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

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Komatsu PC240LC-11E0,PC240NLC-11E0 Hydraulic Excavator Shop Manual UENBM00472 – PDF DOWNLOAD

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Komatsu PC240LC-11E0,PC240NLC-11E0 Hydraulic Excavator Shop Manual UENBM00472 – PDF DOWNLOAD

Language : English
Pages : 2918
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC240LC-11E0,PC240NLC-11E0 Hydraulic Excavator Shop Manual UENBM00472 – PDF DOWNLOAD

• SERIAL NUMBERS K75274 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
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 150
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 150
BATTERY DISCONNECT SWITCH . 151
FUNCTION OF BATTERY DISCONNECT SWITCH . 151
ENGINE SYSTEM . 152
LAYOUT DRAWING OF ENGINE SYSTEM . 152
SPECIFICATIONS OF ENGINE SYSTEM . 153
FUNCTION OF ENGINE SYSTEM . 153
ENGINE CONTROL SYSTEM . 154
ENGINE CONTROL SYSTEM DIAGRAM . 154
OPERATION OF ENGINE CONTROL SYSTEM 155
AUTO-DECELERATION SYSTEM 157
AUTO-DECELERATION SYSTEM DIAGRAM 157
FUNCTION OF AUTO-DECELERATION SYSTEM 157
OPERATION OF AUTO-DECELERATION SYSTEM . 158
ENGINE AUTOMATIC WARM-UP SYSTEM . 159
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 159
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 160
OVERHEAT PREVENTION SYSTEM 161
OVERHEAT PREVENTION SYSTEM DIAGRAM 161
FUNCTION OF OVERHEAT PREVENTION SYSTEM 162
TURBOCHARGER PROTECTION SYSTEM 164
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 164
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 165
AUTOMATIC IDLE STOP SYSTEM 166
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 166
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 166
COMPONENT PARTS OF ENGINE SYSTEM 169
VGT . 169
EGR SYSTEM 173
EGR VALVE . 175
EGR COOLER 177
KCCV SYSTEM . 178
KCCV VENTILATOR . 180
KDPF 182
COOLING SYSTEM 187
LAYOUT DRAWING OF COOLING SYSTEM 187
SPECIFICATIONS OF COOLING SYSTEM 188
CONTROL SYSTEM 189
LAYOUT DRAWING OF CONTROL SYSTEM 189
MACHINE MONITOR SYSTEM 192
MACHINE MONITOR SYSTEM DIAGRAM 192
KomVision SYSTEM 193
LAYOUT DRAWING OF KOMVISION SYSTEM 193
KomVision SYSTEM DIAGRAM 195
FUNCTION OF KomVision SYSTEM 195
KOMTRAX SYSTEM 197
KOMTRAX SYSTEM DIAGRAM 197
FUNCTION OF KOMTRAX SYSTEM 197
PPC LEVERS 198
LH PPC LEVER 198
RH PPC LEVER 199
AUTOMATIC GREASE SYSTEM . 200
OUTLINE OF AUTO GREASE SYSTEM . 200
COMPONENT PARTS OF CONTROL SYSTEM . 215
MACHINE MONITOR . 215
KomVision CONTROLLER 228
KomVision CAMERA 232
GATEWAY FUNCTION CONTROLLER . 233
COMMUNICATION TERMINAL 236
PUMP CONTROLLER . 238
RESISTOR FOR PC-EPC VALVE . 242
CAN TERMINATING RESISTOR 242
PPC OIL PRESSURE SWITCH . 243
ENGINE CONTROLLER . 244
FUEL CONTROL DIAL . 250
SENSOR 252
STRUCTURE OF AMBIENT PRESSURE SENSOR 252
FUNCTION OF AMBIENT PRESSURE SENSOR . 252
STRUCTURE OF ENGINE OIL PRESSURE SWITCH . 252
FUNCTION OF ENGINE OIL PRESSURE SWITCH 253
STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR . 253
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR 253
STRUCTURE OF COOLANT TEMPERATURE SENSOR . 254
FUNCTION OF COOLANT TEMPERATURE SENSOR 254
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR . 254
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR 255
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR . 255
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR 255
STRUCTURE OF COMMON RAIL PRESSURE SENSOR 256
FUNCTION OF COMMON RAIL PRESSURE SENSOR . 256
STRUCTURE OF EGR VALVE LIFT SENSOR 256
FUNCTION OF EGR VALVE LIFT SENSOR . 256
STRUCTURE OF VGT SPEED SENSOR . 257
FUNCTION OF KVGT SPEED SENSOR . 257
STRUCTURE OF KVGT POSITION SENSOR . 257
FUNCTION OF KVGT POSITION SENSOR 258
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR . 258
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR 259
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR . 259
STRUCTURE OF CRANKCASE PRESSURE SENSOR 259
FUNCTION OF CRANKCASE PRESSURE SENSOR . 260
STRUCTURE OF ENGINE OIL LEVEL SENSOR 260
STRUCTURE OF AIR CLEANER CLOGGING SENSOR 260
FUNCTION OF AIR CLEANER CLOGGING SENSOR . 261
STRUCTURE OF WATER-IN-FUEL SENSOR . 261
FUNCTION OF WATER-IN-FUEL SENSOR 261
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 261
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 262
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH . 262
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 262
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 263
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 263
STRUCTURE OF OVERLOAD CAUTION SENSOR 263
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 263
FUNCTION OF OVERLOAD CAUTION SENSOR . 263
HYDRAULIC SYSTEM 264
LAYOUT DRAWING OF HYDRAULIC SYSTEM 264
CLSS 270
STRUCTURE OF CLSS . 270
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 272
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 273
PRESSURE COMPENSATION CONTROL . 286
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 289
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 289
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 290
PUMP AND VALVE CONTROL SYSTEM . 295
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 295
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 296
COMPONENT PARTS OF HYDRAULIC SYSTEM . 298
HYDRAULIC TANK 298
MAIN PUMP . 300
PC-EPC VALVE 324
PILOT OIL FILTER 326
CONTROL VALVE . 326
WORK EQUIPMENT SYSTEM . 383
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 383
STRUCTURE OF VALVE CONTROL 388
ONE-TOUCH POWER MAXIMIZING SYSTEM . 390
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 390
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 391
PPC LOCK SYSTEM . 392
PPC LOCK SYSTEM DIAGRAM . 392
FUNCTION OF PPC LOCK SYSTEM . 392
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 393
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 393
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 393
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 394
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 395
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 395
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 397
TOOL CONTROL SYSTEM . 398
TOOL CONTROL SYSTEM DIAGRAM . 398
FUNCTION OF TOOL CONTROL SYSTEM . 399
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 400
WORK EQUIPMENT AND SWING PPC VALVE 400
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 405
SOLENOID VALVE 411
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 414
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 416
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE . 419
2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE . 421
ATTACHMENT BYPASS SOLENOID VALVE 424
ATT EPC VALVE ASSEMBLY 426
PILOT CIRCUIT ACCUMULATOR . 427
ATTACHMENT CIRCUIT ACCUMULATOR 428
SWING SYSTEM 429
LAYOUT DRAWING OF SWING SYSTEM 429
SWING CONTROL SYSTEM DIAGRAM 433
FUNCTION OF SWING CONTROL SYSTEM 433
COMPONENT PARTS OF SWING SYSTEM . 437
