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KOMATSU PC360LC-11 PC360NLC-11 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00390 – PDF DOWNLOAD
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KOMATSU PC360LC-11 PC360NLC-11 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00390 – PDF DOWNLOAD
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KOMATSU PC360LC-11 PC360NLC-11 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00390 – PDF DOWNLOAD
Language : English
Pages : 2684
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC360LC-11 PC360NLC-11 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00390 – PDF DOWNLOAD
00 INDEX AND FOREWORD................................................................................................................... 3 INDEX............................................................................................................................... 4 ABBREVIATION LIST................................................................................................................... 21 FOREWORD, SAFETY, BASIC INFORMATION................................................................................................. 26 HOW TO READ THE SHOP MANUAL..................................................................................................... 26 SAFETY NOTICE FOR OPERATION..................................................................................................... 28 PRECAUTIONS TO PREVENT FIRE..................................................................................................... 36 ACTIONS IF FIRE OCCURS.......................................................................................................... 38 PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS.................................................................................... 39 ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS................................................................................... 40 PRECAUTIONS FOR DEF............................................................................................................. 41 GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING.............................................................................. 41 PRECAUTIONS FOR ADDING...................................................................................................... 41 PRECAUTIONS FOR STORING..................................................................................................... 41 PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE..................................................................................... 41 THE OTHER PRECAUTIONS....................................................................................................... 41 STORE AdBlue/DEF................................................................................................................ 42 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT.................................................................................... 43 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS......................................................................... 46 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT................................................................................... 52 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT.................................................................................. 54 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT................................................................................ 55 PRACTICAL USE OF KOMTRAX........................................................................................................ 56 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER................................................................................... 57 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER....................................................... 57 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER....................................................... 58 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER....................................................... 59 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS...................................................................... 61 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR....................................................................... 65 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR............................................................... 66 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL............................................................. 68 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH............................................................. 69 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE........................................................ 71 HOW TO READ ELECTRICAL WIRE CODE................................................................................................ 72 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD................................................................................... 76 STANDARD TIGHTENING TORQUE TABLE................................................................................................ 79 CONVERSION TABLE................................................................................................................ 86 01 SPECIFICATIONS....................................................................................................................... 91 CONTENTS............................................................................................................................ 92 ABBREVIATION LIST................................................................................................................... 93 SPECIFICATIONS...................................................................................................................... 98 SPECIFICATION DRAWING........................................................................................................... 98 SPECIFICATION DRAWING: PC360LC-11, PC360NLC-11.............................................................................. 98 WORKING RANGE DRAWINGS.......................................................................................................... 99 WORKING RANGE: PC360LC-11, PC360NLC-11...................................................................................... 99 SPECIFICATIONS.................................................................................................................. 100 SPECIFICATIONS: PC360LC-11, PC360NLC-11..................................................................................... 100 WEIGHT TABLE.................................................................................................................... 103 WEIGHT TABLE: PC360LC-11, PC360NLC-11....................................................................................... 103 TABLE OF FUEL, COOLANT, AND LUBRICANTS.......................................................................................... 105 10 STRUCTURE AND FUNCTION............................................................................................................... 107 CONTENTS............................................................................................................................ 108 ABBREVIATION LIST................................................................................................................... 112 UREA SCR SYSTEM..................................................................................................................... 117 LAYOUT DRAWING OF UREA SCR SYSTEM............................................................................................... 117 UREA SCR SYSTEM DIAGRAM......................................................................................................... 121 FUNCTION OF UREA SCR SYSTEM..................................................................................................... 122 FUNCTION OF AdBlue/DEF SYSTEM............................................................................................... 122 INDUCEMENT STRATEGY......................................................................................................... 124 COMPONENT PARTS OF UREA SCR SYSTEM.............................................................................................. 136 AdBlue/DEF MIXING TUBE...................................................................................................... 136 SCR ASSEMBLY................................................................................................................ 136 AdBlue/DEF TANK............................................................................................................. 139 AdBlue/DEF PUMP............................................................................................................. 141 AdBlue/DEF INJECTOR......................................................................................................... 142 AdBlue/DEF HOSE............................................................................................................. 143 AdBlue/DEF TANK HEATING VALVE............................................................................................... 144 BOOT-UP SYSTEM...................................................................................................................... 145 LAYOUT DRAWING OF BOOT-UP SYSTEM................................................................................................ 145 SYSTEM OPERATING LAMP SYSTEM.................................................................................................... 147 SYSTEM OPERATING LAMP SYSTEM DIAGRAM........................................................................................ 147 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM.................................................................................... 147 BATTERY DISCONNECT SWITCH....................................................................................................... 