Komatsu PC240LC-11E0 PC240NLC-11E0 Excavator Workshop Manual PDF

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Komatsu PC240LC-11E0,PC240NLC-11E0 Hydraulic Excavator Shop Manual UENBM00471 – PDF DOWNLOAD

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Komatsu PC240LC-11E0,PC240NLC-11E0 Hydraulic Excavator Shop Manual UENBM00471 – PDF DOWNLOAD

Language : English
Pages : 2812
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC240LC-11E0,PC240NLC-11E0 Hydraulic Excavator Shop Manual UENBM00471 – PDF DOWNLOAD

• SERIAL NUMBERS K75001 and up

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
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 150
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 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
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 . 446
SWING CIRCLE 447
TRAVEL SYSTEM . 449
LAYOUT DRAWING OF TRAVEL SYSTEM . 449
TRAVEL CONTROL SYSTEM DIAGRAM . 453
FUNCTION OF TRAVEL CONTROL SYSTEM . 453
COMPONENT PARTS OF TRAVEL SYSTEM 455
TRAVEL MOTOR 455
FINAL DRIVE . 467
TRAVEL PPC VALVE 469
CENTER SWIVEL JOINT . 474
UNDERCARRIAGE AND FRAME . 476
LAYOUT DRAWING OF UNDERCARRIAGE . 476
SPECIFICATIONS OF UNDERCARRIAGE . 477
WORK EQUIPMENT 478
STRUCTURE OF WORK EQUIPMENT . 478
FUNCTION OF WORK EQUIPMENT 479
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 480
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 480
BUCKET CLEARANCE ADJUSTMENT SHIM 481
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 481
CAB AND ITS ATTACHMENTS . 482
ROPS CAB 482
STRUCTURE OF ROPS CAB . 482
FUNCTION OF ROPS CAB 482
CAB MOUNT . 483
STRUCTURE OF CAB MOUNT 483
FUNCTION OF CAB MOUNT . 483
CAB TIPPING STOPPER . 484
STRUCTURE OF CAB TIPPING STOPPER 484
FUNCTION OF CAB TIPPING STOPPER . 484
20 STANDARD VALUE TABLE . 485
CONTENTS 486
ABBREVIATION LIST . 487
STANDARD VALUE TABLE FOR ENGINE . 493
STANDARD VALUE TABLE FOR ENGINE: PC240LC-11E0, PC240NLC-11E0 493
STANDARD VALUE TABLE FOR MACHINE 497
STANDARD VALUE TABLE FOR MACHINE: PC240LC-11E0, PC240NLC-11E0 . 497
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 511
STANDARD VALUE TABLE FOR ELECTRICAL . 515
STANDARD VALUE TABLE FOR ELECTRICAL . 515
30 TESTING AND ADJUSTING 525
CONTENTS 526
ABBREVIATION LIST . 529
RELATED INFORMATION ON TESTING AND ADJUSTING 535
TOOLS FOR TESTING AND ADJUSTING . 535
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 542
ENGINE AND COOLING SYSTEM . 544
TEST ENGINE SPEED . 544
METHOD FOR TESTING ENGINE SPEED . 544
TEST BOOST PRESSURE . 547
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 547
METHOD FOR TESTING BOOST PRESSURE . 548
TEST EXHAUST GAS COLOR 549
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 549
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 550
TEST AND ADJUST VALVE CLEARANCE . 552
METHOD FOR TESTING VALVE CLEARANCE 552
METHOD FOR ADJUSTING VALVE CLEARANCE 553
TEST COMPRESSION PRESSURE . 555
METHOD FOR TESTING COMPRESSION PRESSURE . 555
TEST BLOWBY PRESSURE 560
METHOD FOR TESTING BLOWBY PRESSURE 560
TEST ENGINE OIL PRESSURE 562
METHOD FOR TESTING ENGINE OIL PRESSURE 562
TEST EGR VALVE AND VGT OIL PRESSURE . 563
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 563
TEST FUEL PRESSURE 565
METHOD FOR TESTING FUEL PRESSURE 566
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 571
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 572
BLEEDING AIR FROM FUEL SYSTEM . 578
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 578
TEST FUEL CIRCUIT FOR LEAKAGE . 579
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 579
HANDLE CYLINDER CUT-OUT MODE OPERATION 581
HANDLE NO-INJECTION CRANKING OPERATION 582
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 583
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 583
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 583
REPLACING FAN BELT 585
METHOD FOR REPLACING FAN BELT . 585
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 586
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 586
TEST SCR RELATED FUNCTIONS 587
TEST AdBlue/DEF PUMP RAISED PRESSURE 590
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 593
TEST AdBlue/DEF LINE HEATER RELAY 1 . 597
TEST AdBlue/DEF LINE HEATER RELAY 2 . 600
TEST AdBlue/DEF PUMP HEATER RELAY . 602
TEST AdBlue/DEF TANK HEATER VALVE . 605
TEST DENITRATION EFFICIENCY OF SCR 608
CLEAN AdBlue/DEF TANK . 612
METHOD FOR CLEANING AdBlue/DEF TANK . 612
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 616
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 616
POWER TRAIN . 618
TEST SWING CIRCLE BEARING CLEARANCE . 618
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 618
UNDERCARRIAGE AND FRAME . 619
TEST AND ADJUST TRACK TENSION . 619
METHOD FOR TESTING TRACK TENSION 619
METHOD FOR ADJUSTING TRACK TENSION 619
HYDRAULIC SYSTEM 621
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 621
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK . 621
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT . 621
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 627
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 628
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 634
TEST OIL PRESSURE OF CONTROL CIRCUIT 637
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 637
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 639
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 639
TEST PC-EPC VALVE OUTLET PRESSURE . 640
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 641
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 643
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 643
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 644
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 647
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 648
METHOD FOR ADJUSTING LS VALVE . 649
TEST OUTLET PRESSURE OF SOLENOID VALVE 650
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 650
OPERATING CONDITION OF SOLENOID VALVE . 651
TEST PPC VALVE OUTLET PRESSURE 654
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 654