SWING MOTOR . 437
SWING MACHINERY . 449
SWING CIRCLE 450
TRAVEL SYSTEM . 452
LAYOUT DRAWING OF TRAVEL SYSTEM . 452
TRAVEL CONTROL SYSTEM DIAGRAM . 456
FUNCTION OF TRAVEL CONTROL SYSTEM . 456
COMPONENT PARTS OF TRAVEL SYSTEM 458
TRAVEL MOTOR 458
FINAL DRIVE . 470
TRAVEL PPC VALVE 472
CENTER SWIVEL JOINT . 477
UNDERCARRIAGE AND FRAME . 479
LAYOUT DRAWING OF UNDERCARRIAGE . 479
SPECIFICATIONS OF UNDERCARRIAGE . 480
WORK EQUIPMENT 481
STRUCTURE OF WORK EQUIPMENT . 481
FUNCTION OF WORK EQUIPMENT 482
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 483
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 483
BUCKET CLEARANCE ADJUSTMENT SHIM 484
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 484
CAB AND ITS ATTACHMENTS . 485
ROPS CAB 485
STRUCTURE OF ROPS CAB . 485
FUNCTION OF ROPS CAB 485
CAB MOUNT . 486
STRUCTURE OF CAB MOUNT 486
FUNCTION OF CAB MOUNT . 486
CAB TIPPING STOPPER . 487
STRUCTURE OF CAB TIPPING STOPPER 487
FUNCTION OF CAB TIPPING STOPPER . 487
20 STANDARD VALUE TABLE . 489
CONTENTS 490
ABBREVIATION LIST . 491
STANDARD VALUE TABLE FOR ENGINE . 497
STANDARD VALUE TABLE FOR ENGINE: PC240LC-11E0, PC240NLC-11E0 497
STANDARD VALUE TABLE FOR MACHINE 501
STANDARD VALUE TABLE FOR MACHINE: PC240LC-11E0, PC240NLC-11E0 . 501
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 515
STANDARD VALUE TABLE FOR ELECTRICAL . 519
STANDARD VALUE TABLE FOR ELECTRICAL . 519
30 TESTING AND ADJUSTING 529
CONTENTS 530
ABBREVIATION LIST . 533
RELATED INFORMATION ON TESTING AND ADJUSTING 539
TOOLS FOR TESTING AND ADJUSTING . 539
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 546
ENGINE AND COOLING SYSTEM . 548
TEST ENGINE SPEED . 548
METHOD FOR TESTING ENGINE SPEED . 548
TEST BOOST PRESSURE . 551
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 551
METHOD FOR TESTING BOOST PRESSURE . 552
TEST EXHAUST GAS COLOR 553
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 553
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 554
TEST AND ADJUST VALVE CLEARANCE . 556
METHOD FOR TESTING VALVE CLEARANCE 556
METHOD FOR ADJUSTING VALVE CLEARANCE 557
TEST COMPRESSION PRESSURE . 559
METHOD FOR TESTING COMPRESSION PRESSURE . 559
TEST BLOWBY PRESSURE 564
METHOD FOR TESTING BLOWBY PRESSURE 564
TEST ENGINE OIL PRESSURE 566
METHOD FOR TESTING ENGINE OIL PRESSURE 566
TEST EGR VALVE AND VGT OIL PRESSURE . 567
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 567
TEST FUEL PRESSURE 569
METHOD FOR TESTING FUEL PRESSURE 570
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 575
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 576
BLEEDING AIR FROM FUEL SYSTEM . 582
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 582
TEST FUEL CIRCUIT FOR LEAKAGE . 583
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 583
HANDLE CYLINDER CUT-OUT MODE OPERATION 585
HANDLE NO-INJECTION CRANKING OPERATION 586
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 587
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 587
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 587
TEST FAN BELT AND ALTERNATOR BELT . 589
METHOD FOR TESTING FAN BELT AND ALTERNATOR BELT . 589
TEST AUTO-TENSIONER . 590
METHOD FOR TESTING AUTO-TENSIONER . 590
REPLACING FAN BELT 591
METHOD FOR REPLACING FAN BELT . 591
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 592
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 592
TEST SCR RELATED FUNCTIONS 593
TEST AdBlue/DEF PUMP RAISED PRESSURE 596
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 599
TEST AdBlue/DEF LINE HEATER RELAY 1 . 603
TEST AdBlue/DEF LINE HEATER RELAY 2 . 606
TEST AdBlue/DEF PUMP HEATER RELAY . 608
TEST AdBlue/DEF TANK HEATER VALVE . 611
TEST DENITRATION EFFICIENCY OF SCR 614
CLEAN AdBlue/DEF TANK . 618
METHOD FOR CLEANING AdBlue/DEF TANK . 618
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 622
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 622
POWER TRAIN . 624
TEST SWING CIRCLE BEARING CLEARANCE . 624
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 624
UNDERCARRIAGE AND FRAME . 625
TEST AND ADJUST TRACK TENSION . 625
METHOD FOR TESTING TRACK TENSION 625
METHOD FOR ADJUSTING TRACK TENSION 625
HYDRAULIC SYSTEM 627
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 627
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK . 627
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT . 627
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 633
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 634
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 640
TEST OIL PRESSURE OF CONTROL CIRCUIT 643
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 643
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 645
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 645
TEST PC-EPC VALVE OUTLET PRESSURE . 646
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 647
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 649
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 649
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 650
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 653
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 654
METHOD FOR ADJUSTING LS VALVE . 655
TEST OUTLET PRESSURE OF SOLENOID VALVE 656
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 656
OPERATING CONDITION OF SOLENOID VALVE . 657
TEST PPC VALVE OUTLET PRESSURE 660
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 660
TEST ATTACHMENT CIRCUIT OIL PRESSURE 662
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 662
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 664
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 664
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 665
TEST PUMP SWASH PLATE SENSOR 667
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 667
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 668
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 668
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 668
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 669
TEST OIL LEAKAGE 670
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 670
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 670
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 671
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 672
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 672
BLEED AIR FROM HYDRAULIC CIRCUIT 673
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 675
CAB AND ITS ATTACHMENTS . 677
TEST CAB TIPPING STOPPER 677
METHOD FOR TESTING CAB TIPPING STOPPER 677
METHOD FOR ADJUSTING MIRRORS 678
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 678
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 679
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 680
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 681
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 682
ELECTRICAL SYSTEM . 684
ELECTRICAL SYSTEM . 685
SET AND OPERATE MACHINE MONITOR . 685
OPERATOR MODE . 688
