Komatsu PC240LC-11E0 PC240NLC-11E0 Hydraulic Excavator Repair Manual PDF

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Komatsu PC240LC-11E0,PC240NLC-11E0 Hydraulic Excavator Shop Manual UENBM00470 – PDF DOWNLOAD

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Komatsu PC240LC-11E0,PC240NLC-11E0 Hydraulic Excavator Shop Manual UENBM00470 – PDF DOWNLOAD

Language : English
Pages : 2742
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC240LC-11E0,PC240NLC-11E0 Hydraulic Excavator Shop Manual UENBM00470 – PDF DOWNLOAD

• SERIAL NUMBERS K75001 and up

UENBM00470_Front Cover.pdf . 0
00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 21
FOREWORD, SAFETY, BASIC INFORMATION . 27
HOW TO READ THE SHOP MANUAL . 27
SAFETY NOTICE FOR OPERATION . 29
PRECAUTIONS TO PREVENT FIRE . 37
ACTIONS IF FIRE OCCURS 39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 41
PRECAUTIONS FOR DEF . 42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 42
PRECAUTIONS FOR ADDING 42
PRECAUTIONS FOR STORING . 42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 42
THE OTHER PRECAUTIONS . 42
STORE AdBlue/DEF 43
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 44
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 47
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 54
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 56
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 57
PRACTICAL USE OF KOMTRAX 58
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 61
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 63
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 73
HOW TO READ ELECTRICAL WIRE CODE 74
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 78
STANDARD TIGHTENING TORQUE TABLE 81
CONVERSION TABLE 88
01 SPECIFICATIONS . 93
CONTENTS 94
ABBREVIATION LIST . 95
SPECIFICATIONS 101
SPECIFICATION DRAWING . 101
SPECIFICATION DRAWING: PC240LC-11E0, PC240NLC-11E0 101
WORKING RANGE DRAWINGS 102
WORKING RANGE: PC240LC-11E0, PC240NLC-11E0 102
SPECIFICATIONS 103
SPECIFICATIONS: PC240LC-11E0, PC240NLC-11E0 . 103
WEIGHT TABLE 106
WEIGHT TABLE: PC240LC-11E0, PC240NLC-11E0 . 106
TABLE OF FUEL, COOLANT, AND LUBRICANTS 108
10 STRUCTURE AND FUNCTION . 109
CONTENTS 110
ABBREVIATION LIST . 114
UREA SCR SYSTEM . 120
LAYOUT DRAWING OF UREA SCR SYSTEM . 121
UREA SCR SYSTEM DIAGRAM . 126
FUNCTION OF UREA SCR SYSTEM . 127
FUNCTION OF AdBlue/DEF SYSTEM . 127
INDUCEMENT STRATEGY . 129
COMPONENT PARTS OF UREA SCR SYSTEM 137
AdBlue/DEF MIXING TUBE 137
SCR ASSEMBLY 137
AdBlue/DEF TANK . 140
AdBlue/DEF PUMP . 142
AdBlue/DEF INJECTOR . 143
AdBlue/DEF HOSE . 144
AdBlue/DEF TANK HEATING VALVE . 145
BOOT-UP SYSTEM 146
LAYOUT DRAWING OF BOOT-UP SYSTEM 146
SYSTEM OPERATING LAMP SYSTEM 148
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 148
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 148
BATTERY DISCONNECT SWITCH . 149
FUNCTION OF BATTERY DISCONNECT SWITCH . 149
ENGINE SYSTEM . 150
LAYOUT DRAWING OF ENGINE SYSTEM . 150
SPECIFICATIONS OF ENGINE SYSTEM . 151
FUNCTION OF ENGINE SYSTEM . 151
ENGINE CONTROL SYSTEM . 152
ENGINE CONTROL SYSTEM DIAGRAM . 152
FUNCTION OF ENGINE CONTROL SYSTEM . 153
AUTO-DECELERATION SYSTEM 155
AUTO-DECELERATION SYSTEM DIAGRAM 155
FUNCTION OF AUTO-DECELERATION SYSTEM 155
OPERATION OF AUTO-DECELERATION SYSTEM . 156
ENGINE AUTOMATIC WARM-UP SYSTEM . 157
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 157
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 158
OVERHEAT PREVENTION SYSTEM 159
OVERHEAT PREVENTION SYSTEM DIAGRAM 159
FUNCTION OF OVERHEAT PREVENTION SYSTEM 160
TURBOCHARGER PROTECTION SYSTEM 162
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 162
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 163
AUTOMATIC IDLE STOP SYSTEM 164
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 164
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 164
COMPONENT PARTS OF ENGINE SYSTEM 167
VGT . 167
EGR SYSTEM 170
EGR VALVE . 172
EGR COOLER 174
KCCV SYSTEM . 175
KCCV VENTILATOR . 177
KDPF 179
COOLING SYSTEM 184
LAYOUT DRAWING OF COOLING SYSTEM 184
SPECIFICATIONS OF COOLING SYSTEM 185
CONTROL SYSTEM 186
LAYOUT DRAWING OF CONTROL SYSTEM 186
MACHINE MONITOR SYSTEM 189
MACHINE MONITOR SYSTEM DIAGRAM 189
KomVision SYSTEM 190
LAYOUT DRAWING OF KOMVISION SYSTEM 190
KomVision SYSTEM DIAGRAM 191
FUNCTION OF KomVision SYSTEM 192
KOMTRAX SYSTEM 194
KOMTRAX SYSTEM DIAGRAM 194
FUNCTION OF KOMTRAX SYSTEM 194
PPC LEVERS 195
LH PPC LEVER 195
RH PPC LEVER 196
AUTOMATIC GREASE SYSTEM . 197
OUTLINE OF AUTO GREASE SYSTEM . 197
COMPONENT PARTS OF CONTROL SYSTEM . 212
MACHINE MONITOR . 212
KomVision CONTROLLER 225
KomVision CAMERA 229
KOMTRAX TERMINAL 229
PUMP CONTROLLER . 231
RESISTOR FOR PC-EPC VALVE . 235
CAN TERMINATING RESISTOR 236
PPC OIL PRESSURE SWITCH . 236
ENGINE CONTROLLER . 238
FUEL CONTROL DIAL . 244
SENSOR 246
STRUCTURE OF AMBIENT PRESSURE SENSOR 246
FUNCTION OF AMBIENT PRESSURE SENSOR . 246
STRUCTURE OF ENGINE OIL PRESSURE SWITCH . 246
FUNCTION OF ENGINE OIL PRESSURE SWITCH 247
STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR . 247
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR 247
STRUCTURE OF COOLANT TEMPERATURE SENSOR . 248
FUNCTION OF COOLANT TEMPERATURE SENSOR 248
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR . 248
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR 249
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR . 249
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR 249
STRUCTURE OF COMMON RAIL PRESSURE SENSOR 250
FUNCTION OF COMMON RAIL PRESSURE SENSOR . 250
STRUCTURE OF EGR VALVE LIFT SENSOR 250
FUNCTION OF EGR VALVE LIFT SENSOR . 250
STRUCTURE OF VGT SPEED SENSOR . 251
FUNCTION OF KVGT SPEED SENSOR . 251
STRUCTURE OF KVGT POSITION SENSOR . 251
FUNCTION OF KVGT POSITION SENSOR 252
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR . 252
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR 253
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR . 253
STRUCTURE OF CRANKCASE PRESSURE SENSOR 253
FUNCTION OF CRANKCASE PRESSURE SENSOR . 254
STRUCTURE OF ENGINE OIL LEVEL SENSOR 254
STRUCTURE OF AIR CLEANER CLOGGING SENSOR 254
FUNCTION OF AIR CLEANER CLOGGING SENSOR . 255
STRUCTURE OF WATER-IN-FUEL SENSOR . 255
FUNCTION OF WATER-IN-FUEL SENSOR 255
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 255
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 256
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH . 256
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 257
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 257
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 257
STRUCTURE OF OVERLOAD CAUTION SENSOR 257
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 258
FUNCTION OF OVERLOAD CAUTION SENSOR . 258
HYDRAULIC SYSTEM 259
LAYOUT DRAWING OF HYDRAULIC SYSTEM 259
CLSS 265
STRUCTURE OF CLSS . 265
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 267
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 268