149 FUNCTION OF BATTERY DISCONNECT SWITCH....................................................................................... 149 ENGINE SYSTEM....................................................................................................................... 150 LAYOUT DRAWING OF ENGINE SYSTEM................................................................................................. 150 SPECIFICATIONS OF ENGINE SYSTEM............................................................................................. 151 FUNCTION OF ENGINE SYSTEM................................................................................................... 151 ENGINE CONTROL SYSTEM........................................................................................................... 152 ENGINE CONTROL SYSTEM DIAGRAM............................................................................................... 152 FUNCTION OF ENGINE CONTROL SYSTEM........................................................................................... 153 AUTO-DECELERATION SYSTEM........................................................................................................ 155 AUTO-DECELERATION SYSTEM DIAGRAM............................................................................................ 155 FUNCTION OF AUTO-DECELERATION SYSTEM........................................................................................ 155 OPERATION OF AUTO-DECELERATION SYSTEM....................................................................................... 156 ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................................. 157 ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM..................................................................................... 157 FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................. 158 OVERHEAT PREVENTION SYSTEM...................................................................................................... 159 OVERHEAT PREVENTION SYSTEM DIAGRAM.......................................................................................... 159 FUNCTION OF OVERHEAT PREVENTION SYSTEM...................................................................................... 160 TURBOCHARGER PROTECTION SYSTEM.................................................................................................. 161 TURBOCHARGER PROTECTION SYSTEM DIAGRAM...................................................................................... 161 FUNCTION OF TURBOCHARGER PROTECTION SYSTEM.................................................................................. 162 AUTOMATIC IDLE STOP SYSTEM...................................................................................................... 163 AUTOMATIC IDLE STOP SYSTEM DIAGRAM.......................................................................................... 163 FUNCTION OF AUTOMATIC IDLE STOP SYSTEM...................................................................................... 163 COMPONENT PARTS OF ENGINE SYSTEM................................................................................................ 166 VGT......................................................................................................................... 166 EGR SYSTEM.................................................................................................................. 169 EGR VALVE................................................................................................................... 171 EGR COOLER.................................................................................................................. 173 KCCV SYSTEM................................................................................................................. 174 KCCV VENTILATOR............................................................................................................. 176 KDPF........................................................................................................................ 177 COOLING SYSTEM...................................................................................................................... 182 LAYOUT DRAWING OF COOLING SYSTEM................................................................................................ 182 SPECIFICATIONS OF COOLING SYSTEM............................................................................................ 183 CONTROL SYSTEM...................................................................................................................... 184 LAYOUT DRAWING OF CONTROL SYSTEM................................................................................................ 184 MACHINE MONITOR SYSTEM.......................................................................................................... 187 MACHINE MONITOR SYSTEM DIAGRAM.............................................................................................. 187 FUNCTION OF MACHINE MONITOR SYSTEM.......................................................................................... 187 KOMTRAX SYSTEM.................................................................................................................. 189 KOMTRAX SYSTEM DIAGRAM...................................................................................................... 189 FUNCTION OF KOMTRAX SYSTEM.................................................................................................. 189 PPC LEVERS...................................................................................................................... 190 LH PPC LEVER................................................................................................................ 190 RH PPC LEVER................................................................................................................ 191 AUTOMATIC GREASE SYSTEM......................................................................................................... 192 OUTLINE OF AUTO GREASE SYSTEM............................................................................................... 192 COMPONENT PARTS OF CONTROL SYSTEM............................................................................................... 207 MACHINE MONITOR............................................................................................................. 207 KOMTRAX TERMINAL............................................................................................................ 220 PUMP CONTROLLER............................................................................................................. 222 RESISTOR FOR PC-EPC VALVE................................................................................................... 226 CAN TERMINATING RESISTOR.................................................................................................... 226 PPC OIL PRESSURE SWITCH..................................................................................................... 227 ENGINE CONTROLLER........................................................................................................... 228 FUEL CONTROL DIAL........................................................................................................... 235 SENSOR.......................................................................................................................... 237 STRUCTURE OF AMBIENT PRESSURE SENSOR........................................................................................ 237 FUNCTION OF AMBIENT PRESSURE SENSOR......................................................................................... 237 STRUCTURE OF ENGINE OIL PRESSURE SWITCH..................................................................................... 237 FUNCTION OF ENGINE OIL PRESSURE SWITCH...................................................................................... 238 STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR................................................................. 238 FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR.................................................................. 238 STRUCTURE OF COOLANT TEMPERATURE SENSOR..................................................................................... 239 FUNCTION OF COOLANT TEMPERATURE SENSOR...................................................................................... 239 STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR................................................................................... 239 FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR.................................................................................... 240 STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR................................................................................... 240 FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR.................................................................................... 240 STRUCTURE OF COMMON RAIL PRESSURE SENSOR.................................................................................... 241 FUNCTION OF COMMON RAIL PRESSURE SENSOR..................................................................................... 241 STRUCTURE OF EGR VALVE LIFT SENSOR.......................................................................................... 241 FUNCTION OF EGR VALVE LIFT SENSOR........................................................................................... 241 STRUCTURE OF KVGT SPEED SENSOR.............................................................................................. 242 FUNCTION OF KVGT SPEED SENSOR............................................................................................... 242 STRUCTURE OF KVGT POSITION SENSOR........................................................................................... 242 FUNCTION OF KVGT POSITION SENSOR............................................................................................ 