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 689
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 689
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 690
CHECKING FUNCTION OF SERVICE METER 690
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 690
SERVICE MODE 693
SERVICE MODE 693
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 695
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 701
ABNORMALITY RECORD MENU . 712
METHOD FOR CONFIRMING MAINTENANCE RECORD 717
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 718
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 722
DEFAULT MENU 723
DIAGNOSTIC TESTS MENU . 734
ADJUSTMENT MENU . 744
METHOD FOR PERFORMING NO-INJECTION CRANKING . 778
KOMTRAX SETTINGS MENU . 779
METHOD FOR DISPLAYING SERVICE MESSAGE . 781
METHOD FOR STARTING UP KOMTRAX SYSTEM . 783
ADJUST REARVIEW CAMERA ANGLE 788
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 788
ADJUST KomVision CAMERA ANGLE . 791
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 792
ADJUST KomVision RELATED ITEMS 796
SETTING OF KomVision (MAIN SETTING) . 796
SETTING OF KomVision (CAMERA SETTING) . 798
SETTING OF KomVision (CAMERA CALIBRATION) . 800
KomVision screen – Check 12 m visibility 813
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 816
HANDLE BATTERY DISCONNECT SWITCH 817
TEST DIODES . 818
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 818
METHOD FOR TESTING DIODE USING ANALOG TESTER 818
Pm CLINIC . 819
Pm CLINIC SERVICE . 819
Pm CLINIC CHECK SHEET . 823
40 TROUBLESHOOTING 833
CONTENTS 834
ABBREVIATION LIST . 845
RELATED INFORMATION ON TROUBLESHOOTING 851
GENERAL TROUBLESHOOTING POINTS 851
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 852
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 864
CHECKS BEFORE TROUBLESHOOTING . 866
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 868
WALK-AROUND CHECK . 868
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 870
CHECK FUEL LEVEL AND TYPE . 870
CHECK IMPURE INGREDIENT IN FUEL . 870
CHECK FUEL PREFILTER 871
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 871
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 872
CHECK MAIN FILTER . 873
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 875
CHECK COOLANT LEVEL (RESERVOIR TANK) 876
CHECK CLOGGING OF AIR CLEANER . 876
OUTER ELEMENT – CLEAN . 877
ELEMENTS – REPLACE 879
CHECK HYDRAULIC OIL LEVEL . 880
CHECK HYDRAULIC OIL STRAINER 881
CHECK HYDRAULIC FILTER 882
CHECK OIL LEVEL IN SWING MACHINERY CASE . 883
CHECK OIL LEVEL IN DAMPER CASE 884
CHECK OIL LEVEL IN FINAL DRIVE CASE . 884
BLEED AIR FROM FUEL SYSTEM 885
BLEED AIR FROM HYDRAULIC SYSTEM . 885
ELECTRICAL EQUIPMENT – CHECK METHOD . 885
AUTOMATIC GREASE SYSTEM . 893
FINDING MALFUNCTIONS 893
MALFUNCTION FINDING PROCEDURES 895
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM . 897
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 910
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 913
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 917
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 919
CONNECTOR LIST AND LAYOUT . 922
CONNECTOR CONTACT IDENTIFICATION 935
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 975
FUSE LOCATION TABLE . 981
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 983
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 987
FAILURE CODES TABLE . 989
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .1007
FAILURE CODE [879AKA] .1007
FAILURE CODE [879AKB] .1008
FAILURE CODE [879BKA] .1009
FAILURE CODE [879BKB] .1011
FAILURE CODE [879CKA] .1013
FAILURE CODE [879CKB] .1014
FAILURE CODE [879DKZ] .1015
FAILURE CODE [879EMC] .1017
FAILURE CODE [879FMC] .1018
FAILURE CODE [879GKX] .1019
FAILURE CODE [989L00] .1021
FAILURE CODE [989M00] .1022
FAILURE CODE [989N00] .1023
FAILURE CODE [A1U0N3] .1024
FAILURE CODE [A1U0N4] .1026
FAILURE CODE [A900FR] .1028
FAILURE CODE [A900N6] .1029
FAILURE CODE [A900NY] .1030
FAILURE CODE [AA10NX] .1031
FAILURE CODE [AB00KE] .1033
FAILURE CODE [AQ10N3] .1036
FAILURE CODE [AS00N3] .1038
FAILURE CODE [AS00R2] .1040
FAILURE CODE [AS00R3] .1041
FAILURE CODE [AS00R4] .1042
FAILURE CODE [AS00R5] .1043
FAILURE CODE [AS00R6] .1044
FAILURE CODE [AS00ZK] .1045
FAILURE CODE [AS10KM] .1046
FAILURE CODE [AS10NR] .1047
FAILURE CODE [AS10NT] .1048
FAILURE CODE [B@BAZG] .1049
FAILURE CODE [B@BAZK] .1050
FAILURE CODE [B@BCNS] .1052
FAILURE CODE [B@BCQA] .1053
FAILURE CODE [B@BCZK] .1055
FAILURE CODE [B@HANS] .1057
FAILURE CODE [CA115] 1058
FAILURE CODE [CA122] 1059
FAILURE CODE [CA123] 1061
FAILURE CODE [CA131] 1063
FAILURE CODE [CA132] 1065
FAILURE CODE [CA144] 1067
FAILURE CODE [CA145] 1069
FAILURE CODE [CA153] 1071
FAILURE CODE [CA154] 1074
FAILURE CODE [CA187] 1076
FAILURE CODE [CA221] 1078
FAILURE CODE [CA222] 1080
FAILURE CODE [CA227] 1082
FAILURE CODE [CA234] 1083
FAILURE CODE [CA238] 1084
FAILURE CODE [CA239] 1086
FAILURE CODE [CA249] 1088
FAILURE CODE [CA256] 1090
FAILURE CODE [CA271] 1092
FAILURE CODE [CA272] 1094
FAILURE CODE [CA322] 1096
FAILURE CODE [CA323] 1098
FAILURE CODE [CA324] 1100
FAILURE CODE [CA325] 1102
FAILURE CODE [CA331] 1104
FAILURE CODE [CA332] 1106
FAILURE CODE [CA343] 1108
FAILURE CODE [CA351] 1109
FAILURE CODE [CA352] 1110
FAILURE CODE [CA356] 1113
FAILURE CODE [CA357] 1115
FAILURE CODE [CA386] 1117
FAILURE CODE [CA428] 1118
FAILURE CODE [CA429] 1120
FAILURE CODE [CA435] 1122
FAILURE CODE [CA441] 1124
FAILURE CODE [CA442] 1126
FAILURE CODE [CA449] 1127
FAILURE CODE [CA451] 1128
FAILURE CODE [CA452] 1130
FAILURE CODE [CA488] 1132
FAILURE CODE [CA515] 1133
FAILURE CODE [CA516] 1135
FAILURE CODE [CA553] 1137
FAILURE CODE [CA555] 1138
FAILURE CODE [CA556] 1139
FAILURE CODE [CA559] 1140
FAILURE CODE [CA595] 1143
FAILURE CODE [CA687] 1144
FAILURE CODE [CA689] 1146
FAILURE CODE [CA691] 1149
FAILURE CODE [CA692] 1151
FAILURE CODE [CA697] 1153
FAILURE CODE [CA698] 1154
FAILURE CODE [CA731] 1155
FAILURE CODE [CA778] 1157
FAILURE CODE [CA1117] .1162
FAILURE CODE [CA1664] .1163
FAILURE CODE [CA1669] .1165
FAILURE CODE [CA1673] .1166
FAILURE CODE [CA1677] .1167
FAILURE CODE [CA1678] .1168
FAILURE CODE [CA1682] .1169
FAILURE CODE [CA1683] .1171
FAILURE CODE [CA1684] .1173
FAILURE CODE [CA1686] .1175
FAILURE CODE [CA1691] .1176
FAILURE CODE [CA1694] .1179
FAILURE CODE [CA1695] .1182
FAILURE CODE [CA1696] .1183
FAILURE CODE [CA1712] .1185
FAILURE CODE [CA1713] .1188
FAILURE CODE [CA1714] .1190
FAILURE CODE [CA1715] .1191
FAILURE CODE [CA1776] .1192
FAILURE CODE [CA1777] .1195
FAILURE CODE [CA1843] .1198
FAILURE CODE [CA1844] .1200
FAILURE CODE [CA1879] .1203
FAILURE CODE [CA1881] .1205
FAILURE CODE [CA1883] .1207
FAILURE CODE [CA1885] .1210
FAILURE CODE [CA1887] .1212
FAILURE CODE [CA1921] .1214
FAILURE CODE [CA1922] .1217
FAILURE CODE [CA1942] .1222
FAILURE CODE [CA1993] .1223
FAILURE CODE [CA2185] .1226
FAILURE CODE [CA2186] .1227
FAILURE CODE [CA2249] .1229
FAILURE CODE [CA2271] .1230
FAILURE CODE [CA2272] .1233