PRESSURE COMPENSATION CONTROL . 281
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 284
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 284
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 285
PUMP AND VALVE CONTROL SYSTEM . 290
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 290
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 291
COMPONENT PARTS OF HYDRAULIC SYSTEM . 293
HYDRAULIC TANK 293
MAIN PUMP . 295
PC-EPC VALVE 319
PILOT OIL FILTER 321
CONTROL VALVE . 321
WORK EQUIPMENT SYSTEM . 378
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 378
STRUCTURE OF VALVE CONTROL 383
ONE-TOUCH POWER MAXIMIZING SYSTEM . 385
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 385
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 386
PPC LOCK SYSTEM . 387
PPC LOCK SYSTEM DIAGRAM . 387
FUNCTION OF PPC LOCK SYSTEM . 387
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 388
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 388
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 388
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 389
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 391
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 391
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 393
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 394
WORK EQUIPMENT AND SWING PPC VALVE 394
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 399
SOLENOID VALVE 405
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 408
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 410
ATT EPC VALVE ASSEMBLY 413
PILOT CIRCUIT ACCUMULATOR . 414
ATTACHMENT CIRCUIT ACCUMULATOR 415
SWING SYSTEM 416
LAYOUT DRAWING OF SWING SYSTEM 416
SWING CONTROL SYSTEM DIAGRAM 420
FUNCTION OF SWING CONTROL SYSTEM 420
COMPONENT PARTS OF SWING SYSTEM . 424
SWING MOTOR . 424
SWING MACHINERY . 435
SWING CIRCLE 436
TRAVEL SYSTEM . 438
LAYOUT DRAWING OF TRAVEL SYSTEM . 438
TRAVEL CONTROL SYSTEM DIAGRAM . 442
FUNCTION OF TRAVEL CONTROL SYSTEM . 442
COMPONENT PARTS OF TRAVEL SYSTEM 444
TRAVEL MOTOR 444
FINAL DRIVE . 457
TRAVEL PPC VALVE 458
CENTER SWIVEL JOINT . 463
UNDERCARRIAGE AND FRAME . 465
LAYOUT DRAWING OF UNDERCARRIAGE . 465
SPECIFICATIONS OF UNDERCARRIAGE . 466
WORK EQUIPMENT 467
STRUCTURE OF WORK EQUIPMENT . 467
FUNCTION OF WORK EQUIPMENT 468
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 469
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 469
BUCKET CLEARANCE ADJUSTMENT SHIM 470
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 470
CAB AND ITS ATTACHMENTS . 471
ROPS CAB 471
STRUCTURE OF ROPS CAB . 471
FUNCTION OF ROPS CAB 471
CAB MOUNT . 472
STRUCTURE OF CAB MOUNT 472
FUNCTION OF CAB MOUNT . 472
CAB TIPPING STOPPER . 473
STRUCTURE OF CAB TIPPING STOPPER 473
FUNCTION OF CAB TIPPING STOPPER . 473
20 STANDARD VALUE TABLE . 475
CONTENTS 476
ABBREVIATION LIST . 477
STANDARD VALUE TABLE FOR ENGINE . 483
STANDARD VALUE TABLE FOR ENGINE: PC240LC-11E0, PC240NLC-11E0 483
STANDARD VALUE TABLE FOR MACHINE 487
STANDARD VALUE TABLE FOR MACHINE: PC240LC-11E0, PC240NLC-11E0 . 487
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 501
STANDARD VALUE TABLE FOR ELECTRICAL . 505
STANDARD VALUE TABLE FOR ELECTRICAL . 505
30 TESTING AND ADJUSTING 515
CONTENTS 516
ABBREVIATION LIST . 519
RELATED INFORMATION ON TESTING AND ADJUSTING 525
TOOLS FOR TESTING AND ADJUSTING . 525
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 532
ENGINE AND COOLING SYSTEM . 534
TEST ENGINE SPEED . 534
METHOD FOR TESTING ENGINE SPEED . 534
TEST BOOST PRESSURE . 537
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 537
METHOD FOR TESTING BOOST PRESSURE . 538
TEST EXHAUST GAS COLOR 539
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 539
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 540
TEST AND ADJUST VALVE CLEARANCE . 542
METHOD FOR TESTING VALVE CLEARANCE 542
METHOD FOR ADJUSTING VALVE CLEARANCE 543
TEST COMPRESSION PRESSURE . 544
METHOD FOR TESTING COMPRESSION PRESSURE . 544
TEST BLOWBY PRESSURE 549
METHOD FOR TESTING BLOWBY PRESSURE 549
TEST ENGINE OIL PRESSURE 551
METHOD FOR TESTING ENGINE OIL PRESSURE 551
TEST EGR VALVE AND VGT OIL PRESSURE . 552
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 552
TEST FUEL PRESSURE 554
METHOD FOR TESTING FUEL PRESSURE 555
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 560
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 561
BLEEDING AIR FROM FUEL SYSTEM . 567
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 567
TEST FUEL CIRCUIT FOR LEAKAGE . 568
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 568
HANDLE CYLINDER CUT-OUT MODE OPERATION 570
HANDLE NO-INJECTION CRANKING OPERATION 571
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 572
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 572
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 572
REPLACING FAN BELT 574
METHOD FOR REPLACING FAN BELT . 574
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 575
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 575
TEST SCR RELATED FUNCTIONS 576
TEST AdBlue/DEF PUMP RAISED PRESSURE 579
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 582
TEST AdBlue/DEF LINE HEATER RELAY 1 . 586
TEST AdBlue/DEF LINE HEATER RELAY 2 . 589
TEST AdBlue/DEF PUMP HEATER RELAY . 591
TEST AdBlue/DEF TANK HEATER VALVE . 594
TEST DENITRATION EFFICIENCY OF SCR 597
CLEAN AdBlue/DEF TANK . 601
METHOD FOR CLEANING AdBlue/DEF TANK . 601
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 605
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 605
POWER TRAIN . 607
TEST SWING CIRCLE BEARING CLEARANCE . 607
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 607
UNDERCARRIAGE AND FRAME . 608
TEST AND ADJUST TRACK TENSION . 608
METHOD FOR TESTING TRACK TENSION 608
METHOD FOR ADJUSTING TRACK TENSION 608
HYDRAULIC SYSTEM 610
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 610
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 610
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 616
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 617
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 623
TEST OIL PRESSURE OF CONTROL CIRCUIT 626
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 626
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 628
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 628
TEST PC-EPC VALVE OUTLET PRESSURE . 629
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 630
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 631
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 631
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 633
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 635
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 636
METHOD FOR ADJUSTING LS VALVE . 637
TEST OUTLET PRESSURE OF SOLENOID VALVE 638
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 638
OPERATING CONDITION OF SOLENOID VALVE . 639
TEST PPC VALVE OUTLET PRESSURE 642