243 STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR........................................................................... 243 STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR.......................................................... 244 FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR........................................................... 244 STRUCTURE OF CRANKCASE PRESSURE SENSOR...................................................................................... 244 FUNCTION OF CRANKCASE PRESSURE SENSOR....................................................................................... 245 STRUCTURE OF ENGINE OIL LEVEL SENSOR........................................................................................ 245 STRUCTURE OF AIR CLEANER CLOGGING SENSOR.................................................................................... 245 FUNCTION OF AIR CLEANER CLOGGING SENSOR..................................................................................... 246 STRUCTURE OF WATER-IN-FUEL SENSOR........................................................................................... 246 FUNCTION OF WATER-IN-FUEL SENSOR............................................................................................ 246 STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH...................................................................... 246 SPECIFICATIONS - QUICK COUPLER LOW PRESSURE WARNING SWITCH.................................................................. 247 FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH....................................................................... 247 STRUCTURE OF AUTO GREASE PRESSURE SWITCH.................................................................................... 247 SPECIFICATIONS - AUTO GREASE PRESSURE SWITCH................................................................................ 248 FUNCTION OF AUTO GREASE PRESSURE SWITCH..................................................................................... 248 STRUCTURE OF OVERLOAD CAUTION SENSOR........................................................................................ 248 SPECIFICATIONS - OVERLOAD CAUTION SENSOR.................................................................................... 248 FUNCTION OF OVERLOAD CAUTION SENSOR......................................................................................... 248 HYDRAULIC SYSTEM.................................................................................................................... 249 LAYOUT DRAWING OF HYDRAULIC SYSTEM.............................................................................................. 249 CLSS............................................................................................................................ 252 STRUCTURE OF CLSS........................................................................................................... 252 OPERATION OF UNLOAD VALVE AND LS PRESSURE................................................................................... 254 PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL................................................................................... 255 PRESSURE COMPENSATION CONTROL............................................................................................... 268 ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................................... 271 ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM............................................................................. 271 FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................... 272 PUMP AND VALVE CONTROL SYSTEM................................................................................................... 277 PUMP AND VALVE CONTROL SYSTEM DIAGRAM....................................................................................... 277 FUNCTION OF PUMP AND VALVE CONTROL SYSTEM................................................................................... 278 COMPONENT PARTS OF HYDRAULIC SYSTEM............................................................................................. 280 HYDRAULIC TANK.............................................................................................................. 280 MAIN PUMP................................................................................................................... 283 CONTROL VALVE............................................................................................................... 309 WORK EQUIPMENT SYSTEM............................................................................................................... 366 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM......................................................................................... 366 STRUCTURE OF VALVE CONTROL...................................................................................................... 372 ONE-TOUCH POWER MAXIMIZING SYSTEM............................................................................................... 374 ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM................................................................................... 374 FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM............................................................................... 375 MACHINE PUSH-UP SYSTEM.......................................................................................................... 376 MACHINE PUSH-UP SYSTEM DIAGRAM.............................................................................................. 376 FUNCTION OF MACHINE PUSH-UP SYSTEM.......................................................................................... 377 PPC LOCK SYSTEM................................................................................................................. 378 PPC LOCK SYSTEM DIAGRAM..................................................................................................... 378 FUNCTION OF PPC LOCK SYSTEM................................................................................................. 378 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................................. 379 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM..................................................................... 379 FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................. 379 OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................ 380 OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT......................................................................................... 381 OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT............................................................................. 381 FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT......................................................................... 382 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM........................................................................................ 383 WORK EQUIPMENT AND SWING PPC VALVE.......................................................................................... 383 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE).............................................................................. 388 2ND-LINE ATTACHMENT PPC VALVE............................................................................................... 392 SOLENOID VALVE.............................................................................................................. 394 ATTACHMENT CIRCUIT SELECTOR VALVE........................................................................................... 397 ATT EPC VALVE ASSEMBLY...................................................................................................... 399 RETURN OIL FILTER........................................................................................................... 400 QUICK COUPLER CONTROL VALVE................................................................................................. 402 PILOT CIRCUIT ACCUMULATOR................................................................................................... 404 SWING SYSTEM........................................................................................................................ 405 LAYOUT DRAWING OF SWING SYSTEM.................................................................................................. 405 SWING CONTROL SYSTEM DIAGRAM.................................................................................................... 408 FUNCTION OF SWING CONTROL SYSTEM............................................................................................ 408 COMPONENT PARTS OF SWING SYSTEM................................................................................................. 412 SWING MOTOR................................................................................................................. 412 SWING MACHINERY............................................................................................................. 423 SWING CIRCLE................................................................................................................ 424 TRAVEL SYSTEM....................................................................................................................... 426 LAYOUT DRAWING OF TRAVEL SYSTEM................................................................................................. 426 TRAVEL CONTROL SYSTEM DIAGRAM................................................................................................... 430 FUNCTION OF TRAVEL CONTROL SYSTEM........................................................................................... 430 COMPONENT PARTS OF TRAVEL SYSTEM................................................................................................ 432 TRAVEL MOTOR................................................................................................................ 432 FINAL DRIVE................................................................................................................. 444 TRAVEL PPC VALVE............................................................................................................ 