FAILURE CODE [CA2288] .1236
FAILURE CODE [CA2311] .1237
FAILURE CODE [CA2349] .1238
FAILURE CODE [CA2353] .1241
FAILURE CODE [CA2357] .1243
FAILURE CODE [CA2381] .1244
FAILURE CODE [CA2382] .1247
FAILURE CODE [CA2383] .1250
FAILURE CODE [CA2386] .1253
FAILURE CODE [CA2387] .1255
FAILURE CODE [CA2555] .1256
FAILURE CODE [CA2556] .1259
FAILURE CODE [CA2637] .1262
FAILURE CODE [CA2639] .1264
FAILURE CODE [CA2771] .1267
FAILURE CODE [CA2777] .1273
FAILURE CODE [CA2976] .1276
FAILURE CODE [CA3133] .1278
FAILURE CODE [CA3134] .1281
FAILURE CODE [CA3135] .1283
FAILURE CODE [CA3142] .1286
FAILURE CODE [CA3143] .1287
FAILURE CODE [CA3144] .1288
FAILURE CODE [CA3146] .1290
FAILURE CODE [CA3147] .1291
FAILURE CODE [CA3148] .1292
FAILURE CODE [CA3151] .1294
FAILURE CODE [CA3165] .1300
FAILURE CODE [CA3229] .1302
FAILURE CODE [CA3231] .1304
FAILURE CODE [CA3232] .1306
FAILURE CODE [CA3235] .1310
FAILURE CODE [CA3239] .1312
FAILURE CODE [CA3241] .1315
FAILURE CODE [CA3242] .1318
FAILURE CODE [CA3251] .1321
FAILURE CODE [CA3253] .1323
FAILURE CODE [CA3254] .1326
FAILURE CODE [CA3255] .1329
FAILURE CODE [CA3256] .1333
FAILURE CODE [CA3311] .1335
FAILURE CODE [CA3312] .1337
FAILURE CODE [CA3313] .1340
FAILURE CODE [CA3314] .1341
FAILURE CODE [CA3315] .1342
FAILURE CODE [CA3316] .1344
FAILURE CODE [CA3317] .1345
FAILURE CODE [CA3318] .1346
FAILURE CODE [CA3319] .1348
FAILURE CODE [CA3321] .1349
FAILURE CODE [CA3322] .1351
FAILURE CODE [CA3419] .1353
FAILURE CODE [CA3421] .1355
FAILURE CODE [CA3497] .1357
FAILURE CODE [CA3498] .1358
FAILURE CODE [CA3543] .1359
FAILURE CODE [CA3545] .1366
FAILURE CODE [CA3547] .1368
FAILURE CODE [CA3558] .1369
FAILURE CODE [CA3559] .1371
FAILURE CODE [CA3562] .1373
FAILURE CODE [CA3563] .1375
FAILURE CODE [CA3567] .1378
FAILURE CODE [CA3568] .1381
FAILURE CODE [CA3571] .1385
FAILURE CODE [CA3572] .1387
FAILURE CODE [CA3574] .1389
FAILURE CODE [CA3575] .1391
FAILURE CODE [CA3577] .1393
FAILURE CODE [CA3578] .1395
FAILURE CODE [CA3582] .1397
FAILURE CODE [CA3583] .1403
FAILURE CODE [CA3596] .1405
FAILURE CODE [CA3649] .1407
FAILURE CODE [CA3681] .1409
FAILURE CODE [CA3682] .1414
FAILURE CODE [CA3713] .1420
FAILURE CODE [CA3717] .1423
FAILURE CODE [CA3718] .1424
FAILURE CODE [CA3725] .1425
FAILURE CODE [CA3741] .1428
FAILURE CODE [CA3748] .1429
FAILURE CODE [CA3751] .1431
FAILURE CODE [CA3755] .1433
FAILURE CODE [CA3866] .1435
FAILURE CODE [CA3867] .1439
FAILURE CODE [CA3868] .1442
FAILURE CODE [CA3899] .1446
FAILURE CODE [CA3911] .1448
FAILURE CODE [CA3912] .1452
FAILURE CODE [CA3932] .1454
FAILURE CODE [CA3933] .1456
FAILURE CODE [CA3934] .1458
FAILURE CODE [CA3935] .1461
FAILURE CODE [CA3936] .1463
FAILURE CODE [CA4151] .1465
FAILURE CODE [CA4152] .1469
FAILURE CODE [CA4155] .1473
FAILURE CODE [CA4156] .1475
FAILURE CODE [CA4157] .1477
FAILURE CODE [CA4158] .1479
FAILURE CODE [CA4159] .1480
FAILURE CODE [CA4161] .1481
FAILURE CODE [CA4162] .1484
FAILURE CODE [CA4163] .1487
FAILURE CODE [CA4164] .1488
FAILURE CODE [CA4165] .1490
FAILURE CODE [CA4166] .1492
FAILURE CODE [CA4168] .1493
FAILURE CODE [CA4169] .1496
FAILURE CODE [CA4171] .1498
FAILURE CODE [CA4249] .1501
FAILURE CODE [CA4251] .1503
FAILURE CODE [CA4259] .1505
FAILURE CODE [CA4261] .1508
FAILURE CODE [CA4277] .1511
FAILURE CODE [CA4281] .1515
FAILURE CODE [CA4459] .1518
FAILURE CODE [CA4461] .1521
FAILURE CODE [CA4658] .1524
FAILURE CODE [CA4731] .1528
FAILURE CODE [CA4732] .1529
FAILURE CODE [CA4739] .1530
FAILURE CODE [CA4768] .1531
FAILURE CODE [CA4769] .1533
FAILURE CODE [CA4842] .1536
FAILURE CODE [CA4952] .1540
FAILURE CODE [CA5115] .1542
FAILURE CODE [CA5179] .1545
FAILURE CODE [CA5181] .1547
FAILURE CODE [CA5383] .1549
FAILURE CODE [D110KB] .1551
FAILURE CODE [D19JKZ] .1553
FAILURE CODE [D811MC] .1556
FAILURE CODE [D862KA] .1557
FAILURE CODE [D8ALKA] .1559
FAILURE CODE [D8ALKB] .1562
FAILURE CODE [D8AQKR] .1564
FAILURE CODE [D8G1KT] .1566
FAILURE CODE [D8G6KT] .1567
FAILURE CODE [DA20MC] .1568
FAILURE CODE [DA22KK] .1569
FAILURE CODE [DA25KP] .1572
FAILURE CODE [DA26KP] .1575
FAILURE CODE [DA29KQ] .1578
FAILURE CODE [DA2LKA] .1580
FAILURE CODE [DA2LKB] .1583
FAILURE CODE [DA2QKR] .1585
FAILURE CODE [DA2RKR] .1594
FAILURE CODE [DAF0KM] .1595
FAILURE CODE [DAF0MB] .1596
FAILURE CODE [DAF0MC] .1597
FAILURE CODE [DAF8KB] .1598
FAILURE CODE [DAF9KQ] .1600
FAILURE CODE [DAFGMC] .1601
FAILURE CODE [DAFLKA] .1602
FAILURE CODE [DAFLKB] .1605
FAILURE CODE [DAFQKR] .1607
FAILURE CODE [DAZ9KQ] .1615
FAILURE CODE [DAZQKR] .1616
FAILURE CODE [DB2QKR] .1623
FAILURE CODE [DB2RKR] .1631
FAILURE CODE [DBP0KM] .1636
FAILURE CODE [DBP0KT] .1637
FAILURE CODE [DBP5KB] .1638
FAILURE CODE [DBP5KY] .1641
FAILURE CODE [DBPQKR] .1644
FAILURE CODE [DDNRKA] .1652
FAILURE CODE [DDNRKY] .1654
FAILURE CODE [DDNS00] .1656
FAILURE CODE [DFB1KZ] .1658
FAILURE CODE [DFB2KZ] .1660
FAILURE CODE [DFB3L8] .1662
FAILURE CODE [DFB4L8] .1664
FAILURE CODE [DFB5KZ] .1666
FAILURE CODE [DFB6KZ] .1668
FAILURE CODE [DGH2KA] .1670
FAILURE CODE [DGH2KB] .1672
FAILURE CODE [DHA4KA] .1674
FAILURE CODE [DHAAMA] .1676
FAILURE CODE [DHACMA] .1678
FAILURE CODE [DHPAMA] .1680
FAILURE CODE [DHPBMA] .1683
FAILURE CODE [DHS3MA] .1686
FAILURE CODE [DHS4MA] .1689
FAILURE CODE [DHS8MA] .1692
FAILURE CODE [DHS9MA] .1695
FAILURE CODE [DHSAMA] .1698
FAILURE CODE [DHSBMA] .1701
FAILURE CODE [DHSCMA] .1704
FAILURE CODE [DHSDMA] .1707
FAILURE CODE [DHSFMA] .1710
FAILURE CODE [DHSGMA] .1713
FAILURE CODE [DHSHMA] .1716
FAILURE CODE [DHSJMA] .1719
FAILURE CODE [DHX1MA] .1722
FAILURE CODE [DHZAMA] .1725
FAILURE CODE [DHZCL8] .1729
FAILURE CODE [DKR0MA] .1730
FAILURE CODE [DKR1MA] .1733
FAILURE CODE [DKULKA] .1736
FAILURE CODE [DKULKB] .1738
FAILURE CODE [DKULKY] .1740
FAILURE CODE [DR10KA] .1742
FAILURE CODE [DR12KA] .1745
FAILURE CODE [DR20KA] .1747
FAILURE CODE [DR21KX] .1749
FAILURE CODE [DR30KA] .1751
FAILURE CODE [DR31KX] .1753
FAILURE CODE [DR40KA] .1755
FAILURE CODE [DUMBKA] .1757
FAILURE CODE [DUMBKB] .1760
FAILURE CODE [DV00KA] .1762
FAILURE CODE [DV00KB] .1763
FAILURE CODE [DV20KB] .1764
FAILURE CODE [DW43KA] .1766
FAILURE CODE [DW43KB] .1768
FAILURE CODE [DW43KY] .1770
FAILURE CODE [DW45KA] .1772
FAILURE CODE [DW45KB] .1775
FAILURE CODE [DW45KY] .1778
FAILURE CODE [DW4CKY] .1780
FAILURE CODE [DW91KA] .1782
FAILURE CODE [DW91KB] .1784
FAILURE CODE [DW91KY] .1786
FAILURE CODE [DWA2KA] .1788
FAILURE CODE [DWA2KB] .1790
FAILURE CODE [DWA2KY] .1792
FAILURE CODE [DWK0KA] .1794
FAILURE CODE [DWK0KB] .1796
FAILURE CODE [DWK0KY] .1798
FAILURE CODE [DWK2KA] .1800
FAILURE CODE [DWK2KB] .1802
FAILURE CODE [DWK2KY] .1804
FAILURE CODE [DWK8KA] .1806
FAILURE CODE [DWK8KB] .1808
FAILURE CODE [DWK8KY] .1810
FAILURE CODE [DWPUKA] .1812
FAILURE CODE [DWPUKB] .1814
FAILURE CODE [DXA8KA] .1816
FAILURE CODE [DXA8KB] .1818
FAILURE CODE [DXA9KA] .1820
FAILURE CODE [DXA9KB] .1822
FAILURE CODE [DXE0KA] .1824
FAILURE CODE [DXE0KB] .1825
FAILURE CODE [DXE4KA] .1827
FAILURE CODE [DXE4KB] .1829