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 642
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 644
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 644
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 645
TEST PUMP SWASH PLATE SENSOR 647
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 647
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 648
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 648
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 648
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 649
TEST OIL LEAKAGE 650
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 650
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 650
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 651
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 652
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 652
BLEED AIR FROM HYDRAULIC CIRCUIT 653
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 655
CAB AND ITS ATTACHMENTS . 657
TEST CAB TIPPING STOPPER 657
METHOD FOR TESTING CAB TIPPING STOPPER 657
METHOD FOR ADJUSTING MIRRORS 658
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 658
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 659
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 660
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 661
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 662
ELECTRICAL SYSTEM . 664
ELECTRICAL SYSTEM . 665
SET AND OPERATE MACHINE MONITOR . 665
OPERATOR MODE . 668
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 669
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 669
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 670
CHECKING FUNCTION OF SERVICE METER 670
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 670
SERVICE MODE 673
METHOD FOR OPERATING SERVICE MODE . 673
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 675
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 681
ABNORMALITY RECORD MENU . 692
METHOD FOR CONFIRMING MAINTENANCE RECORD 697
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 698
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 702
DEFAULT MENU 703
DIAGNOSTIC TESTS MENU . 710
ADJUSTMENT MENU . 719
METHOD FOR PERFORMING NO-INJECTION CRANKING . 740
KOMTRAX SETTINGS MENU . 741
METHOD FOR DISPLAYING SERVICE MESSAGE . 744
METHOD FOR STARTING UP KOMTRAX TERMINAL . 746
ADJUST REARVIEW CAMERA ANGLE 751
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 751
ADJUST KomVision CAMERA ANGLE . 754
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 755
ADJUST KomVision RELATED ITEMS 759
SETTING OF KomVision (MAIN SETTING) . 759
SETTING OF KomVision (CAMERA SETTING) . 761
SETTING OF KomVision (CAMERA CALIBRATION) . 761
KomVision screen – Check 12 m visibility 775
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 778
HANDLE BATTERY DISCONNECT SWITCH 779
TEST DIODES . 780
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 780
METHOD FOR TESTING DIODE USING ANALOG TESTER 780
Pm CLINIC . 781
Pm CLINIC SERVICE . 781
Pm CLINIC CHECK SHEET . 785
40 TROUBLESHOOTING 795
CONTENTS 796
ABBREVIATION LIST . 807
RELATED INFORMATION ON TROUBLESHOOTING 813
GENERAL TROUBLESHOOTING POINTS 813
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 815
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 827
CHECKS BEFORE TROUBLESHOOTING . 829
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 831
WALK-AROUND CHECK . 831
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 833
CHECK FUEL LEVEL AND TYPE . 833
CHECK IMPURE INGREDIENT IN FUEL . 833
CHECK FUEL PREFILTER 834
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 834
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 835
CHECK MAIN FILTER . 836
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 838
CHECK COOLANT LEVEL (RESERVOIR TANK) 839
CHECK CLOGGING OF AIR CLEANER . 839
OUTER ELEMENT – CLEAN . 840
ELEMENTS – REPLACE 842
CHECK HYDRAULIC OIL LEVEL . 843
CHECK HYDRAULIC OIL STRAINER 844
CHECK HYDRAULIC FILTER 845
CHECK OIL LEVEL IN SWING MACHINERY CASE . 846
CHECK OIL LEVEL IN DAMPER CASE 847
CHECK OIL LEVEL IN FINAL DRIVE CASE . 847
BLEED AIR FROM FUEL SYSTEM 848
BLEED AIR FROM HYDRAULIC SYSTEM . 848
ELECTRICAL EQUIPMENT – CHECK METHOD . 848
AUTOMATIC GREASE SYSTEM . 856
FINDING MALFUNCTIONS 856
MALFUNCTION FINDING PROCEDURES 858
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION . 860
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 870
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 873
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 877
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 879
CONNECTOR LIST AND LAYOUT . 882
CONNECTOR CONTACT IDENTIFICATION 895
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 935
FUSE LOCATION TABLE . 941
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 943
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 947
FAILURE CODES TABLE . 949
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 966
FAILURE CODE [879AKA] . 966
FAILURE CODE [879AKB] . 967
FAILURE CODE [879BKA] . 968
FAILURE CODE [879BKB] . 970
FAILURE CODE [879CKA] . 972
FAILURE CODE [879CKB] . 973
FAILURE CODE [879DKZ] . 974
FAILURE CODE [879EMC] . 976
FAILURE CODE [879FMC] . 977
FAILURE CODE [879GKX] . 978
FAILURE CODE [989L00] . 980
FAILURE CODE [989M00] . 981
FAILURE CODE [989N00] . 982
FAILURE CODE [A1U0N3] . 983
FAILURE CODE [A1U0N4] . 985
FAILURE CODE [A900FR] . 987
FAILURE CODE [A900N6] . 988
FAILURE CODE [A900NY] . 989
FAILURE CODE [AA10NX] . 990
FAILURE CODE [AB00KE] . 992
FAILURE CODE [AQ10N3] . 995
FAILURE CODE [AS00N3] . 997
FAILURE CODE [AS00R2] . 999
FAILURE CODE [AS00R3] .1000
FAILURE CODE [AS00R4] .1001
FAILURE CODE [AS00R5] .1002
FAILURE CODE [AS00R6] .1003
FAILURE CODE [AS00ZK] .1004
FAILURE CODE [AS10KM] .1005
FAILURE CODE [AS10NR] .1006
FAILURE CODE [AS10NT] .1007
FAILURE CODE [B@BAZG] .1008
FAILURE CODE [B@BAZK] .1009
FAILURE CODE [B@BCNS] .1011
FAILURE CODE [B@BCQA] .1012
FAILURE CODE [B@BCZK] .1014
FAILURE CODE [B@HANS] .1016
FAILURE CODE [CA115] 1017
FAILURE CODE [CA122] 1018
FAILURE CODE [CA123] 1020
FAILURE CODE [CA131] 1022
FAILURE CODE [CA132] 1024
FAILURE CODE [CA144] 1026
FAILURE CODE [CA145] 1028
FAILURE CODE [CA153] 1030
FAILURE CODE [CA154] 1033
FAILURE CODE [CA187] 1035
FAILURE CODE [CA221] 1037
FAILURE CODE [CA222] 1039
FAILURE CODE [CA227] 1041
FAILURE CODE [CA234] 1042
FAILURE CODE [CA238] 1043
FAILURE CODE [CA239] 1045
FAILURE CODE [CA249] 1047
FAILURE CODE [CA256] 1049
FAILURE CODE [CA271] 1051
FAILURE CODE [CA272] 1053
FAILURE CODE [CA322] 1055
FAILURE CODE [CA323] 1057
FAILURE CODE [CA324] 1059
FAILURE CODE [CA325] 1061
FAILURE CODE [CA331] 1063
FAILURE CODE [CA332] 1065
FAILURE CODE [CA343] 1067
FAILURE CODE [CA351] 1068
FAILURE CODE [CA352] 1069
FAILURE CODE [CA356] 1072
FAILURE CODE [CA357] 1074
FAILURE CODE [CA386] 1076
FAILURE CODE [CA428] 1077
FAILURE CODE [CA429] 1079
FAILURE CODE [CA435] 1081
FAILURE CODE [CA441] 1083
FAILURE CODE [CA442] 1085