445 CENTER SWIVEL JOINT......................................................................................................... 450 UNDERCARRIAGE AND FRAME............................................................................................................. 452 LAYOUT DRAWING OF UNDERCARRIAGE................................................................................................. 452 SPECIFICATIONS OF UNDERCARRIAGE............................................................................................. 452 WORK EQUIPMENT...................................................................................................................... 453 STRUCTURE OF WORK EQUIPMENT..................................................................................................... 453 FUNCTION OF WORK EQUIPMENT...................................................................................................... 454 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM........................................................................................ 455 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM........................................................................ 455 BUCKET CLEARANCE ADJUSTMENT SHIM................................................................................................ 456 FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM................................................................................ 456 CAB AND ITS ATTACHMENTS............................................................................................................. 457 ROPS CAB........................................................................................................................ 457 STRUCTURE OF ROPS CAB....................................................................................................... 457 FUNCTION OF ROPS CAB........................................................................................................ 457 CAB MOUNT....................................................................................................................... 458 STRUCTURE OF CAB MOUNT...................................................................................................... 458 FUNCTION OF CAB MOUNT....................................................................................................... 458 CAB TIPPING STOPPER............................................................................................................. 459 STRUCTURE OF CAB TIPPING STOPPER............................................................................................ 459 FUNCTION OF CAB TIPPING STOPPER............................................................................................. 459 20 STANDARD VALUE TABLE................................................................................................................. 461 CONTENTS............................................................................................................................ 462 ABBREVIATION LIST................................................................................................................... 463 STANDARD VALUE TABLE FOR ENGINE..................................................................................................... 468 STANDARD VALUE TABLE FOR ENGINE: PC360LC-11, PC360NLC-11........................................................................ 468 STANDARD VALUE TABLE FOR MACHINE.................................................................................................... 473 STANDARD VALUE TABLE FOR MACHINE: PC360LC-11, PC360NLC-11....................................................................... 473 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE......................................................................... 487 STANDARD VALUE TABLE FOR ELECTRICAL................................................................................................. 491 STANDARD VALUE TABLE FOR ELECTRICAL............................................................................................. 491 30 TESTING AND ADJUSTING................................................................................................................ 501 CONTENTS............................................................................................................................ 502 ABBREVIATION LIST................................................................................................................... 505 RELATED INFORMATION ON TESTING AND ADJUSTING........................................................................................ 510 TOOLS FOR TESTING AND ADJUSTING................................................................................................. 510 SKETCH OF TOOLS FOR TESTING AND ADJUSTING....................................................................................... 516 ENGINE AND COOLING SYSTEM........................................................................................................... 518 TEST ENGINE SPEED............................................................................................................... 518 METHOD FOR TESTING ENGINE SPEED............................................................................................. 518 TEST BOOST PRESSURE............................................................................................................. 522 METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR........................................................................ 522 METHOD FOR TESTING BOOST PRESSURE........................................................................................... 523 TEST EXHAUST GAS COLOR.......................................................................................................... 524 METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER................................................................. 524 METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER......................................................................... 525 TEST AND ADJUST VALVE CLEARANCE................................................................................................. 526 METHOD FOR TESTING VALVE CLEARANCE.......................................................................................... 526 METHOD FOR ADJUSTING VALVE CLEARANCE........................................................................................ 528 TEST COMPRESSION PRESSURE....................................................................................................... 529 METHOD FOR TESTING COMPRESSION PRESSURE..................................................................................... 529 TEST BLOWBY PRESSURE............................................................................................................ 532 METHOD FOR TESTING BLOWBY PRESSURE.......................................................................................... 532 TEST ENGINE OIL PRESSURE........................................................................................................ 534 METHOD FOR TESTING ENGINE OIL PRESSURE...................................................................................... 534 TEST EGR VALVE AND VGT OIL PRESSURE............................................................................................. 536 METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE........................................................................... 536 TEST FUEL PRESSURE.............................................................................................................. 538 METHOD FOR TESTING FUEL PRESSURE............................................................................................ 539 TEST FUEL DISCHARGE, RETURN AND LEAKAGE......................................................................................... 545 METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE....................................................................... 546 BLEED AIR FROM FUEL SYSTEM...................................................................................................... 552 METHOD FOR BLEEDING AIR FROM FUEL SYSTEM.................................................................................... 552 TEST FUEL CIRCUIT FOR LEAKAGE................................................................................................... 553 METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE................................................................................. 553 HANDLE CYLINDER CUT-OUT MODE OPERATION.......................................................................................... 555 HANDLE NO-INJECTION CRANKING OPERATION.......................................................................................... 556 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION......................................................................... 557 METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION.................................................................. 557 METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION................................................................ 557 METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT........................................................................ 558 WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER.................................................................. 559 METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER................................................. 559 TEST SCR RELATED FUNCTIONS...................................................................................................... 560 TEST AdBlue/DEF PUMP RAISED PRESSURE........................................................................................ 563 TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR.............................................................................. 566 TEST AdBlue/DEF LINE HEATER RELAY 1......................................................................................... 