FAILURE CODE [DXE4KY] .1831
FAILURE CODE [DXE5KA] .1833
FAILURE CODE [DXE5KB] .1835
FAILURE CODE [DXE6KA] .1837
FAILURE CODE [DXE6KB] .1839
FAILURE CODE [DXE7KA] .1841
FAILURE CODE [DXE7KB] .1843
FAILURE CODE [DXE7KY] .1845
FAILURE CODE [DXE8KA] .1847
FAILURE CODE [DXE8KB] .1849
FAILURE CODE [DXE8KY] .1851
FAILURE CODE [DXE9KA] .1853
FAILURE CODE [DXE9KB] .1855
FAILURE CODE [DXE9KY] .1857
FAILURE CODE [DXEAKA] .1859
FAILURE CODE [DXEAKB] .1861
FAILURE CODE [DXEAKY] .1863
FAILURE CODE [DXEKKA] .1865
FAILURE CODE [DXEKKB] .1867
FAILURE CODE [DXEKKY] .1869
FAILURE CODE [DXELKA] .1871
FAILURE CODE [DXELKB] .1873
FAILURE CODE [DXELKY] .1875
FAILURE CODE [DY20KA] .1877
FAILURE CODE [DY20MA] .1879
FAILURE CODE [DY2CKB] .1881
FAILURE CODE [DY2DKB] .1884
FAILURE CODE [DY2EKB] .1886
FAILURE CODE [F313KA] .1888
FAILURE CODE [F313KB] .1890
FAILURE CODE [F318KB] .1893
FAILURE CODE [F318KY] .1896
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1898
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1898
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1904
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1907
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1909
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1911
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1914
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1915
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1916
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1917
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1918
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1919
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1920
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1921
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1922
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1923
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1924
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1925
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1927
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1928
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1929
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1930
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1932
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1933
E-24 FUNCTION SWITCH DOES NOT OPERATE .1934
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1935
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1936
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1937
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1938
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1939
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1940
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1941
E-32 ALARM BUZZER CANNOT BE CANCELED 1943
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1944
E-34 SERVICE MODE CANNOT BE SELECTED 1945
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1946
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1949
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1951
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1954
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1956
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1959
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1960
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1962
E-43 HORN DOES NOT SOUND 1963
E-44 HORN DOES NOT STOP SOUNDING 1966
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1968
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1969
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1971
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1972
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1973
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1974
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1975
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1976
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1977
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1978
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1979
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1980
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1982
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1983
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1984
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1984
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1985
FAILURE MODE AND CAUSE TABLE 1987
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1996
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1997
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 2000
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .2001
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2002
H-6 SPEED OR POWER OF BOOM IS LOW .2004
H-7 ARM SPEED OR POWER IS LOW .2008
H-8 BUCKET SPEED OR POWER IS LOW 2013
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 2016
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .2017
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 2019
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .2021
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .2022
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 2023
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .2024
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .2025
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .2026
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 2027
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 2028
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 2029
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .2030
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .2032
H-23 TRAVEL SPEED IS LOW 2035
H-24 ONE OF TRACKS DOES NOT RUN .2037
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2038
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 2039
H-27 SWINGS ONLY IN ONE DIRECTION .2040
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .2041
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 2042
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 2043
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 2044
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .2045
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .2046
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .2047
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2048
H-36 Quick coupler cylinder will not extend .2049
H-37 Quick coupler cylinder will not retract (but buzzer doesnot sound) .2051
H-38 Buzzer does not sound (but quick coupler cylinder doesretract) .2053
H-39 Quick coupler cylinder extends and retracts slowly .2055
TROUBLESHOOTING OF ENGINE (S-MODE) 2056
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .2056
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2057
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2058
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2059
S-4 ENGINE STARTABILITY IS POOR .2061