FAILURE CODE [CA449] 1086
FAILURE CODE [CA451] 1087
FAILURE CODE [CA452] 1089
FAILURE CODE [CA488] 1091
FAILURE CODE [CA515] 1092
FAILURE CODE [CA516] 1094
FAILURE CODE [CA553] 1096
FAILURE CODE [CA555] 1097
FAILURE CODE [CA556] 1098
FAILURE CODE [CA559] 1099
FAILURE CODE [CA595] 1102
FAILURE CODE [CA687] 1103
FAILURE CODE [CA689] 1105
FAILURE CODE [CA691] 1108
FAILURE CODE [CA692] 1110
FAILURE CODE [CA697] 1112
FAILURE CODE [CA698] 1113
FAILURE CODE [CA731] 1114
FAILURE CODE [CA778] 1116
FAILURE CODE [CA1117] .1121
FAILURE CODE [CA1664] .1122
FAILURE CODE [CA1669] .1124
FAILURE CODE [CA1673] .1125
FAILURE CODE [CA1677] .1126
FAILURE CODE [CA1678] .1127
FAILURE CODE [CA1682] .1128
FAILURE CODE [CA1683] .1130
FAILURE CODE [CA1684] .1132
FAILURE CODE [CA1686] .1134
FAILURE CODE [CA1691] .1135
FAILURE CODE [CA1694] .1138
FAILURE CODE [CA1695] .1141
FAILURE CODE [CA1696] .1142
FAILURE CODE [CA1712] .1144
FAILURE CODE [CA1713] .1147
FAILURE CODE [CA1714] .1149
FAILURE CODE [CA1715] .1150
FAILURE CODE [CA1776] .1151
FAILURE CODE [CA1777] .1154
FAILURE CODE [CA1843] .1157
FAILURE CODE [CA1844] .1159
FAILURE CODE [CA1879] .1162
FAILURE CODE [CA1881] .1164
FAILURE CODE [CA1883] .1166
FAILURE CODE [CA1885] .1169
FAILURE CODE [CA1887] .1171
FAILURE CODE [CA1921] .1173
FAILURE CODE [CA1922] .1176
FAILURE CODE [CA1942] .1181
FAILURE CODE [CA1993] .1182
FAILURE CODE [CA2185] .1185
FAILURE CODE [CA2186] .1186
FAILURE CODE [CA2249] .1188
FAILURE CODE [CA2271] .1189
FAILURE CODE [CA2272] .1192
FAILURE CODE [CA2288] .1195
FAILURE CODE [CA2311] .1196
FAILURE CODE [CA2349] .1197
FAILURE CODE [CA2353] .1200
FAILURE CODE [CA2357] .1202
FAILURE CODE [CA2381] .1203
FAILURE CODE [CA2382] .1206
FAILURE CODE [CA2383] .1209
FAILURE CODE [CA2386] .1212
FAILURE CODE [CA2387] .1214
FAILURE CODE [CA2555] .1215
FAILURE CODE [CA2556] .1218
FAILURE CODE [CA2637] .1221
FAILURE CODE [CA2639] .1223
FAILURE CODE [CA2771] .1226
FAILURE CODE [CA2777] .1232
FAILURE CODE [CA2976] .1235
FAILURE CODE [CA3133] .1237
FAILURE CODE [CA3134] .1240
FAILURE CODE [CA3135] .1242
FAILURE CODE [CA3142] .1245
FAILURE CODE [CA3143] .1246
FAILURE CODE [CA3144] .1247
FAILURE CODE [CA3146] .1249
FAILURE CODE [CA3147] .1250
FAILURE CODE [CA3148] .1251
FAILURE CODE [CA3151] .1253
FAILURE CODE [CA3165] .1259
FAILURE CODE [CA3229] .1261
FAILURE CODE [CA3231] .1263
FAILURE CODE [CA3232] .1265
FAILURE CODE [CA3235] .1269
FAILURE CODE [CA3239] .1271
FAILURE CODE [CA3241] .1274
FAILURE CODE [CA3242] .1277
FAILURE CODE [CA3251] .1280
FAILURE CODE [CA3253] .1282
FAILURE CODE [CA3254] .1285
FAILURE CODE [CA3255] .1288
FAILURE CODE [CA3256] .1292
FAILURE CODE [CA3311] .1294
FAILURE CODE [CA3312] .1296
FAILURE CODE [CA3313] .1299
FAILURE CODE [CA3314] .1300
FAILURE CODE [CA3315] .1301
FAILURE CODE [CA3316] .1303
FAILURE CODE [CA3317] .1304
FAILURE CODE [CA3318] .1305
FAILURE CODE [CA3319] .1307
FAILURE CODE [CA3321] .1308
FAILURE CODE [CA3322] .1310
FAILURE CODE [CA3419] .1312
FAILURE CODE [CA3421] .1314
FAILURE CODE [CA3497] .1316
FAILURE CODE [CA3498] .1317
FAILURE CODE [CA3543] .1318
FAILURE CODE [CA3545] .1325
FAILURE CODE [CA3547] .1327
FAILURE CODE [CA3558] .1328
FAILURE CODE [CA3559] .1330
FAILURE CODE [CA3562] .1332
FAILURE CODE [CA3563] .1334
FAILURE CODE [CA3567] .1337
FAILURE CODE [CA3568] .1340
FAILURE CODE [CA3571] .1344
FAILURE CODE [CA3572] .1346
FAILURE CODE [CA3574] .1348
FAILURE CODE [CA3575] .1350
FAILURE CODE [CA3577] .1352
FAILURE CODE [CA3578] .1354
FAILURE CODE [CA3582] .1356
FAILURE CODE [CA3583] .1362
FAILURE CODE [CA3596] .1364
FAILURE CODE [CA3649] .1366
FAILURE CODE [CA3681] .1368
FAILURE CODE [CA3682] .1373
FAILURE CODE [CA3713] .1379
FAILURE CODE [CA3717] .1382
FAILURE CODE [CA3718] .1383
FAILURE CODE [CA3725] .1384
FAILURE CODE [CA3741] .1387
FAILURE CODE [CA3748] .1388
FAILURE CODE [CA3751] .1390
FAILURE CODE [CA3755] .1392
FAILURE CODE [CA3866] .1394
FAILURE CODE [CA3867] .1398
FAILURE CODE [CA3868] .1401
FAILURE CODE [CA3899] .1405
FAILURE CODE [CA3911] .1407
FAILURE CODE [CA3912] .1411
FAILURE CODE [CA3932] .1413
FAILURE CODE [CA3933] .1415
FAILURE CODE [CA3934] .1417
FAILURE CODE [CA3935] .1420
FAILURE CODE [CA3936] .1422
FAILURE CODE [CA4151] .1424
FAILURE CODE [CA4152] .1428
FAILURE CODE [CA4155] .1432
FAILURE CODE [CA4156] .1434
FAILURE CODE [CA4157] .1437
FAILURE CODE [CA4158] .1439
FAILURE CODE [CA4159] .1440
FAILURE CODE [CA4161] .1441
FAILURE CODE [CA4162] .1444
FAILURE CODE [CA4163] .1447
FAILURE CODE [CA4164] .1448
FAILURE CODE [CA4165] .1450
FAILURE CODE [CA4166] .1452
FAILURE CODE [CA4168] .1453
FAILURE CODE [CA4169] .1456
FAILURE CODE [CA4171] .1458
FAILURE CODE [CA4249] .1461
FAILURE CODE [CA4251] .1463
FAILURE CODE [CA4259] .1465
FAILURE CODE [CA4261] .1468
FAILURE CODE [CA4277] .1471
FAILURE CODE [CA4281] .1475
FAILURE CODE [CA4459] .1478
FAILURE CODE [CA4461] .1481
FAILURE CODE [CA4658] .1484
FAILURE CODE [CA4731] .1488
FAILURE CODE [CA4732] .1489
FAILURE CODE [CA4739] .1490
FAILURE CODE [CA4768] .1491
FAILURE CODE [CA4769] .1493
FAILURE CODE [CA4842] .1496
FAILURE CODE [CA4952] .1500
FAILURE CODE [CA5115] .1502
FAILURE CODE [CA5179] .1505
FAILURE CODE [CA5181] .1507
FAILURE CODE [CA5383] .1509
FAILURE CODE [D110KB] .1511
FAILURE CODE [D19JKZ] .1513
FAILURE CODE [D811MC] .1516
FAILURE CODE [D862KA] .1517
FAILURE CODE [D8ALKA] .1518
FAILURE CODE [D8ALKB] .1520
FAILURE CODE [D8AQKR] .1522
FAILURE CODE [DA20MC] .1524
FAILURE CODE [DA22KK] .1525
FAILURE CODE [DA25KP] .1528
FAILURE CODE [DA26KP] .1531
FAILURE CODE [DA29KQ] .1533
FAILURE CODE [DA2LKA] .1535
FAILURE CODE [DA2LKB] .1537
FAILURE CODE [DA2QKR] .1539
FAILURE CODE [DA2RKR] .1542
FAILURE CODE [DAF0MB] .1543
FAILURE CODE [DAF0MC] .1544
FAILURE CODE [DAF8KB] .1545
FAILURE CODE [DAF9KQ] .1547
FAILURE CODE [DAFGMC] .1548
FAILURE CODE [DAFLKA] .1549
FAILURE CODE [DAFLKB] .1551
FAILURE CODE [DAFQKR] .1553
FAILURE CODE [DAZ9KQ] .1554
FAILURE CODE [DAZQKR] .1555
FAILURE CODE [DB2QKR] .1560
FAILURE CODE [DB2RKR] .1565
FAILURE CODE [DDNRKA] .1570
FAILURE CODE [DDNRKY] .1572
FAILURE CODE [DDNS00] .1574
FAILURE CODE [DFB1KZ] .1576
FAILURE CODE [DFB2KZ] .1579
FAILURE CODE [DFB3L8] .1582
FAILURE CODE [DFB4L8] .1584
FAILURE CODE [DFB5KZ] .1586
FAILURE CODE [DFB6KZ] .1589
FAILURE CODE [DGH2KA] .1592
FAILURE CODE [DGH2KB] .1594
FAILURE CODE [DHA4KA] .1596
FAILURE CODE [DHAAMA] .1598
FAILURE CODE [DHACMA] .1600
FAILURE CODE [DHPAMA] .1602
FAILURE CODE [DHPBMA] .1605
FAILURE CODE [DHS3MA] .1608
FAILURE CODE [DHS4MA] .1611
FAILURE CODE [DHS8MA] .1614
FAILURE CODE [DHS9MA] .1617
FAILURE CODE [DHSAMA] .1620
FAILURE CODE [DHSBMA] .1623
FAILURE CODE [DHSCMA] .1626
FAILURE CODE [DHSDMA] .1629
FAILURE CODE [DHSFMA] .1632
FAILURE CODE [DHSGMA] .1635
FAILURE CODE [DHSHMA] .1638
FAILURE CODE [DHSJMA] .1641
FAILURE CODE [DHX1MA] .1644
FAILURE CODE [DKR0MA] .1647
FAILURE CODE [DKR1MA] .1650
FAILURE CODE [DKULKA] .1653
FAILURE CODE [DKULKB] .1655
FAILURE CODE [DKULKY] .1657
FAILURE CODE [DR21KX] .1659