570 TEST AdBlue/DEF LINE HEATER RELAY 2......................................................................................... 572 TEST AdBlue/DEF PUMP HEATER RELAY........................................................................................... 575 TEST AdBlue/DEF TANK HEATER VALVE........................................................................................... 578 TEST DENITRATION EFFICIENCY OF SCR.......................................................................................... 581 CLEAN AdBlue/DEF TANK........................................................................................................... 585 METHOD FOR CLEANING AdBlue/DEF TANK......................................................................................... 585 POWER TRAIN......................................................................................................................... 589 TEST SWING CIRCLE BEARING CLEARANCE............................................................................................. 589 METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE........................................................................... 589 UNDERCARRIAGE AND FRAME............................................................................................................. 590 TEST AND ADJUST TRACK TENSION................................................................................................... 590 METHOD FOR TESTING TRACK TENSION............................................................................................ 590 METHOD FOR ADJUSTING TRACK TENSION.......................................................................................... 590 HYDRAULIC SYSTEM.................................................................................................................... 592 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM................................................................................ 592 METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK................................................................. 592 METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT....................................................... 592 METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT............................................................ 595 METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT........................................................... 595 TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS...................................................... 596 METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS............................................... 597 METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS............................................. 605 TEST OIL PRESSURE OF CONTROL CIRCUIT............................................................................................ 609 METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT.......................................................................... 609 TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT......................................................................... 611 TEST PC VALVE OUTPUT PRESSURE (SERVO PISTON INLET PRESSURE)................................................................. 611 TEST PC-EPC VALVE OUTPUT PRESSURE........................................................................................... 612 METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT................................................................ 613 TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT......................................................................... 614 METHOD FOR TESTING OIL PRESSURE WITH SENSOR ADAPTER (SPECIAL TOOL).......................................................... 614 METHOD FOR TESTING LS DIFFERENTIAL PRESSURE................................................................................. 616 METHOD FOR TESTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INLET PRESSURE)................................................... 617 METHOD FOR TESTING LS-EPC VALVE OUTPUT PRESSURE............................................................................. 618 METHOD FOR ADJUSTING LS VALVE............................................................................................... 618 TEST OUTLET PRESSURE OF SOLENOID VALVE.......................................................................................... 620 METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE........................................................................ 620 OPERATING CONDITION OF SOLENOID VALVE....................................................................................... 621 TEST PPC VALVE OUTPUT PRESSURE.................................................................................................. 623 METHOD FOR TESTING PPC VALVE OUTPUT PRESSURE................................................................................ 623 ADJUST WORK EQUIPMENT AND SWING PPC VALVES...................................................................................... 625 METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES............................................................ 625 MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE............................................................. 626 TEST PUMP SWASH PLATE SENSOR.................................................................................................... 628 METHOD FOR TESTING PUMP SWASH PLATE SENSOR.................................................................................. 628 TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT........................................................................ 629 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER................................... 629 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER........................................................ 629 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE........................................................... 630 TEST OIL LEAKAGE................................................................................................................ 631 METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER........................................................................... 631 METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER............................................................................ 631 METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER......................................................................... 632 METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR............................................................................. 632 METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR............................................................................ 632 BLEED AIR FROM HYDRAULIC CIRCUIT................................................................................................ 634 METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT.............................................................................. 636 CAB AND ITS ATTACHMENTS............................................................................................................. 639 TEST CAB TIPPING STOPPER........................................................................................................ 639 METHOD FOR TESTING CAB TIPPING STOPPER...................................................................................... 639 METHOD FOR ADJUSTING MIRRORS.................................................................................................... 640 PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A)....................................................................... 640 PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A)................................................... 641 PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B)...................................................................... 642 PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B).................................................. 643 PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C)....................................................................... 644 ELECTRICAL SYSTEM................................................................................................................... 646 SET AND OPERATE MACHINE MONITOR................................................................................................. 646 OPERATOR MODE............................................................................................................... 649 DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN................................................................. 650 DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN.................................................................... 650 CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)........................................................................... 651 CHECKING FUNCTION OF SERVICE METER.......................................................................................... 651 METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD................................................................... 651 SERVICE MODE................................................................................................................ 654 METHOD FOR OPERATING SERVICE MODE........................................................................................... 654 METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION...................................................................... 656 METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION...................................................................... 663 ABNORMALITY RECORD MENU..................................................................................................... 673 METHOD FOR CONFIRMING MAINTENANCE RECORD.................................................................................... 