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2063
S-6 ENGINE STOPS DURING OPERATION .2065
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2067
S-8 ENGINE LACKS POWER 2068
S-9 KDPF GETS CLOGGED IN A SHORT TIME .2070
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2072
S-11 OIL BECOMES CONTAMINATED QUICKLY .2073
S-12 FUEL CONSUMPTION IS EXCESSIVE 2074
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2075
S-14 OIL PRESSURE DROPS .2076
S-15 FUEL MIXES INTO ENGINE OIL .2078
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2079
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2080
S-18 UNUSUAL NOISE IS HEARD .2081
S-19 VIBRATION IS EXCESSIVE .2082
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .2083
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2084
S-22 ACTIVE REGENERATION TAKES TIME .2086
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2087
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2088
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2090
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2091
50 DISASSEMBLY AND ASSEMBLY .2093
CONTENTS 2094
ABBREVIATION LIST .2099
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2105
HOW TO READ THIS MANUAL .2105
COATING MATERIALS LIST 2107
SPECIAL TOOLS LIST 2112
SKETCHES OF SPECIAL TOOLS .2124
ENGINE AND COOLING SYSTEM .2130
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2130
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2130
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2133
REMOVE AND INSTALL INJECTOR ASSEMBLY 2137
METHOD FOR REMOVING INJECTOR ASSEMBLY .2137
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2142
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2150
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2151
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2160
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2176
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2176
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2177
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2180
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2180
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2183
REMOVE AND INSTALL STARTER ASSEMBLY .2188
METHOD FOR REMOVING STARTER ASSEMBLY 2188
METHOD FOR INSTALLING STARTER ASSEMBLY 2190
REMOVE AND INSTALL ALTERNATOR BELT 2192
METHOD FOR REMOVING ALTERNATOR BELT .2192
METHOD FOR INSTALLING ALTERNATOR BELT .2194
REMOVE AND INSTALL RADIATOR ASSEMBLY 2196
METHOD FOR REMOVING RADIATOR ASSEMBLY .2196
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2198
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2200
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2200
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2203
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2206
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2206
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2207
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2209
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2210
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2218
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2229
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2229
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2232
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2236
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2236
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2237
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2240
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2240
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2241
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2242
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2242
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2244
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2250
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2250
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2254
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2260
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2260
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2265
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2271
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2271
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2276
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2282
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2282
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2282
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2289
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2289
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2289
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2291
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2291
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2293
REMOVE AND INSTALL KDPF ASSEMBLY 2296
METHOD FOR REMOVING KDPF ASSEMBLY .2296
METHOD FOR INSTALLING KDPF ASSEMBLY .2298
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2300
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2301
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2304
REMOVE AND INSTALL SCR ASSEMBLY .2309
METHOD FOR REMOVING SCR ASSEMBLY 2309
METHOD FOR INSTALLING SCR ASSEMBLY 2311
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2313
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2313
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2319
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2325
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2325
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2331
REMOVE AND INSTALL KCCV ASSEMBLY 2338
METHOD FOR REMOVING KCCV ASSEMBLY .2338
METHOD FOR INSTALLING KCCV ASSEMBLY .2341
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2345
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2345
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2350
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2355
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2355
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2357
REMOVE AND INSTALL AdBlue/DEF PUMP 2359
METHOD FOR REMOVING AdBlue/DEF PUMP .2359
METHOD FOR INSTALLING AdBlue/DEF PUMP .2361
REMOVE AND INSTALL AdBlue/DEF HOSE 2364
METHOD FOR REMOVING AdBlue/DEF HOSE .2364
METHOD FOR INSTALLING AdBlue/DEF HOSE .2372
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2378
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2378
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2379
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2381
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2381
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2383
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2386
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2386
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2387
POWER TRAIN .2388
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2388