FAILURE CODE [DR31KX] .1661
FAILURE CODE [DV20KB] .1663
FAILURE CODE [DW43KA] .1665
FAILURE CODE [DW43KB] .1667
FAILURE CODE [DW43KY] .1669
FAILURE CODE [DW45KA] .1671
FAILURE CODE [DW45KB] .1674
FAILURE CODE [DW45KY] .1677
FAILURE CODE [DW4CKY] .1679
FAILURE CODE [DW91KA] .1681
FAILURE CODE [DW91KB] .1683
FAILURE CODE [DW91KY] .1685
FAILURE CODE [DWA2KA] .1687
FAILURE CODE [DWA2KB] .1689
FAILURE CODE [DWA2KY] .1691
FAILURE CODE [DWK0KA] .1693
FAILURE CODE [DWK0KB] .1695
FAILURE CODE [DWK0KY] .1697
FAILURE CODE [DWK2KA] .1699
FAILURE CODE [DWK2KB] .1701
FAILURE CODE [DWK2KY] .1703
FAILURE CODE [DWK8KA] .1705
FAILURE CODE [DWK8KB] .1707
FAILURE CODE [DWK8KY] .1709
FAILURE CODE [DXA8KA] .1711
FAILURE CODE [DXA8KB] .1713
FAILURE CODE [DXA9KA] .1715
FAILURE CODE [DXA9KB] .1717
FAILURE CODE [DXE0KA] .1719
FAILURE CODE [DXE0KB] .1720
FAILURE CODE [DXE4KA] .1722
FAILURE CODE [DXE4KB] .1724
FAILURE CODE [DXE4KY] .1726
FAILURE CODE [DXE5KA] .1728
FAILURE CODE [DXE5KB] .1730
FAILURE CODE [DXE6KA] .1732
FAILURE CODE [DXE6KB] .1734
FAILURE CODE [DXE7KA] .1736
FAILURE CODE [DXE7KB] .1738
FAILURE CODE [DXE7KY] .1740
FAILURE CODE [DXE8KA] .1742
FAILURE CODE [DXE8KB] .1744
FAILURE CODE [DXE8KY] .1746
FAILURE CODE [DXE9KA] .1748
FAILURE CODE [DXE9KB] .1750
FAILURE CODE [DXE9KY] .1752
FAILURE CODE [DXEAKA] .1754
FAILURE CODE [DXEAKB] .1756
FAILURE CODE [DXEAKY] .1758
FAILURE CODE [DY20KA] .1760
FAILURE CODE [DY20MA] .1762
FAILURE CODE [DY2CKB] .1764
FAILURE CODE [DY2DKB] .1767
FAILURE CODE [DY2EKB] .1769
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1771
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1771
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1777
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1780
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1782
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1784
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1787
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1788
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1789
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1790
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1791
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1792
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1793
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1794
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1795
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1796
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1797
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1798
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1800
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1801
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1802
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1803
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1805
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1806
E-24 FUNCTION SWITCH DOES NOT OPERATE .1807
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1808
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1809
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1810
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1811
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1812
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1813
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1814
E-32 ALARM BUZZER CANNOT BE CANCELED 1816
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1817
E-34 SERVICE MODE CANNOT BE SELECTED 1818
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1819
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1822
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1824
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1827
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1829
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1832
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1833
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1835
E-43 HORN DOES NOT SOUND 1836
E-44 HORN DOES NOT STOP SOUNDING 1839
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1841
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1842
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1844
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1845
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1846
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1847
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1848
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1849
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1850
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1851
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1852
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1853
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1855
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1856
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1857
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1857
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1858
FAILURE MODE AND CAUSE TABLE 1860
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1869
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1870
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1873
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1874
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1875
H-6 SPEED OR POWER OF BOOM IS LOW .1877
H-7 ARM SPEED OR POWER IS LOW .1881
H-8 BUCKET SPEED OR POWER IS LOW 1886
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1889
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1890
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1892
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .1894
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .1895
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1896
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1897
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1898
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .1899
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1900
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1901
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1902
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .1903
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .1905
H-23 TRAVEL SPEED IS LOW 1908
H-24 ONE OF TRACKS DOES NOT RUN .1910
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1911
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1912
H-27 SWINGS ONLY IN ONE DIRECTION .1913
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .1914
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1915
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1916
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1917
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .1918
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .1919
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .1920
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1921