678 METHOD FOR OPERATING MAINTENANCE MODE SETTING............................................................................... 679 METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING............................................................................. 683 DEFAULT MENU................................................................................................................ 684 DIAGNOSTIC TESTS MENU....................................................................................................... 691 ADJUSTMENT MENU............................................................................................................. 700 METHOD FOR PERFORMING NO-INJECTION CRANKING................................................................................. 717 KOMTRAX SETTINGS MENU....................................................................................................... 718 METHOD FOR DISPLAYING SERVICE MESSAGE....................................................................................... 720 METHOD FOR STARTING UP KOMTRAX TERMINAL......................................................................................... 722 ADJUST REARVIEW CAMERA ANGLE.................................................................................................... 727 METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE................................................................................. 727 HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER..................................................................................... 730 HANDLE BATTERY DISCONNECT SWITCH................................................................................................ 731 TEST DIODES..................................................................................................................... 732 METHOD FOR TESTING DIODE USING DIGITAL TESTER............................................................................... 732 METHOD FOR TESTING DIODE USING ANALOG TESTER................................................................................ 732 Pm CLINIC........................................................................................................................... 733 Pm CLINIC SERVICE............................................................................................................... 733 Pm CLINIC CHECK SHEET....................................................................................................... 734 40 TROUBLESHOOTING...................................................................................................................... 747 CONTENTS............................................................................................................................ 748 ABBREVIATION LIST................................................................................................................... 759 RELATED INFORMATION ON TROUBLESHOOTING.............................................................................................. 764 GENERAL TROUBLESHOOTING POINTS.................................................................................................. 764 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM...................................................................................... 765 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................... 777 CHECKS BEFORE TROUBLESHOOTING................................................................................................... 779 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING..................................................................................... 781 WALK-AROUND CHECK........................................................................................................... 781 TESTING IN ACCORDANCE WITH TESTING PROCEDURE.................................................................................... 783 CHECK FUEL LEVEL AND TYPE................................................................................................... 783 CHECK IMPURE INGREDIENT IN FUEL............................................................................................. 783 CHECK FUEL PREFILTER........................................................................................................ 784 WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT.......................................................................... 784 METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE............................................................................... 785 CHECK MAIN FILTER........................................................................................................... 786 CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN).............................................................................. 788 CHECK COOLANT LEVEL (RESERVOIR TANK)........................................................................................ 789 CHECK CLOGGING OF AIR CLEANER............................................................................................... 790 OUTER ELEMENT - CLEAN....................................................................................................... 790 ELEMENTS - REPLACE.......................................................................................................... 792 CHECK HYDRAULIC OIL LEVEL................................................................................................... 793 CHECK HYDRAULIC OIL STRAINER................................................................................................ 794 CHECK HYDRAULIC FILTER...................................................................................................... 795 CHECK OIL LEVEL IN SWING MACHINERY CASE..................................................................................... 796 CHECK OIL LEVEL IN DAMPER CASE.............................................................................................. 796 CHECK OIL LEVEL IN FINAL DRIVE CASE......................................................................................... 797 BLEED AIR FROM FUEL SYSTEM.................................................................................................. 797 BLEED AIR FROM HYDRAULIC SYSTEM............................................................................................. 797 ELECTRICAL EQUIPMENT - CHECK METHOD......................................................................................... 797 AUTOMATIC GREASE SYSTEM......................................................................................................... 803 FINDING MALFUNCTIONS........................................................................................................ 803 MALFUNCTION FINDING PROCEDURES.............................................................................................. 805 ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION................................................................................. 807 PROCEDURE FOR TESTING AND TROUBLESHOOTING....................................................................................... 817 SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS................................................................................. 820 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.................................................................................. 824 TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM............................................. 826 Connector list and layout....................................................................................................... 829 CONNECTOR CONTACT IDENTIFICATION................................................................................................ 842 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE......................................................................................... 882 FUSE LOCATION TABLE............................................................................................................. 888 PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)..................................................................... 890 PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])..................................... 894 FAILURE CODES TABLE............................................................................................................. 896 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)................................................................................... 913 FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit..................................................... 913 FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit.................................................... 914 FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit............................................................. 915 FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit............................................................ 917 FAILURE CODE [879CKA] Ventilating Sensor Open Circuit........................................................................... 919 FAILURE CODE [879CKB] Ventilating Sensor Short Circuit.......................................................................... 920 FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit............................................................. 921 FAILURE CODE [879EMC] Ventilation Damper Malfunction............................................................................ 923 FAILURE CODE [879FMC] Air Mix Damper Malfunction................................................................................ 924 FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range............................................................ 925 FAILURE CODE [989L00] Engine Controller Lock Caution 1.......................................................................... 927 FAILURE CODE [989M00] Engine Controller Lock Caution 2.......................................................................... 928 FAILURE CODE [989N00] Engine Controller Lock Caution 3.......................................................................... 