doesnot sound) .2021
H-38 Buzzer does not sound (but quick coupler cylinder doesretract) .2023
H-39 Quick coupler cylinder extends and retracts slowly .2025
TROUBLESHOOTING OF ENGINE (S-MODE) 2026
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .2026
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2027
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2028
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2029
S-4 ENGINE STARTABILITY IS POOR .2031
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2033
S-6 ENGINE STOPS DURING OPERATION .2035
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2037
S-8 ENGINE LACKS POWER 2038
S-9 KDPF GETS CLOGGED IN A SHORT TIME .2040
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2042
S-11 OIL BECOMES CONTAMINATED QUICKLY .2043
S-12 FUEL CONSUMPTION IS EXCESSIVE 2044
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2045
S-14 OIL PRESSURE DROPS .2046
S-15 FUEL MIXES INTO ENGINE OIL .2048
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2049
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2050
S-18 UNUSUAL NOISE IS HEARD .2051
S-19 VIBRATION IS EXCESSIVE .2052
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .2053
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2054
S-22 ACTIVE REGENERATION TAKES TIME .2056
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2057
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2058
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2060
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2061
50 DISASSEMBLY AND ASSEMBLY .2063
CONTENTS 2064
ABBREVIATION LIST .2069
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2075
HOW TO READ THIS MANUAL .2075
COATING MATERIALS LIST 2077
SPECIAL TOOLS LIST 2082
SKETCHES OF SPECIAL TOOLS .2094
ENGINE AND COOLING SYSTEM .2100
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2100
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2100
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2103
REMOVE AND INSTALL INJECTOR ASSEMBLY 2107
METHOD FOR REMOVING INJECTOR ASSEMBLY .2107
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2112
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2120
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2121
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2130
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2146
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2146
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2147
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2150
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2150
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2153
REMOVE AND INSTALL STARTER ASSEMBLY .2158
METHOD FOR REMOVING STARTER ASSEMBLY 2158
METHOD FOR INSTALLING STARTER ASSEMBLY 2160
REMOVE AND INSTALL ALTERNATOR BELT 2162
METHOD FOR REMOVING ALTERNATOR BELT .2162
METHOD FOR INSTALLING ALTERNATOR BELT .2164
REMOVE AND INSTALL RADIATOR ASSEMBLY 2166
METHOD FOR REMOVING RADIATOR ASSEMBLY .2166
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2168
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2170
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2170
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2173
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2176
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2176
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2177
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2179
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2180
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2188
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2199
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2199
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2202
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2206
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2206
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2207
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2210
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2210
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2211
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2212
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2212
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2214
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2220
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2220
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2224
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2230
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2230
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2235
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2241
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2241
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2246
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2252
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2252
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2252
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2259
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2259
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2259
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2261
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2261
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2263
REMOVE AND INSTALL KDPF ASSEMBLY 2266
METHOD FOR REMOVING KDPF ASSEMBLY .2266
METHOD FOR INSTALLING KDPF ASSEMBLY .2268
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2270
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2271
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2274
REMOVE AND INSTALL SCR ASSEMBLY .2279
METHOD FOR REMOVING SCR ASSEMBLY 2279
METHOD FOR INSTALLING SCR ASSEMBLY 2281
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2283
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2283
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2289
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2295
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2295
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2301
REMOVE AND INSTALL KCCV ASSEMBLY 2308
METHOD FOR REMOVING KCCV ASSEMBLY .2308
METHOD FOR INSTALLING KCCV ASSEMBLY .2311
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2315
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2315
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2320
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2325
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2325
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2327
REMOVE AND INSTALL AdBlue/DEF PUMP 2329
METHOD FOR REMOVING AdBlue/DEF PUMP .2329
METHOD FOR INSTALLING AdBlue/DEF PUMP .2331
REMOVE AND INSTALL AdBlue/DEF HOSE 2334
METHOD FOR REMOVING AdBlue/DEF HOSE .2334
METHOD FOR INSTALLING AdBlue/DEF HOSE .2342
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2348
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2348