H-36 Quick coupler cylinder will not extend .1922
H-37 Quick coupler cylinder will not retract (but buzzer doesnot sound) .1924
H-38 Buzzer does not sound (but quick coupler cylinder doesretract) .1926
H-39 Quick coupler cylinder extends and retracts slowly .1928
TROUBLESHOOTING OF ENGINE (S-MODE) 1929
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1929
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1930
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1931
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1932
S-4 ENGINE STARTABILITY IS POOR .1934
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1936
S-6 ENGINE STOPS DURING OPERATION .1938
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1940
S-8 ENGINE LACKS POWER 1941
S-9 KDPF GETS CLOGGED IN A SHORT TIME .1943
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1945
S-11 OIL BECOMES CONTAMINATED QUICKLY .1946
S-12 FUEL CONSUMPTION IS EXCESSIVE 1947
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1948
S-14 OIL PRESSURE DROPS .1949
S-15 FUEL MIXES INTO ENGINE OIL .1951
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1952
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .1953
S-18 UNUSUAL NOISE IS HEARD .1955
S-19 VIBRATION IS EXCESSIVE .1956
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .1957
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .1958
S-22 ACTIVE REGENERATION TAKES TIME .1960
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1961
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1962
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .1964
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1965
50 DISASSEMBLY AND ASSEMBLY .1967
CONTENTS 1968
ABBREVIATION LIST .1973
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .1979
HOW TO READ THIS MANUAL .1979
COATING MATERIALS LIST 1981
SPECIAL TOOLS LIST 1985
SKETCHES OF SPECIAL TOOLS .1997
ENGINE AND COOLING SYSTEM .2003
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2003
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2003
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2006
REMOVE AND INSTALL INJECTOR ASSEMBLY 2010
METHOD FOR REMOVING INJECTOR ASSEMBLY .2010
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2015
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2023
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2024
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2033
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2049
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2049
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2050
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2053
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2053
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2056
REMOVE AND INSTALL STARTER ASSEMBLY .2061
METHOD FOR REMOVING STARTER ASSEMBLY 2061
METHOD FOR INSTALLING STARTER ASSEMBLY 2063
REMOVE AND INSTALL ALTERNATOR BELT 2065
METHOD FOR REMOVING ALTERNATOR BELT .2065
METHOD FOR INSTALLING ALTERNATOR BELT .2067
REMOVE AND INSTALL RADIATOR ASSEMBLY 2069
METHOD FOR REMOVING RADIATOR ASSEMBLY .2069
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2071
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2073
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2073
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2076
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2079
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2079
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2080
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2082
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2083
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2091
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2102
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2102
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2105
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2109
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2109
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2110
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2113
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2113
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2114
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2115
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2115
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2117
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2123
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2123
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2127
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2131
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2131
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2136
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2142
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2142
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2147
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2153
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2153
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2153
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2155
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2155
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2155
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2157
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2157
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2159
REMOVE AND INSTALL KDPF ASSEMBLY 2162
METHOD FOR REMOVING KDPF ASSEMBLY .2162
METHOD FOR INSTALLING KDPF ASSEMBLY .2164
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2166
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2167
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2170
REMOVE AND INSTALL SCR ASSEMBLY .2175
METHOD FOR REMOVING SCR ASSEMBLY 2175
METHOD FOR INSTALLING SCR ASSEMBLY 2177
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2179
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2179
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2185
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2191
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2191
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2198
REMOVE AND INSTALL KCCV ASSEMBLY 2206
METHOD FOR REMOVING KCCV ASSEMBLY .2206
METHOD FOR INSTALLING KCCV ASSEMBLY .2208
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2213
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2213
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2218
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2223
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2223
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2225
REMOVE AND INSTALL AdBlue/DEF PUMP 2227
METHOD FOR REMOVING AdBlue/DEF PUMP .2227
METHOD FOR INSTALLING AdBlue/DEF PUMP .2229
REMOVE AND INSTALL AdBlue/DEF HOSE 2232
METHOD FOR REMOVING AdBlue/DEF HOSE .2232
METHOD FOR INSTALLING AdBlue/DEF HOSE .2239