929 FAILURE CODE [A1U0N3] HC Desorb Request 1....................................................................................... 930 FAILURE CODE [A1U0N4] HC Desorb Request 2....................................................................................... 932 FAILURE CODE [A900FR] Abrupt Engine Stop by Auto Idling Stop 3.................................................................. 934 FAILURE CODE [A900N6] Abrupt Engine Stop by Auto Idling Stop 1.................................................................. 935 FAILURE CODE [A900NY] Abrupt Engine Stop by Auto Idling Stop 2.................................................................. 936 FAILURE CODE [AA10NX] Air Cleaner Clogging...................................................................................... 937 FAILURE CODE [AB00KE] Charge Voltage Low........................................................................................ 939 FAILURE CODE [AQ10N3] Manual Stationary Regeneration Request (KDOC Face Plugging)............................................... 942 FAILURE CODE [AS00N3] Manual Stationary Regeneration Request (SCR).............................................................. 944 FAILURE CODE [AS00R2] Warning 2 (SCR Device Abnormality)........................................................................ 946 FAILURE CODE [AS00R3] Inducement 1 (SCR Device Abnormality)..................................................................... 947 FAILURE CODE [AS00R4] Inducement 2 (SCR Device Abnormality)..................................................................... 948 FAILURE CODE [AS00R5] Inducement 3 (SCR Device Abnormality)..................................................................... 949 FAILURE CODE [AS00R6] Temporary Recovery of Inducement.......................................................................... 950 FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Error 5.............................................................................. 951 FAILURE CODE [AS10KM] AdBlue/DEF Injector Overheat Warning...................................................................... 952 FAILURE CODE [AS10NR] AdBlue/DEF Injector High Temperature Warning.............................................................. 953 FAILURE CODE [AS10NT] AdBlue/DEF Injector Overheat Caution...................................................................... 954 FAILURE CODE [B@BAZG] Engine Oil Pressure Low................................................................................... 955 FAILURE CODE [B@BAZK] Eng Oil Level Low......................................................................................... 956 FAILURE CODE [B@BCNS] Eng Water Overheat........................................................................................ 958 FAILURE CODE [B@BCZK] Eng Water Level Low....................................................................................... 959 FAILURE CODE [B@HANS] Hyd Oil Overheat.......................................................................................... 961 FAILURE CODE [CA115] Engine NE and Backup Speed Sensor Error.................................................................... 962 FAILURE CODE [CA122] Charge Air Pressure Sensor High Error...................................................................... 963 FAILURE CODE [CA123] Charge Air Pressure Sensor Low Error....................................................................... 965 FAILURE CODE [CA131] Throttle Sensor High Error................................................................................. 967 FAILURE CODE [CA132] Throttle Sensor Low Error.................................................................................. 969 FAILURE CODE [CA144] Coolant Temperature Sensor High Error...................................................................... 971 FAILURE CODE [CA145] Coolant Temperature Sensor Low Error....................................................................... 973 FAILURE CODE [CA153] Charge Air Temperature Sensor High Error................................................................... 975 FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error.................................................................... 978 FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error.......................................................................... 981 FAILURE CODE [CA221] Ambient Pressure Sensor High Error......................................................................... 983 FAILURE CODE [CA222] Ambient Pressure Sensor Low Error.......................................................................... 985 FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error......................................................................... 987 FAILURE CODE [CA234] Engine Overspeed........................................................................................... 988 FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error....................................................................... 989 FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Error.................................................................. 991 FAILURE CODE [CA249] Ambient Air Temp Sensor High Error......................................................................... 993 FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error.......................................................................... 995 FAILURE CODE [CA271] IMV or PCV 1 Short Circuit Error........................................................................... 997 FAILURE CODE [CA272] IMV or PCV 1 Open Circuit Error............................................................................ 999 FAILURE CODE [CA281] Supply Pump Pressure Balance Error.........................................................................1001 FAILURE CODE [CA322] Injector #1 (L#1) Open Circuit Error or Short Circuit Error................................................1002 FAILURE CODE [CA323] Injector #5 (L#5) Open Circuit Error or Short Circuit Error................................................1004 FAILURE CODE [CA324] Injector #3 (L#3) Open Circuit Error or Short Circuit Error................................................1006 FAILURE CODE [CA325] Injector #6 (L#6) Open Circuit Error or Short Circuit Error................................................1008 FAILURE CODE [CA331] Injector #2 (L#2) Open Circuit Error or Short Circuit Error................................................1010 FAILURE CODE [CA332] Injector #4 (L#4) Open Circuit Error or Short Circuit Error................................................1012 FAILURE CODE [CA343] Engine Controller Internal Failure.........................................................................1014 FAILURE CODE [CA351] Injectors Drive Circuit Error..............................................................................1015 FAILURE CODE [CA352] Sensor 1 Supply Voltage Low Error..........................................................................1016 FAILURE CODE [CA356] MAF Sensor High Error......................................................................................1019 FAILURE CODE [CA357] MAF Sensor Low Error.......................................................................................1021 FAILURE CODE [CA386] Sensor 1 Supply Voltage High Error.........................................................................1023 FAILURE CODE [CA428] Water in Fuel Sensor High Error............................................................................1024 FAILURE CODE [CA429] Water in Fuel Sensor Low Error.............................................................................1026 FAILURE CODE [CA435] Engine Oil Pressure SW Error...............................................................................1028 FAILURE CODE [CA441] Battery Voltage Low Error..................................................................................1030 FAILURE CODE [CA442] Battery Voltage High Error.................................................................................1032 FAILURE CODE [CA449] Common Rail Pressure High Error 2..........................................................................1033 FAILURE CODE [CA451] Common Rail Pressure Sensor High Error.....................................................................1037 FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error......................................................................1040 FAILURE CODE [CA488] Charge Air Temperature High Torque Derate..................................................................1042 FAILURE CODE [CA515] Common Rail Pressure Sensor Supply Voltage High Error......................................................1043 FAILURE CODE [CA516] Common Rail Pressure Sensor Supply Voltage Low Error.......................................................1045 FAILURE CODE [CA553] Common Rail Pressure High Error 1..........................................................................1047 FAILURE CODE [CA555] Crankcase Pressure High Error 2............................................................................1048 FAILURE CODE [CA556] Crankcase Pressure High Error 3............................................................................1049 FAILURE CODE [CA559] Common Rail Pressure Low Error 1...........................................................................1050 FAILURE CODE [CA595] Turbocharger Speed High Error 2............................................................................1054 FAILURE CODE [CA687] Turbocharger Speed Low Error...............................................................................1055 FAILURE CODE [CA689] Engine NE Speed Sensor Error...............................................................................1057 FAILURE CODE [CA691] Intake Air Temperature Sensor High Error...................................................................1062 FAILURE CODE [CA692] Intake Air Temperature Sensor Low Error....................................................................1064 FAILURE CODE [CA697] Engine Controller Internal Temperature Sensor High