TEST ATTACHMENT CIRCUIT OIL PRESSURE 656
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 656
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 658
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 658
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 659
TEST PUMP SWASH PLATE SENSOR 661
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 661
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 662
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 662
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 662
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 663
TEST OIL LEAKAGE 664
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 664
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 664
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 665
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 666
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 666
BLEED AIR FROM HYDRAULIC CIRCUIT 667
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 669
CAB AND ITS ATTACHMENTS . 671
TEST CAB TIPPING STOPPER 671
METHOD FOR TESTING CAB TIPPING STOPPER 671
METHOD FOR ADJUSTING MIRRORS 672
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 672
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 673
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 674
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 675
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 676
ELECTRICAL SYSTEM . 678
ELECTRICAL SYSTEM . 679
SET AND OPERATE MACHINE MONITOR . 679
OPERATOR MODE . 682
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 683
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 683
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 684
CHECKING FUNCTION OF SERVICE METER 684
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 684
SERVICE MODE 687
SERVICE MODE 687
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 689
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 695
ABNORMALITY RECORD MENU . 706
METHOD FOR CONFIRMING MAINTENANCE RECORD 711
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 712
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 716
DEFAULT MENU 717
DIAGNOSTIC TESTS MENU . 728
ADJUSTMENT MENU . 738
METHOD FOR PERFORMING NO-INJECTION CRANKING . 772
KOMTRAX SETTINGS MENU . 773
METHOD FOR DISPLAYING SERVICE MESSAGE . 775
METHOD FOR STARTING UP KOMTRAX TERMINAL . 777
ADJUST REARVIEW CAMERA ANGLE 782
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 782
ADJUST KomVision CAMERA ANGLE . 785
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 786
ADJUST KomVision RELATED ITEMS 790
SETTING OF KomVision (MAIN SETTING) . 790
SETTING OF KomVision (CAMERA SETTING) . 792
SETTING OF KomVision (CAMERA CALIBRATION) . 792
KomVision screen – Check 12 m visibility 806
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 809
HANDLE BATTERY DISCONNECT SWITCH 810
TEST DIODES . 811
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 811
METHOD FOR TESTING DIODE USING ANALOG TESTER 811
Pm CLINIC . 812
Pm CLINIC SERVICE . 812
Pm CLINIC CHECK SHEET . 816
40 TROUBLESHOOTING 827
CONTENTS 828
ABBREVIATION LIST . 839
RELATED INFORMATION ON TROUBLESHOOTING 845
GENERAL TROUBLESHOOTING POINTS 845
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 846
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 858
CHECKS BEFORE TROUBLESHOOTING . 860
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 862
WALK-AROUND CHECK . 862
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 864
CHECK FUEL LEVEL AND TYPE . 864
CHECK IMPURE INGREDIENT IN FUEL . 864
CHECK FUEL PREFILTER 865
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 865
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 866
CHECK MAIN FILTER . 867
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 869
CHECK COOLANT LEVEL (RESERVOIR TANK) 870
CHECK CLOGGING OF AIR CLEANER . 870
OUTER ELEMENT – CLEAN . 871
ELEMENTS – REPLACE 873
CHECK HYDRAULIC OIL LEVEL . 874
CHECK HYDRAULIC OIL STRAINER 875
CHECK HYDRAULIC FILTER 876
CHECK OIL LEVEL IN SWING MACHINERY CASE . 877
CHECK OIL LEVEL IN DAMPER CASE 878
CHECK OIL LEVEL IN FINAL DRIVE CASE . 878
BLEED AIR FROM FUEL SYSTEM 879
BLEED AIR FROM HYDRAULIC SYSTEM . 879
ELECTRICAL EQUIPMENT – CHECK METHOD . 879
AUTOMATIC GREASE SYSTEM . 887
FINDING MALFUNCTIONS 887
MALFUNCTION FINDING PROCEDURES 889
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM . 891
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 901
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 904
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 908
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 910
CONNECTOR LIST AND LAYOUT . 913
CONNECTOR CONTACT IDENTIFICATION 926
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 966
FUSE LOCATION TABLE . 972
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 974
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 978
FAILURE CODE TABLE 980
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 998
FAILURE CODE [879AKA] . 998
FAILURE CODE [879AKB] . 999
FAILURE CODE [879BKA] .1000
FAILURE CODE [879BKB] .1002
FAILURE CODE [879CKA] .1004
FAILURE CODE [879CKB] .1005
FAILURE CODE [879DKZ] .1006
FAILURE CODE [879EMC] .1008
FAILURE CODE [879FMC] .1009
FAILURE CODE [879GKX] .1010
FAILURE CODE [989L00] .1012
FAILURE CODE [989M00] .1013
FAILURE CODE [989N00] .1014
FAILURE CODE [A1U0N3] .1015
FAILURE CODE [A1U0N4] .1017
FAILURE CODE [A900FR] .1019
FAILURE CODE [A900N6] .1020
FAILURE CODE [A900NY] .1021
FAILURE CODE [AA10NX] .1022
FAILURE CODE [AB00KE] .1024
FAILURE CODE [AQ10N3] .1027
FAILURE CODE [AS00N3] .1029
FAILURE CODE [AS00R2] .1031
FAILURE CODE [AS00R3] .1032
FAILURE CODE [AS00R4] .1033
FAILURE CODE [AS00R5] .1034
FAILURE CODE [AS00R6] .1035
FAILURE CODE [AS00ZK] .1036
FAILURE CODE [AS10KM] .1037
FAILURE CODE [AS10NR] .1038
FAILURE CODE [AS10NT] .1039
FAILURE CODE [B@BAZG] .1040
FAILURE CODE [B@BAZK] .1041
FAILURE CODE [B@BCNS] .1043
FAILURE CODE [B@BCQA] .1044
FAILURE CODE [B@BCZK] .1046