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2349
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2351
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2351
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2353
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2356
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2356
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2357
POWER TRAIN .2358
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2358
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2358
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2359
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2361
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2361
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2365
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2374
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2374
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2377
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2380
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2380
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2384
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2391
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2391
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2391
UNDERCARRIAGE AND FRAME .2393
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2393
METHOD FOR SEPARATING TRACK ASSEMBLY 2393
METHOD FOR INSTALLING TRACK ASSEMBLY 2395
REMOVE AND INSTALL SPROCKET .2398
METHOD FOR REMOVING SPROCKET 2398
METHOD FOR INSTALLING SPROCKET 2398
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2400
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2400
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2401
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2402
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2402
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2403
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2407
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2408
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2409
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2410
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2411
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2412
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2414
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2414
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2416
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2418
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2418
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2420
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2423
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2423
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2426
HYDRAULIC SYSTEM 2430
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2430
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2430
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2432
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2435
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2436
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2437
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2438
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2438
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2441
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2445
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2445
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2448
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2452
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2452
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2459
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2467
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2467
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2469
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2473
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2473
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2473
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2475
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2475
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2476
REMOVE AND INSTALL QUICK COUPLER VALVE 2478
WORK EQUIPMENT 2480
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2480
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2480
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2484
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2490
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2490
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2493
CAB AND ITS ATTACHMENTS .2499
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2499
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2499
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2505
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2512
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2514
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2514
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2524
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2524
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2527
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2533
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2533
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2540
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2547
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2547
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2553
REMOVE AND INSTALL OPERATOR’S SEAT 2560
METHOD FOR REMOVING OPERATOR’S SEAT .2560
METHOD FOR INSTALLING OPERATOR’S SEAT .2562
REMOVE AND INSTALL SEAT BELT 2565
METHOD FOR REMOVING SEAT BELT .2565
METHOD FOR INSTALLING SEAT BELT .2566
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2567
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2567
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2572
ELECTRICAL SYSTEM .2581
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2581
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2581
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2583
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2584
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2584
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2588
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2593
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2593
METHOD FOR INSTALLING KomVision CONTROLLER 2594
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2596
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2596
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2599
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2602
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2602
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2603
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2604
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2604