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2388
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2389
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2391
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2391
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2395
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2404
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2404
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2407
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2410
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2410
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2414
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2421
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2421
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2421
UNDERCARRIAGE AND FRAME .2423
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2423
METHOD FOR SEPARATING TRACK ASSEMBLY 2423
METHOD FOR INSTALLING TRACK ASSEMBLY 2425
REMOVE AND INSTALL SPROCKET .2428
METHOD FOR REMOVING SPROCKET 2428
METHOD FOR INSTALLING SPROCKET 2428
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2430
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2430
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2431
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2432
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2432
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2433
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2437
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2438
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2439
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2440
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2441
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2442
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2444
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2444
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2446
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2448
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2448
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2450
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2453
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2453
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2456
HYDRAULIC SYSTEM 2460
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2460
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2460
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2462
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2465
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2466
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2467
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2468
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2468
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2471
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2475
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2475
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2478
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2482
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2482
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2489
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2497
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2497
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2499
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2503
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2503
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2503
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2505
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2505
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2506
REMOVE AND INSTALL QUICK COUPLER VALVE 2508
WORK EQUIPMENT 2510
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2510
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2510
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2514
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2520
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2520
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2523
CAB AND ITS ATTACHMENTS .2529
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2529
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2529
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2535
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2542
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2544
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2544
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2554
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2554
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2557
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2563
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2563
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2570
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2577
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2577
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2583
REMOVE AND INSTALL OPERATOR’S SEAT 2590
METHOD FOR REMOVING OPERATOR’S SEAT .2590
METHOD FOR INSTALLING OPERATOR’S SEAT .2592
REMOVE AND INSTALL SEAT BELT 2595
METHOD FOR REMOVING SEAT BELT .2595
METHOD FOR INSTALLING SEAT BELT .2596
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2597
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2597
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2602
ELECTRICAL SYSTEM .2611
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2611
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2611
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2613
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2614
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2614
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2618
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2623
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2623
METHOD FOR INSTALLING KomVision CONTROLLER 2624
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2626
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2626
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2629
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2632
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2632
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2633
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2634
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2634
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2635
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2636
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2636
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2637
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2639
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2639
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2641
REMOVE AND INSTALL KomVision CAMERA .2644
METHOD FOR REMOVING KomVision CAMERA 2644