FAILURE CODE [B@HANS] .1048
FAILURE CODE [CA115] 1049
FAILURE CODE [CA122] 1050
FAILURE CODE [CA123] 1052
FAILURE CODE [CA131] 1054
FAILURE CODE [CA132] 1056
FAILURE CODE [CA144] 1058
FAILURE CODE [CA145] 1060
FAILURE CODE [CA153] 1062
FAILURE CODE [CA154] 1065
FAILURE CODE [CA187] 1067
FAILURE CODE [CA221] 1069
FAILURE CODE [CA222] 1071
FAILURE CODE [CA227] 1073
FAILURE CODE [CA234] 1074
FAILURE CODE [CA238] 1075
FAILURE CODE [CA239] 1077
FAILURE CODE [CA249] 1079
FAILURE CODE [CA256] 1081
FAILURE CODE [CA271] 1083
FAILURE CODE [CA272] 1085
FAILURE CODE [CA322] 1087
FAILURE CODE [CA323] 1089
FAILURE CODE [CA324] 1091
FAILURE CODE [CA325] 1093
FAILURE CODE [CA331] 1095
FAILURE CODE [CA332] 1097
FAILURE CODE [CA343] 1099
FAILURE CODE [CA351] 1100
FAILURE CODE [CA352] 1101
FAILURE CODE [CA356] 1104
FAILURE CODE [CA357] 1106
FAILURE CODE [CA386] 1108
FAILURE CODE [CA428] 1109
FAILURE CODE [CA429] 1111
FAILURE CODE [CA435] 1113
FAILURE CODE [CA441] 1115
FAILURE CODE [CA442] 1117
FAILURE CODE [CA449] 1118
FAILURE CODE [CA451] 1119
FAILURE CODE [CA452] 1121
FAILURE CODE [CA488] 1123
FAILURE CODE [CA515] 1124
FAILURE CODE [CA516] 1126
FAILURE CODE [CA553] 1128
FAILURE CODE [CA555] 1129
FAILURE CODE [CA556] 1130
FAILURE CODE [CA559] 1131
FAILURE CODE [CA595] 1134
FAILURE CODE [CA687] 1135
FAILURE CODE [CA689] 1137
FAILURE CODE [CA691] 1140
FAILURE CODE [CA692] 1142
FAILURE CODE [CA697] 1144
FAILURE CODE [CA698] 1145
FAILURE CODE [CA731] 1146
FAILURE CODE [CA778] 1148
FAILURE CODE [CA1117] .1153
FAILURE CODE [CA1664] .1154
FAILURE CODE [CA1669] .1156
FAILURE CODE [CA1673] .1157
FAILURE CODE [CA1677] .1158
FAILURE CODE [CA1678] .1159
FAILURE CODE [CA1682] .1160
FAILURE CODE [CA1683] .1162
FAILURE CODE [CA1684] .1164
FAILURE CODE [CA1686] .1166
FAILURE CODE [CA1691] .1167
FAILURE CODE [CA1694] .1170
FAILURE CODE [CA1695] .1173
FAILURE CODE [CA1696] .1174
FAILURE CODE [CA1712] .1176
FAILURE CODE [CA1713] .1179
FAILURE CODE [CA1714] .1181
FAILURE CODE [CA1715] .1182
FAILURE CODE [CA1776] .1183
FAILURE CODE [CA1777] .1186
FAILURE CODE [CA1843] .1189
FAILURE CODE [CA1844] .1191
FAILURE CODE [CA1879] .1194
FAILURE CODE [CA1881] .1196
FAILURE CODE [CA1883] .1198
FAILURE CODE [CA1885] .1201
FAILURE CODE [CA1887] .1203
FAILURE CODE [CA1921] .1205
FAILURE CODE [CA1922] .1208
FAILURE CODE [CA1942] .1213
FAILURE CODE [CA1993] .1214
FAILURE CODE [CA2185] .1217
FAILURE CODE [CA2186] .1218
FAILURE CODE [CA2249] .1220
FAILURE CODE [CA2271] .1221
FAILURE CODE [CA2272] .1224
FAILURE CODE [CA2288] .1227
FAILURE CODE [CA2311] .1228
FAILURE CODE [CA2349] .1229
FAILURE CODE [CA2353] .1232
FAILURE CODE [CA2357] .1234
FAILURE CODE [CA2381] .1235
FAILURE CODE [CA2382] .1238
FAILURE CODE [CA2383] .1241
FAILURE CODE [CA2386] .1244
FAILURE CODE [CA2387] .1246
FAILURE CODE [CA2555] .1247
FAILURE CODE [CA2556] .1250
FAILURE CODE [CA2637] .1253
FAILURE CODE [CA2639] .1255
FAILURE CODE [CA2771] .1258
FAILURE CODE [CA2777] .1264
FAILURE CODE [CA2976] .1267
FAILURE CODE [CA3133] .1269
FAILURE CODE [CA3134] .1272
FAILURE CODE [CA3135] .1274
FAILURE CODE [CA3142] .1277
FAILURE CODE [CA3143] .1278
FAILURE CODE [CA3144] .1279
FAILURE CODE [CA3146] .1281
FAILURE CODE [CA3147] .1282
FAILURE CODE [CA3148] .1283
FAILURE CODE [CA3151] .1285
FAILURE CODE [CA3165] .1291
FAILURE CODE [CA3229] .1293
FAILURE CODE [CA3231] .1295
FAILURE CODE [CA3232] .1297
FAILURE CODE [CA3235] .1301
FAILURE CODE [CA3239] .1303
FAILURE CODE [CA3241] .1306
FAILURE CODE [CA3242] .1309
FAILURE CODE [CA3251] .1312
FAILURE CODE [CA3253] .1314
FAILURE CODE [CA3254] .1317
FAILURE CODE [CA3255] .1320
FAILURE CODE [CA3256] .1324
FAILURE CODE [CA3311] .1326
FAILURE CODE [CA3312] .1328
FAILURE CODE [CA3313] .1331
FAILURE CODE [CA3314] .1332
FAILURE CODE [CA3315] .1333
FAILURE CODE [CA3316] .1335
FAILURE CODE [CA3317] .1336
FAILURE CODE [CA3318] .1337
FAILURE CODE [CA3319] .1339
FAILURE CODE [CA3321] .1340
FAILURE CODE [CA3322] .1342
FAILURE CODE [CA3419] .1344
FAILURE CODE [CA3421] .1346
FAILURE CODE [CA3497] .1348
FAILURE CODE [CA3498] .1349
FAILURE CODE [CA3543] .1350
FAILURE CODE [CA3545] .1357
FAILURE CODE [CA3547] .1359
FAILURE CODE [CA3558] .1360
FAILURE CODE [CA3559] .1362
FAILURE CODE [CA3562] .1364
FAILURE CODE [CA3563] .1366
FAILURE CODE [CA3567] .1369
FAILURE CODE [CA3568] .1372
FAILURE CODE [CA3571] .1376
FAILURE CODE [CA3572] .1378
FAILURE CODE [CA3574] .1380
FAILURE CODE [CA3575] .1382
FAILURE CODE [CA3577] .1384
FAILURE CODE [CA3578] .1386
FAILURE CODE [CA3582] .1388
FAILURE CODE [CA3583] .1394
FAILURE CODE [CA3596] .1396
FAILURE CODE [CA3649] .1398
FAILURE CODE [CA3681] .1400
FAILURE CODE [CA3682] .1405
FAILURE CODE [CA3713] .1411
FAILURE CODE [CA3717] .1414
FAILURE CODE [CA3718] .1415
FAILURE CODE [CA3725] .1416
FAILURE CODE [CA3741] .1419
FAILURE CODE [CA3748] .1420
FAILURE CODE [CA3751] .1422
FAILURE CODE [CA3755] .1424
FAILURE CODE [CA3866] .1426
FAILURE CODE [CA3867] .1430
FAILURE CODE [CA3868] .1433
FAILURE CODE [CA3899] .1437
FAILURE CODE [CA3911] .1439
FAILURE CODE [CA3912] .1443
FAILURE CODE [CA3932] .1445
FAILURE CODE [CA3933] .1447
FAILURE CODE [CA3934] .1449
FAILURE CODE [CA3935] .1452
FAILURE CODE [CA3936] .1454
FAILURE CODE [CA4151] .1456
FAILURE CODE [CA4152] .1460
FAILURE CODE [CA4155] .1464
FAILURE CODE [CA4156] .1466
FAILURE CODE [CA4157] .1469
FAILURE CODE [CA4158] .1471
FAILURE CODE [CA4159] .1472
FAILURE CODE [CA4161] .1473
FAILURE CODE [CA4162] .1476
FAILURE CODE [CA4163] .1479
FAILURE CODE [CA4164] .1480
FAILURE CODE [CA4165] .1482
FAILURE CODE [CA4166] .1484
FAILURE CODE [CA4168] .1485
FAILURE CODE [CA4169] .1488
FAILURE CODE [CA4171] .1490
FAILURE CODE [CA4249] .1493
FAILURE CODE [CA4251] .1495
FAILURE CODE [CA4259] .1497
FAILURE CODE [CA4261] .1500
FAILURE CODE [CA4277] .1503
FAILURE CODE [CA4281] .1507
FAILURE CODE [CA4459] .1510
FAILURE CODE [CA4461] .1513
FAILURE CODE [CA4658] .1516
FAILURE CODE [CA4731] .1520
FAILURE CODE [CA4732] .1521
FAILURE CODE [CA4739] .1522
FAILURE CODE [CA4768] .1523
FAILURE CODE [CA4769] .1525
FAILURE CODE [CA4842] .1528