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2605
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2606
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2606
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2607
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2609
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2609
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2611
REMOVE AND INSTALL KomVision CAMERA .2614
METHOD FOR REMOVING KomVision CAMERA 2614
METHOD FOR INSTALLING KomVision CAMERA 2617
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2620
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2620
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2623
60 MAINTENANCE STANDARD .2627
CONTENTS 2628
ABBREVIATION LIST .2629
ENGINE AND COOLING SYSTEM .2635
MAINTENANCE STANDARD OF ENGINE MOUNT 2635
MAINTENANCE STANDARD OF COOLING SYSTEM 2636
POWER TRAIN .2637
MAINTENANCE STANDARD OF SWING CIRCLE 2637
MAINTENANCE STANDARD OF SWING MACHINERY .2638
MAINTENANCE STANDARD OF FINAL DRIVE .2640
MAINTENANCE STANDARD OF SPROCKET 2642
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2643
UNDERCARRIAGE AND FRAME .2645
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2645
MAINTENANCE STANDARD OF IDLER .2647
MAINTENANCE STANDARD OF TRACK ROLLER 2649
MAINTENANCE STANDARD OF CARRIER ROLLER 2650
MAINTENANCE STANDARD OF TRACK SHOE 2651
MAINTENANCE STANDARD OF TRIPLE SHOE .2654
MAINTENANCE STANDARD OF SWAMP SHOE 2655
MAINTENANCE STANDARD OF ROAD LINER 2656
HYDRAULIC SYSTEM 2657
MAINTENANCE STANDARD OF HYDRAULIC TANK 2657
MAINTENANCE STANDARD OF MAIN PUMP .2658
MAINTENANCE STANDARD OF LS-EPC VALVE 2659
MAINTENANCE STANDARD OF PC-EPC VALVE 2660
MAINTENANCE STANDARD OF SWING MOTOR .2661
MAINTENANCE STANDARD OF TRAVEL MOTOR 2664
MAINTENANCE STANDARD OF CONTROL VALVE .2667
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2677
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2680
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2683
MAINTENANCE STANDARD OF EPC VALVE .2684
MAINTENANCE STANDARD OF SOLENOID VALVE 2686
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 2687
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2689
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2690
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2691
WORK EQUIPMENT 2692
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2692
DIMENSION OF ARM 2697
DIMENSIONS OF BUCKET 2699
MAINTENANCE STANDARD OF BOOM CYLINDER .2701
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2702
MAINTENANCE STANDARD OF ARM CYLINDER 2703
MAINTENANCE STANDARD OF BUCKET CYLINDER .2704
80 APPENDIX .2705
CONTENTS 2706
ABBREVIATION LIST .2708
AIR CONDITIONER SYSTEM 2714
PRECAUTIONS FOR REFRIGERANT .2714
AIR CONDITIONER COMPONENT .2715
SPECIFICATIONS OF AIR CONDITIONER .2717
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2718
OUTLINE OF REFRIGERATION CYCLE 2719
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2721
AIR CONDITIONER UNIT 2721
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2721
FUNCTION OF AIR CONDITIONER UNIT 2723
COMPONENT PARTS OF AIR CONDITIONER UNIT .2725
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2726
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2726
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2726
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2726
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2727
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2727
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2727
FUNCTION OF DUAL PRESSURE SWITCH 2728
AIR CONDITIONER CONTROLLER 2729
STRUCTURE OF AIR CONDITIONER CONTROLLER .2729
COMPRESSOR 2730
STRUCTURE OF COMPRESSOR .2730
SPECIFICATIONS OF COMPRESSOR 2730
FUNCTION OF COMPRESSOR 2730
CONDENSER .2731
STRUCTURE OF CONDENSER 2731
SPECIFICATIONS OF CONDENSER .2731
FUNCTION OF CONDENSER .2731
SENSORS FOR AIR CONDITIONER SYSTEM 2733
STRUCTURE OF SUNLIGHT SENSOR 2733
FUNCTION OF SUNLIGHT SENSOR .2733
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2733
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2733
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2735
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2737
AIR CONDITIONER SYSTEM DIAGRAM 2739
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2740
FUNCTION OF AIR CONDITIONER CONTROLLER 2741
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2742
TESTING AIR LEAKAGE (DUCT) 2746
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2746
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2748
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2749
TEST VENT (MODE) CHANGEOVER .2750
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2750
TESTING FRESH/RECIRC AIR CHANGEOVER .2752
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2752
TEST SUNLIGHT SENSOR 2753
METHOD FOR TESTING SUNLIGHT SENSOR 2753
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2754
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2754
TEST RELAYS .2755
METHOD FOR TESTING RELAYS .2755
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2756
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2757
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2760
FAILURE CODE [879AKA] .2762
FAILURE CODE [879AKB] .2763
FAILURE CODE [879BKA] .2764
FAILURE CODE [879BKB] .2766
FAILURE CODE [879CKA] .2768
FAILURE CODE [879CKB] .2769
FAILURE CODE [879DKZ] .2770
FAILURE CODE [879EMC] .2772
FAILURE CODE [879FMC] .2773
FAILURE CODE [879GKX] .2774
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2776
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2778
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2781
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2783
TROUBLESHOOTING USING GAUGE PRESSURE 2785
CONNECTION OF SERVICE TOOL 2788
METHOD FOR CONNECTING SERVICE TOOL 2788
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2790
HANDLE COMPRESSOR OIL .2792
METHOD FOR REPLACING DESICCANT 2794
90 CIRCUIT DIAGRAMS .2797
CONTENTS 2798
ABBREVIATION LIST .2799
HYDRAULIC CIRCUIT DIAGRAM .2805
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2805
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2809
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2811
ELECTRICAL CIRCUIT DIAGRAM 2813
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2813
ELECTRICAL CIRCUIT DIAGRAM (1/9) 2817
ELECTRICAL CIRCUIT DIAGRAM (2/9) 2819
ELECTRICAL CIRCUIT DIAGRAM (3/9) 2821
ELECTRICAL CIRCUIT DIAGRAM (4/9) 2823
ELECTRICAL CIRCUIT DIAGRAM (5/9) 2825
ELECTRICAL CIRCUIT DIAGRAM (6/9) 2827
ELECTRICAL CIRCUIT DIAGRAM (7/9) 2829
ELECTRICAL CIRCUIT DIAGRAM (8/9) 2831
ELECTRICAL CIRCUIT DIAGRAM (9/9) 2833
INDEX 2835

DESCRIPTION:

Komatsu PC240LC-11E0,PC240NLC-11E0 Hydraulic Excavator Shop Manual UENBM00660 – PDF DOWNLOAD

• SERIAL NUMBERS K75001-K75273

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

G.B 30/12/24