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2245
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2245
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2246
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2248
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2248
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2250
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2253
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2253
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2254
POWER TRAIN .2255
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2255
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2255
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2256
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2258
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2258
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2262
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2271
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2271
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2274
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2277
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2277
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2281
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2288
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2288
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2288
UNDERCARRIAGE AND FRAME .2290
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2290
METHOD FOR SEPARATING TRACK ASSEMBLY 2290
METHOD FOR INSTALLING TRACK ASSEMBLY 2292
REMOVE AND INSTALL SPROCKET .2295
METHOD FOR REMOVING SPROCKET 2295
METHOD FOR INSTALLING SPROCKET 2295
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2297
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2297
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2298
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2300
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2300
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2301
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2305
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2306
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2307
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2308
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2309
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2310
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2312
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2312
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2314
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2316
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2316
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2318
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2321
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2321
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2324
HYDRAULIC SYSTEM 2328
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2328
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2328
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2330
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2333
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2334
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2335
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2336
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2336
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2338
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2341
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2341
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2344
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2347
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2347
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2354
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2362
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2362
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2364
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2368
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2368
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2369
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2371
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2371
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2372
REMOVE AND INSTALL QUICK COUPLER VALVE 2374
WORK EQUIPMENT 2376
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2376
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2376
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2380
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2386
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2386
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2389
CAB AND ITS ATTACHMENTS .2395
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2395
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY .2395
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY .2400
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2407
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2409
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2409
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2419
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2419
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2422
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2428
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2428
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2435
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2442
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2442
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2447
REMOVE AND INSTALL OPERATOR’S SEAT 2453
METHOD FOR REMOVING OPERATOR’S SEAT .2453
METHOD FOR INSTALLING OPERATOR’S SEAT .2455
REMOVE AND INSTALL SEAT BELT 2458
METHOD FOR REMOVING SEAT BELT .2458
METHOD FOR INSTALLING SEAT BELT .2459
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2460
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2460
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2465
ELECTRICAL SYSTEM .2474
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2474
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2474
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2476
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2477
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2477
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2481
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2486
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2486
METHOD FOR INSTALLING KomVision CONTROLLER 2487
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2488
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2488
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2491
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2494
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2494
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2495