FAILURE CODE [CA4952] .1532
FAILURE CODE [CA5115] .1534
FAILURE CODE [CA5179] .1537
FAILURE CODE [CA5181] .1539
FAILURE CODE [CA5383] .1541
FAILURE CODE [D110KB] .1543
FAILURE CODE [D19JKZ] .1545
FAILURE CODE [D811MC] .1548
FAILURE CODE [D862KA] .1549
FAILURE CODE [D8ALKA] .1550
FAILURE CODE [D8ALKB] .1552
FAILURE CODE [D8AQKR] .1554
FAILURE CODE [DA20MC] .1556
FAILURE CODE [DA22KK] .1557
FAILURE CODE [DA25KP] .1560
FAILURE CODE [DA26KP] .1563
FAILURE CODE [DA29KQ] .1566
FAILURE CODE [DA2LKA] .1568
FAILURE CODE [DA2LKB] .1570
FAILURE CODE [DA2QKR] .1572
FAILURE CODE [DA2RKR] .1575
FAILURE CODE [DAF0KM] .1576
FAILURE CODE [DAF0MB] .1577
FAILURE CODE [DAF0MC] .1578
FAILURE CODE [DAF8KB] .1579
FAILURE CODE [DAF9KQ] .1581
FAILURE CODE [DAFGMC] .1582
FAILURE CODE [DAFLKA] .1583
FAILURE CODE [DAFLKB] .1585
FAILURE CODE [DAFQKR] .1587
FAILURE CODE [DAZ9KQ] .1588
FAILURE CODE [DAZQKR] .1589
FAILURE CODE [DB2QKR] .1594
FAILURE CODE [DB2RKR] .1599
FAILURE CODE [DBP0KM] .1604
FAILURE CODE [DBP0KT] .1605
FAILURE CODE [DBP5KB] .1606
FAILURE CODE [DBP5KY] .1609
FAILURE CODE [DBPQKR] .1612
FAILURE CODE [DDNRKA] .1617
FAILURE CODE [DDNRKY] .1619
FAILURE CODE [DDNS00] .1621
FAILURE CODE [DFB1KZ] .1623
FAILURE CODE [DFB2KZ] .1625
FAILURE CODE [DFB3L8] .1627
FAILURE CODE [DFB4L8] .1629
FAILURE CODE [DFB5KZ] .1631
FAILURE CODE [DFB6KZ] .1633
FAILURE CODE [DGH2KA] .1635
FAILURE CODE [DGH2KB] .1637
FAILURE CODE [DHA4KA] .1639
FAILURE CODE [DHAAMA] .1641
FAILURE CODE [DHACMA] .1643
FAILURE CODE [DHPAMA] .1645
FAILURE CODE [DHPBMA] .1648
FAILURE CODE [DHS3MA] .1651
FAILURE CODE [DHS4MA] .1654
FAILURE CODE [DHS8MA] .1657
FAILURE CODE [DHS9MA] .1660
FAILURE CODE [DHSAMA] .1663
FAILURE CODE [DHSBMA] .1666
FAILURE CODE [DHSCMA] .1669
FAILURE CODE [DHSDMA] .1672
FAILURE CODE [DHSFMA] .1675
FAILURE CODE [DHSGMA] .1678
FAILURE CODE [DHSHMA] .1681
FAILURE CODE [DHSJMA] .1684
FAILURE CODE [DHX1MA] .1687
FAILURE CODE [DKR0MA] .1690
FAILURE CODE [DKR1MA] .1693
FAILURE CODE [DKULKA] .1696
FAILURE CODE [DKULKB] .1698
FAILURE CODE [DKULKY] .1700
FAILURE CODE [DR10KA] .1702
FAILURE CODE [DR12KA] .1705
FAILURE CODE [DR20KA] .1707
FAILURE CODE [DR21KX] .1709
FAILURE CODE [DR30KA] .1711
FAILURE CODE [DR31KX] .1713
FAILURE CODE [DR40KA] .1715
FAILURE CODE [DUMBKA] .1717
FAILURE CODE [DUMBKB] .1719
FAILURE CODE [DV20KB] .1721
FAILURE CODE [DW43KA] .1723
FAILURE CODE [DW43KB] .1725
FAILURE CODE [DW43KY] .1727
FAILURE CODE [DW45KA] .1729
FAILURE CODE [DW45KB] .1732
FAILURE CODE [DW45KY] .1735
FAILURE CODE [DW4CKY] .1737
FAILURE CODE [DW91KA] .1739
FAILURE CODE [DW91KB] .1741
FAILURE CODE [DW91KY] .1743
FAILURE CODE [DWA2KA] .1745
FAILURE CODE [DWA2KB] .1747
FAILURE CODE [DWA2KY] .1749
FAILURE CODE [DWK0KA] .1751
FAILURE CODE [DWK0KB] .1753
FAILURE CODE [DWK0KY] .1755
FAILURE CODE [DWK2KA] .1757
FAILURE CODE [DWK2KB] .1759
FAILURE CODE [DWK2KY] .1761
FAILURE CODE [DWK8KA] .1763
FAILURE CODE [DWK8KB] .1765
FAILURE CODE [DWK8KY] .1767
FAILURE CODE [DXA8KA] .1769
FAILURE CODE [DXA8KB] .1771
FAILURE CODE [DXA9KA] .1773
FAILURE CODE [DXA9KB] .1775
FAILURE CODE [DXE0KA] .1777
FAILURE CODE [DXE0KB] .1778
FAILURE CODE [DXE4KA] .1780
FAILURE CODE [DXE4KB] .1782
FAILURE CODE [DXE4KY] .1784
FAILURE CODE [DXE5KA] .1786
FAILURE CODE [DXE5KB] .1788
FAILURE CODE [DXE6KA] .1790
FAILURE CODE [DXE6KB] .1792
FAILURE CODE [DXE7KA] .1794
FAILURE CODE [DXE7KB] .1796
FAILURE CODE [DXE7KY] .1798
FAILURE CODE [DXE8KA] .1800
FAILURE CODE [DXE8KB] .1802
FAILURE CODE [DXE8KY] .1804
FAILURE CODE [DXE9KA] .1806
FAILURE CODE [DXE9KB] .1808
FAILURE CODE [DXE9KY] .1810
FAILURE CODE [DXEAKA] .1812
FAILURE CODE [DXEAKB] .1814
FAILURE CODE [DXEAKY] .1816
FAILURE CODE [DY20KA] .1818
FAILURE CODE [DY20MA] .1820
FAILURE CODE [DY2CKB] .1822
FAILURE CODE [DY2DKB] .1825
FAILURE CODE [DY2EKB] .1827
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1829
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1829
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1835
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1838
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1840
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1842
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1845
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1846
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1847
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1848
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1849
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1850
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1851
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1852
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1853
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1854
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1855
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1856
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1858
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1859
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1860
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1861
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1863
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1864
E-24 FUNCTION SWITCH DOES NOT OPERATE .1865
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1866
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1867
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1868
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1869
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1870
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1871
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1872
E-32 ALARM BUZZER CANNOT BE CANCELED 1874
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1875
E-34 SERVICE MODE CANNOT BE SELECTED 1876
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1877
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1880
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1882
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1885