METHOD FOR INSTALLING KomVision CAMERA 2647
REMOVE AND INSTALL KomVision CAMERA .2650
METHOD FOR REMOVING KomVision CAMERA 2650
METHOD FOR INSTALLING KomVision CAMERA 2653
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY .2656
METHOD FOR REMOVING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2656
METHOD FOR INSTALLING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2661
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 2666
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS .2666
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS .2674
REMOVE AND INSTALL COMMUNICATION TERMINAL .2683
METHOD FOR REMOVING COMMUNICATION TERMINAL 2683
METHOD FOR INSTALLING COMMUNICATION TERMINAL 2685
60 MAINTENANCE STANDARD .2689
CONTENTS 2690
ABBREVIATION LIST .2691
ENGINE AND COOLING SYSTEM .2697
MAINTENANCE STANDARD OF ENGINE MOUNT 2697
MAINTENANCE STANDARD OF COOLING SYSTEM 2698
POWER TRAIN .2699
MAINTENANCE STANDARD OF SWING CIRCLE 2699
MAINTENANCE STANDARD OF SWING MACHINERY .2700
MAINTENANCE STANDARD OF FINAL DRIVE .2702
MAINTENANCE STANDARD OF SPROCKET 2704
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2705
UNDERCARRIAGE AND FRAME .2707
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2707
MAINTENANCE STANDARD OF IDLER .2709
MAINTENANCE STANDARD OF TRACK ROLLER 2711
MAINTENANCE STANDARD OF CARRIER ROLLER 2712
MAINTENANCE STANDARD OF TRACK SHOE 2713
MAINTENANCE STANDARD OF TRIPLE SHOE .2716
MAINTENANCE STANDARD OF SWAMP SHOE 2717
MAINTENANCE STANDARD OF ROAD LINER 2718
HYDRAULIC SYSTEM 2719
MAINTENANCE STANDARD OF HYDRAULIC TANK 2719
MAINTENANCE STANDARD OF MAIN PUMP .2720
MAINTENANCE STANDARD OF LS-EPC VALVE 2721
MAINTENANCE STANDARD OF PC-EPC VALVE 2722
MAINTENANCE STANDARD OF SWING MOTOR .2723
MAINTENANCE STANDARD OF TRAVEL MOTOR 2726
MAINTENANCE STANDARD OF CONTROL VALVE .2729
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2739
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2742
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2745
MAINTENANCE STANDARD OF EPC VALVE .2746
MAINTENANCE STANDARD OF SOLENOID VALVE 2748
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 2749
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2751
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2752
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2753
WORK EQUIPMENT 2754
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2754
DIMENSION OF ARM 2759
DIMENSIONS OF BUCKET 2761
MAINTENANCE STANDARD OF BOOM CYLINDER .2763
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2764
MAINTENANCE STANDARD OF ARM CYLINDER 2765
MAINTENANCE STANDARD OF BUCKET CYLINDER .2766
80 APPENDIX .2767
CONTENTS 2768
ABBREVIATION LIST .2770
AIR CONDITIONER SYSTEM 2776
PRECAUTIONS FOR REFRIGERANT .2776
AIR CONDITIONER COMPONENT .2777
SPECIFICATIONS OF AIR CONDITIONER .2779
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2780
OUTLINE OF REFRIGERATION CYCLE 2781
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2783
AIR CONDITIONER UNIT 2783
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2783
FUNCTION OF AIR CONDITIONER UNIT 2785
COMPONENT PARTS OF AIR CONDITIONER UNIT .2787
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2788
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2788
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2788
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2788
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2789
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2789
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2789
FUNCTION OF DUAL PRESSURE SWITCH 2790
AIR CONDITIONER CONTROLLER 2791
STRUCTURE OF AIR CONDITIONER CONTROLLER .2791
COMPRESSOR 2792
STRUCTURE OF COMPRESSOR .2792
SPECIFICATIONS OF COMPRESSOR 2792
FUNCTION OF COMPRESSOR 2792
CONDENSER .2793
STRUCTURE OF CONDENSER 2793
SPECIFICATIONS OF CONDENSER .2793
FUNCTION OF CONDENSER .2793
SENSORS FOR AIR CONDITIONER SYSTEM 2795
STRUCTURE OF SUNLIGHT SENSOR 2795
FUNCTION OF SUNLIGHT SENSOR .2795
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2795
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2795
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2797
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2799
AIR CONDITIONER SYSTEM DIAGRAM 2801
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2802
FUNCTION OF AIR CONDITIONER CONTROLLER 2803
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2804
TESTING AIR LEAKAGE (DUCT) 2808
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2808
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2810
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2811
TEST VENT (MODE) CHANGEOVER .2812
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2812
TESTING FRESH/RECIRC AIR CHANGEOVER .2814
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2814
TEST SUNLIGHT SENSOR 2815
METHOD FOR TESTING SUNLIGHT SENSOR 2815
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2816
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2816
TEST RELAYS .2817
METHOD FOR TESTING RELAYS .2817
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2818
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2819
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2822
FAILURE CODE [879AKA] .2824
FAILURE CODE [879AKB] .2825
FAILURE CODE [879BKA] .2826
FAILURE CODE [879BKB] .2828
FAILURE CODE [879CKA] .2830
FAILURE CODE [879CKB] .2831
FAILURE CODE [879DKZ] .2832
FAILURE CODE [879EMC] .2834
FAILURE CODE [879FMC] .2835
FAILURE CODE [879GKX] .2836
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2838
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2840
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2843
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2845
TROUBLESHOOTING USING GAUGE PRESSURE 2847
CONNECTION OF SERVICE TOOL 2850
METHOD FOR CONNECTING SERVICE TOOL 2850
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2852
HANDLE COMPRESSOR OIL .2854
METHOD FOR REPLACING DESICCANT 2856
90 CIRCUIT DIAGRAMS .2859
CONTENTS 2860
ABBREVIATION LIST .2861
HYDRAULIC CIRCUIT DIAGRAM .2867
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2867
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2871
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2873
ELECTRICAL CIRCUIT DIAGRAM 2875
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2875
ELECTRICAL CIRCUIT DIAGRAM (1/10) .2879
ELECTRICAL CIRCUIT DIAGRAM (2/10) .2881
ELECTRICAL CIRCUIT DIAGRAM (3/10) .2883
ELECTRICAL CIRCUIT DIAGRAM (4/10) .2885
ELECTRICAL CIRCUIT DIAGRAM (5/10) .2887
ELECTRICAL CIRCUIT DIAGRAM (6/10) .2889
ELECTRICAL CIRCUIT DIAGRAM (7/10) .2891
ELECTRICAL CIRCUIT DIAGRAM (8/10) .2893
ELECTRICAL CIRCUIT DIAGRAM (9/10) .2895
ELECTRICAL CIRCUIT DIAGRAM (10/10) 2897
INDEX 2899

DESCRIPTION:

Komatsu PC240LC-11E0,PC240NLC-11E0 Hydraulic Excavator Shop Manual UENBM00472 – PDF DOWNLOAD

• SERIAL NUMBERS K75274 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 29/12/24