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2496
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2496
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2497
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2498
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2498
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2499
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2501
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2501
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2503
REMOVE AND INSTALL KomVision CAMERA .2505
METHOD FOR REMOVING KomVision CAMERA 2505
METHOD FOR INSTALLING KomVision CAMERA 2508
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2511
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2511
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2514
60 MAINTENANCE STANDARD .2517
CONTENTS 2518
ABBREVIATION LIST .2519
ENGINE AND COOLING SYSTEM .2525
MAINTENANCE STANDARD OF ENGINE MOUNT 2525
MAINTENANCE STANDARD OF COOLING SYSTEM 2526
POWER TRAIN .2527
MAINTENANCE STANDARD OF SWING CIRCLE 2527
MAINTENANCE STANDARD OF SWING MACHINERY .2528
MAINTENANCE STANDARD OF FINAL DRIVE .2530
MAINTENANCE STANDARD OF SPROCKET 2532
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2533
UNDERCARRIAGE AND FRAME .2535
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2535
MAINTENANCE STANDARD OF IDLER .2537
MAINTENANCE STANDARD OF TRACK ROLLER 2539
MAINTENANCE STANDARD OF CARRIER ROLLER 2540
MAINTENANCE STANDARD OF TRACK SHOE 2541
MAINTENANCE STANDARD OF TRIPLE SHOE .2544
MAINTENANCE STANDARD OF SWAMP SHOE 2545
MAINTENANCE STANDARD OF ROAD LINER 2546
HYDRAULIC SYSTEM 2547
MAINTENANCE STANDARD OF HYDRAULIC TANK 2547
MAINTENANCE STANDARD OF MAIN PUMP .2548
MAINTENANCE STANDARD OF LS-EPC VALVE 2549
MAINTENANCE STANDARD OF PC-EPC VALVE 2550
MAINTENANCE STANDARD OF SWING MOTOR .2551
MAINTENANCE STANDARD OF TRAVEL MOTOR 2554
MAINTENANCE STANDARD OF CONTROL VALVE .2557
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2567
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2570
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2573
MAINTENANCE STANDARD OF EPC VALVE .2574
MAINTENANCE STANDARD OF SOLENOID VALVE 2576
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 2577
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2579
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2580
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2581
WORK EQUIPMENT 2582
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2582
DIMENSION OF ARM 2587
DIMENSIONS OF BUCKET 2589
MAINTENANCE STANDARD OF BOOM CYLINDER .2591
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2592
MAINTENANCE STANDARD OF ARM CYLINDER 2593
MAINTENANCE STANDARD OF BUCKET CYLINDER .2594
80 APPENDIX .2595
CONTENTS 2596
ABBREVIATION LIST .2598
AIR CONDITIONER SYSTEM 2604
PRECAUTIONS FOR REFRIGERANT .2604
AIR CONDITIONER COMPONENT .2605
SPECIFICATIONS OF AIR CONDITIONER .2607
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2608
OUTLINE OF REFRIGERATION CYCLE 2609
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2611
AIR CONDITIONER UNIT 2611
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2611
FUNCTION OF AIR CONDITIONER UNIT 2613
COMPONENT PARTS OF AIR CONDITIONER UNIT .2615
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2616
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2616
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2616
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2616
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2617
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2617
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2617
FUNCTION OF DUAL PRESSURE SWITCH 2618
AIR CONDITIONER CONTROLLER 2619
STRUCTURE OF AIR CONDITIONER CONTROLLER .2619
COMPRESSOR 2620
STRUCTURE OF COMPRESSOR .2620
SPECIFICATIONS OF COMPRESSOR 2620
FUNCTION OF COMPRESSOR 2620
CONDENSER .2621
STRUCTURE OF CONDENSER 2621
SPECIFICATIONS OF CONDENSER .2621
FUNCTION OF CONDENSER .2621
SENSORS FOR AIR CONDITIONER SYSTEM 2623
STRUCTURE OF SUNLIGHT SENSOR 2623
FUNCTION OF SUNLIGHT SENSOR .2623
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2623
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2623
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2625
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2627
AIR CONDITIONER SYSTEM DIAGRAM 2629
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2630
FUNCTION OF AIR CONDITIONER CONTROLLER 2631
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2632
TESTING AIR LEAKAGE (DUCT) 2636
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2636
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2638
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2639
TEST VENT (MODE) CHANGEOVER .2640
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2640
TESTING FRESH/RECIRC AIR CHANGEOVER .2642
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2642
TEST SUNLIGHT SENSOR 2643
METHOD FOR TESTING SUNLIGHT SENSOR 2643
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2644
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2644
TEST RELAYS .2646
METHOD FOR TESTING RELAYS .2646
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2647
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2649
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2652
FAILURE CODE [879AKA] .2654
FAILURE CODE [879AKB] .2655
FAILURE CODE [879BKA] .2656
FAILURE CODE [879BKB] .2658
FAILURE CODE [879CKA] .2660
FAILURE CODE [879CKB] .2661
FAILURE CODE [879DKZ] .2662
FAILURE CODE [879EMC] .2664
FAILURE CODE [879FMC] .2665
FAILURE CODE [879GKX] .2666
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2668
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2670
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2673
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2675
TROUBLESHOOTING USING GAUGE PRESSURE 2677
CONNECTION OF SERVICE TOOL 2680
METHOD FOR CONNECTING SERVICE TOOL 2680
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2682
HANDLE COMPRESSOR OIL .2684
METHOD FOR REPLACING DESICCANT 2686
90 CIRCUIT DIAGRAMS .2689
CONTENTS 2690
ABBREVIATION LIST .2691
HYDRAULIC CIRCUIT DIAGRAM .2697
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2697
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2701
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2703
ELECTRICAL CIRCUIT DIAGRAM 2705
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2705
ELECTRICAL CIRCUIT DIAGRAM (1/8) 2709
ELECTRICAL CIRCUIT DIAGRAM (2/8) 2711
ELECTRICAL CIRCUIT DIAGRAM (3/8) 2713
ELECTRICAL CIRCUIT DIAGRAM (4/8) 2715
ELECTRICAL CIRCUIT DIAGRAM (5/8) 2717
ELECTRICAL CIRCUIT DIAGRAM (6/8) 2719
ELECTRICAL CIRCUIT DIAGRAM (7/8) 2721
ELECTRICAL CIRCUIT DIAGRAM (8/8) 2723
INDEX 2725

DESCRIPTION:

Komatsu PC240LC-11E0,PC240NLC-11E0 Hydraulic Excavator Shop Manual UENBM00470 – PDF DOWNLOAD

• SERIAL NUMBERS K75001 and up

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

G.B 31/12/24