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1887
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1890
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1891
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1893
E-43 HORN DOES NOT SOUND 1894
E-44 HORN DOES NOT STOP SOUNDING 1897
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1899
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1900
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1902
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1903
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1904
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1905
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1906
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1907
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1908
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1909
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1910
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1911
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1913
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1914
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1915
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1915
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1916
FAILURE MODE AND CAUSE TABLE 1918
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1927
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1928
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1931
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1932
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1933
H-6 SPEED OR POWER OF BOOM IS LOW .1935
H-7 ARM SPEED OR POWER IS LOW .1939
H-8 BUCKET SPEED OR POWER IS LOW 1944
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1947
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1948
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1950
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .1952
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .1953
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1954
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1955
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1956
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .1957
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1958
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1959
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1960
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .1961
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .1963
H-23 TRAVEL SPEED IS LOW 1966
H-24 ONE OF TRACKS DOES NOT RUN .1968
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1969
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1970
H-27 SWINGS ONLY IN ONE DIRECTION .1971
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .1972
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1973
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1974
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1975
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .1976
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .1977
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .1978
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1979
H-36 Quick coupler cylinder will not extend .1980
H-37 Quick coupler cylinder will not retract (but buzzer doesnot sound) .1982
H-38 Buzzer does not sound (but quick coupler cylinder doesretract) .1984
H-39 Quick coupler cylinder extends and retracts slowly .1986
TROUBLESHOOTING OF ENGINE (S-MODE) 1987
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1987
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1988
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1989
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1990
S-4 ENGINE STARTABILITY IS POOR .1992
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1994
S-6 ENGINE STOPS DURING OPERATION .1996
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1998
S-8 ENGINE LACKS POWER 1999
S-9 KDPF GETS CLOGGED IN A SHORT TIME .2001
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2003
S-11 OIL BECOMES CONTAMINATED QUICKLY .2004
S-12 FUEL CONSUMPTION IS EXCESSIVE 2005
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2006
S-14 OIL PRESSURE DROPS .2007
S-15 FUEL MIXES INTO ENGINE OIL .2009
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2010
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2011
S-18 UNUSUAL NOISE IS HEARD .2012
S-19 VIBRATION IS EXCESSIVE .2013
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .2014
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2015
S-22 ACTIVE REGENERATION TAKES TIME .2017
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2018
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2019
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2021
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2022
50 DISASSEMBLY AND ASSEMBLY .2023
CONTENTS 2024
ABBREVIATION LIST .2029
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2035
HOW TO READ THIS MANUAL .2035
COATING MATERIALS LIST 2037
SPECIAL TOOLS LIST 2041
SKETCHES OF SPECIAL TOOLS .2053
ENGINE AND COOLING SYSTEM .2059
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2059
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2059
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2062
REMOVE AND INSTALL INJECTOR ASSEMBLY 2066
METHOD FOR REMOVING INJECTOR ASSEMBLY .2066
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2071
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2079
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2080
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2089
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2105
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2105
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2106
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2109
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2109
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2112
REMOVE AND INSTALL STARTER ASSEMBLY .2117
METHOD FOR REMOVING STARTER ASSEMBLY 2117
METHOD FOR INSTALLING STARTER ASSEMBLY 2119
REMOVE AND INSTALL ALTERNATOR BELT 2121
METHOD FOR REMOVING ALTERNATOR BELT .2121
METHOD FOR INSTALLING ALTERNATOR BELT .2123
REMOVE AND INSTALL RADIATOR ASSEMBLY 2125
METHOD FOR REMOVING RADIATOR ASSEMBLY .2125
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2127
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2129
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2129
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2132
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2135
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2135
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2136
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2138
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2139
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2147
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2158
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2158
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2161
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2165
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2165
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2166
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2169
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2169
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2170
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2171
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2171
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2173
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2179
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2179
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2183
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2189
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2189
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2194
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2200
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2200
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2205
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2211
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2211
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2211
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2213
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2213
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2213
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2215
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2215
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2217
REMOVE AND INSTALL KDPF ASSEMBLY 2220
METHOD FOR REMOVING KDPF ASSEMBLY .2220
METHOD FOR INSTALLING KDPF ASSEMBLY .2222
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2224
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2225
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2228
REMOVE AND INSTALL SCR ASSEMBLY .2233
METHOD FOR REMOVING SCR ASSEMBLY 2233
METHOD FOR INSTALLING SCR ASSEMBLY 2235
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2237
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2237
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2243
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2249
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2249
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2256
REMOVE AND INSTALL KCCV ASSEMBLY 2264
METHOD FOR REMOVING KCCV ASSEMBLY .2264
METHOD FOR INSTALLING KCCV ASSEMBLY .2267
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2271
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2271
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2276
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2281
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2281
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2283
REMOVE AND INSTALL AdBlue/DEF PUMP 2285
METHOD FOR REMOVING AdBlue/DEF PUMP .2285
METHOD FOR INSTALLING AdBlue/DEF PUMP .2287
REMOVE AND INSTALL AdBlue/DEF HOSE 2290
METHOD FOR REMOVING AdBlue/DEF HOSE .2290
METHOD FOR INSTALLING AdBlue/DEF HOSE .2298
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2304
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2304
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2305
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2307
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2307
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2309
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2312
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2312
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2313
POWER TRAIN .2314
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2314
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2314
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2315
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2317
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2317
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2321
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2330
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2330
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2333
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2336
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2336
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2340
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2347
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2347
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2347
UNDERCARRIAGE AND FRAME .2349
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2349
METHOD FOR SEPARATING TRACK ASSEMBLY 2349
METHOD FOR INSTALLING TRACK ASSEMBLY 2351
REMOVE AND INSTALL SPROCKET .2354
METHOD FOR REMOVING SPROCKET 2354
METHOD FOR INSTALLING SPROCKET 2354
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2356
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2356
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2357
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2358
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2358
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2359
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2363
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2364
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2365
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2366
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2367
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2368
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2370
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2370
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2372
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2374
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2374
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2376
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2379
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2379
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2382
HYDRAULIC SYSTEM 2386
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2386
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2386
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2388
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2391
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2392
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2393
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2394
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2394
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2397
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2400
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2400
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2403
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2406
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2406
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2413
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2421
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2421
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2423
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2427
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2427
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2427
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2429
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2429
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2430
REMOVE AND INSTALL QUICK COUPLER VALVE 2432
WORK EQUIPMENT 2434
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2434
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2434
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2438
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2444
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2444
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2447
CAB AND ITS ATTACHMENTS .2453
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2453
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2453
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2459
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2466
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2468
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2468
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2478
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2478
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2481
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2487
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2487
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2494
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2501
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2501
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2507
REMOVE AND INSTALL OPERATOR’S SEAT 2514
METHOD FOR REMOVING OPERATOR’S SEAT .2514
METHOD FOR INSTALLING OPERATOR’S SEAT .2516
REMOVE AND INSTALL SEAT BELT 2519
METHOD FOR REMOVING SEAT BELT .2519
METHOD FOR INSTALLING SEAT BELT .2520
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2521
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2521
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2526
ELECTRICAL SYSTEM .2535
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2535
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2535
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2537
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2538
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2538
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2542
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2547
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2547
METHOD FOR INSTALLING KomVision CONTROLLER 2548
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2550
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2550
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2553
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2556
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2556
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2557
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2558
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2558
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2559
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2560
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2560
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2561
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2563
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2563
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2565
REMOVE AND INSTALL KomVision CAMERA .2568
METHOD FOR REMOVING KomVision CAMERA 2568
METHOD FOR INSTALLING KomVision CAMERA 2571
REMOVE AND INSTALL KomVision CAMERA .2574
METHOD FOR REMOVING KomVision CAMERA 2574
METHOD FOR INSTALLING KomVision CAMERA 2577
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2580
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2580
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2583
60 MAINTENANCE STANDARD .2587
CONTENTS 2588
ABBREVIATION LIST .2589
ENGINE AND COOLING SYSTEM .2595
MAINTENANCE STANDARD OF ENGINE MOUNT 2595
MAINTENANCE STANDARD OF COOLING SYSTEM 2596
POWER TRAIN .2597
MAINTENANCE STANDARD OF SWING CIRCLE 2597
MAINTENANCE STANDARD OF SWING MACHINERY .2598
MAINTENANCE STANDARD OF FINAL DRIVE .2600
MAINTENANCE STANDARD OF SPROCKET 2602
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2603
UNDERCARRIAGE AND FRAME .2605
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2605
MAINTENANCE STANDARD OF IDLER .2607
MAINTENANCE STANDARD OF TRACK ROLLER 2609
MAINTENANCE STANDARD OF CARRIER ROLLER 2610
MAINTENANCE STANDARD OF TRACK SHOE 2611
MAINTENANCE STANDARD OF TRIPLE SHOE .2614
MAINTENANCE STANDARD OF SWAMP SHOE 2615
MAINTENANCE STANDARD OF ROAD LINER 2616
HYDRAULIC SYSTEM 2617
MAINTENANCE STANDARD OF HYDRAULIC TANK 2617
MAINTENANCE STANDARD OF MAIN PUMP .2618
MAINTENANCE STANDARD OF LS-EPC VALVE 2619
MAINTENANCE STANDARD OF PC-EPC VALVE 2620
MAINTENANCE STANDARD OF SWING MOTOR .2621
MAINTENANCE STANDARD OF TRAVEL MOTOR 2624
MAINTENANCE STANDARD OF CONTROL VALVE .2627
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2637
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2640
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2643
MAINTENANCE STANDARD OF EPC VALVE .2644
MAINTENANCE STANDARD OF SOLENOID VALVE 2646
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 2647
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2649
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2650
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2651
WORK EQUIPMENT 2652
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2652
DIMENSION OF ARM 2657
DIMENSIONS OF BUCKET 2659
MAINTENANCE STANDARD OF BOOM CYLINDER .2661
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2662
MAINTENANCE STANDARD OF ARM CYLINDER 2663
MAINTENANCE STANDARD OF BUCKET CYLINDER .2664
80 APPENDIX .2665
CONTENTS 2666
ABBREVIATION LIST .2668
AIR CONDITIONER SYSTEM 2674
PRECAUTIONS FOR REFRIGERANT .2674
AIR CONDITIONER COMPONENT .2675
SPECIFICATIONS OF AIR CONDITIONER .2677
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2678
OUTLINE OF REFRIGERATION CYCLE 2679
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2681
AIR CONDITIONER UNIT 2681
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2681
FUNCTION OF AIR CONDITIONER UNIT 2683
COMPONENT PARTS OF AIR CONDITIONER UNIT .2685
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2686
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2686
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2686
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2686
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2687
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2687
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2687
FUNCTION OF DUAL PRESSURE SWITCH 2688
AIR CONDITIONER CONTROLLER 2689
STRUCTURE OF AIR CONDITIONER CONTROLLER .2689
COMPRESSOR 2690
STRUCTURE OF COMPRESSOR .2690
SPECIFICATIONS OF COMPRESSOR 2690
FUNCTION OF COMPRESSOR 2690
CONDENSER .2691
STRUCTURE OF CONDENSER 2691
SPECIFICATIONS OF CONDENSER .2691
FUNCTION OF CONDENSER .2691
SENSORS FOR AIR CONDITIONER SYSTEM 2693
STRUCTURE OF SUNLIGHT SENSOR 2693
FUNCTION OF SUNLIGHT SENSOR .2693
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2693
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2693
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2695
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2697
AIR CONDITIONER SYSTEM DIAGRAM 2699
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2700
FUNCTION OF AIR CONDITIONER CONTROLLER 2701
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2702
TESTING AIR LEAKAGE (DUCT) 2706
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2706
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2708
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2709
TEST VENT (MODE) CHANGEOVER .2710
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2710
TESTING FRESH/RECIRC AIR CHANGEOVER .2712
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2712
TEST SUNLIGHT SENSOR 2713
METHOD FOR TESTING SUNLIGHT SENSOR 2713
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2714
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2714
TEST RELAYS .2715
METHOD FOR TESTING RELAYS .2715
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2716
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2717
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2720
FAILURE CODE [879AKA] .2722
FAILURE CODE [879AKB] .2723
FAILURE CODE [879BKA] .2724
FAILURE CODE [879BKB] .2726
FAILURE CODE [879CKA] .2728
FAILURE CODE [879CKB] .2729
FAILURE CODE [879DKZ] .2730
FAILURE CODE [879EMC] .2732
FAILURE CODE [879FMC] .2733
FAILURE CODE [879GKX] .2734
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2736
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2738
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2741
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2743
TROUBLESHOOTING USING GAUGE PRESSURE 2745
CONNECTION OF SERVICE TOOL 2748
METHOD FOR CONNECTING SERVICE TOOL 2748
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2750
HANDLE COMPRESSOR OIL .2752
METHOD FOR REPLACING DESICCANT 2754
90 CIRCUIT DIAGRAMS .2757
CONTENTS 2758
ABBREVIATION LIST .2759
HYDRAULIC CIRCUIT DIAGRAM .2765
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2765
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2769
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2771
ELECTRICAL CIRCUIT DIAGRAM 2773
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2773
ELECTRICAL CIRCUIT DIAGRAM (1/8) 2777
ELECTRICAL CIRCUIT DIAGRAM (2/8) 2779
ELECTRICAL CIRCUIT DIAGRAM (3/8) 2781
ELECTRICAL CIRCUIT DIAGRAM (4/8) 2783
ELECTRICAL CIRCUIT DIAGRAM (5/8) 2785
ELECTRICAL CIRCUIT DIAGRAM (6/8) 2787
ELECTRICAL CIRCUIT DIAGRAM (7/8) 2789
ELECTRICAL CIRCUIT DIAGRAM (8/8) 2791
INDEX 2793

DESCRIPTION:

Komatsu PC240LC-11E0,PC240NLC-11E0 Hydraulic Excavator Shop Manual UENBM00471 – 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