Error...................................................1066 FAILURE CODE [CA698] Engine Controller Internal Temperature Sensor Low Error....................................................1067 FAILURE CODE [CA731] Engine Backup Speed Sensor Phase Error.....................................................................1068 FAILURE CODE [CA778] Engine Backup Speed Sensor Error...........................................................................1070 FAILURE CODE [CA1117] Engine Controller Partial Data Lost Error.................................................................1075 FAILURE CODE [CA1664] KDOC Abnormality..........................................................................................1076 FAILURE CODE [CA1669] AdBlue/DEF Level Sensor Voltage High Error................................................................1078 FAILURE CODE [CA1673] AdBlue/DEF Level Low Error 3..............................................................................1079 FAILURE CODE [CA1677] AdBlue/DEF Temperature Sensor Low Error...................................................................1080 FAILURE CODE [CA1678] AdBlue/DEF Temperature Sensor High Error..................................................................1081 FAILURE CODE [CA1682] AdBlue/DEF Pump Priming Error.............................................................................1082 FAILURE CODE [CA1683] AdBlue/DEF Tank Heating Valve Voltage High Error..........................................................1084 FAILURE CODE [CA1684] AdBlue/DEF Tank Heating Valve Voltage Low Error...........................................................1086 FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High Error..............................................................1088 FAILURE CODE [CA1691] Defective Regeneration....................................................................................1089 FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error......................................................................1092 FAILURE CODE [CA1695] Sensor 5 Supply Voltage High Error........................................................................1095 FAILURE CODE [CA1696] Sensor 5 Supply Voltage Low Error.........................................................................1096 FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error.............................................................................1098 FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Error.............................................................1101 FAILURE CODE [CA1714] AdBlue/DEF Quality Sensor Out of Calibration Error........................................................1103 FAILURE CODE [CA1715] AdBlue/DEF Quality Sensor Internal Circuit Error..........................................................1104 FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error....................................................................1105 FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error.....................................................................1108 FAILURE CODE [CA1843] Crankcase Pressure Sensor High Error......................................................................1111 FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error.......................................................................1113 FAILURE CODE [CA1879] KDPF Differential Pressure Sensor High Error..............................................................1116 FAILURE CODE [CA1881] KDPF Differential Pressure Sensor Low Error...............................................................1119 FAILURE CODE [CA1883] KDPF Differential Pressure Sensor In Range Error..........................................................1121 FAILURE CODE [CA1885] Turbo Outlet NOx Sensor Circuit Error.....................................................................1124 FAILURE CODE [CA1887] SCR Outlet NOx Sensor Circuit Error.......................................................................1126 FAILURE CODE [CA1921] KDPF Soot Accumulation High Error 1.......................................................................1128 FAILURE CODE [CA1922] KDPF Soot Accumulation High Error 2.......................................................................1131 FAILURE CODE [CA1942] Crankcase Pressure Sensor In Range Error..................................................................1136 FAILURE CODE [CA1993] KDPF Differential Pressure Low Error......................................................................1137 FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error.................................................................1140 FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error..................................................................1142 FAILURE CODE [CA2249] Common Rail Pressure Low Error 2..........................................................................1144 FAILURE CODE [CA2265] Fuel Feed Pump Open Circuit Error.........................................................................1145 FAILURE CODE [CA2266] Fuel Feed Pump Short Circuit Error........................................................................1147 FAILURE CODE [CA2271] EGR Valve Position Sensor High Error......................................................................1149 FAILURE CODE [CA2272] EGR Valve Position Sensor Low Error.......................................................................1152 FAILURE CODE [CA2288] Turbocharger Speed High Error 1...........................................................................1155 FAILURE CODE [CA2311] lMV Solenoid Error........................................................................................1156 FAILURE CODE [CA2349] EGR Valve Solenoid Open Circuit Error.....................................................................1157 FAILURE CODE [CA2353] EGR Valve Solenoid Short Circuit Error....................................................................1160 FAILURE CODE [CA2357] EGR Valve Servo Error.....................................................................................1162 FAILURE CODE [CA2381] KVGT Position Sensor High Error...........................................................................1163 FAILURE CODE [CA2382] KVGT Position Sensor Low Error............................................................................1166 FAILURE CODE [CA2383] KVGT Solenoid Open Circuit Error..........................................................................1169 FAILURE CODE [CA2386] KVGT Solenoid Short Circuit Error.........................................................................1172 FAILURE CODE [CA2387] KVGT Servo Error..........................................................................................1174 FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error................................................................1175 FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error...............................................................1177 FAILURE CODE [CA2637] KDOC Face Plugging........................................................................................1179 FAILURE CODE [CA2639] Manual Stationary Regeneration Request....................................................................1181 FAILURE CODE [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error..............................................................1184 FAILURE CODE [CA2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable......................................1190 FAILURE CODE [CA2976] AdBlue/DEF Pump Temperature Sensor Signal Error...........................................................1193 FAILURE CODE [CA3133] KDPF Outlet Pressure Sensor High Error....................................................................1195 FAILURE CODE [CA3134] KDPF Outlet Pressure Sensor Low Error.....................................................................1197 FAILURE CODE [CA3135] KDPF Outlet Pressure Sensor In Range Error................................................................1199 FAILURE CODE [CA3142] SCR Temperature Sensor High Error.........................................................................1202 FAILURE CODE [CA3143] SCR Temperature Sensor Low Error..........................................................................1203 FAILURE CODE [CA3144] SCR Temperature Sensor In Range Error.....................................................................1204 FAILURE CODE [CA3146] SCR Outlet Temperature Sensor High Error..................................................................1206 FAILURE CODE [CA3147] SCR Outlet Temperature Sensor Low Error...................................................................1207 FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range Error..............................................................1208 FAILURE CODE [CA3151] SCR Catalyst Efficiency Low Error 2.......................................................................1210 FAILURE CODE [CA3165] SCR Outlet Temperature High Error.........................................................................1216 FAILURE CODE [CA3229] SCR Temperature High Error................................................................................1218 FAILURE CODE [CA3231] SCR Temperature High Error - Non Regeneration.............................................................1220 FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error............................................................1222 FAILURE CODE [CA3235] SCR Outlet Temperature High Error - Non Regeneration......................................................1226 FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error...............................................................1228 FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error................................................................1231 FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error.............................................................................1234 FAILURE CODE [CA3251] KDOC Inlet Temperature High Error.........................................................................1237 FAILURE CODE [CA3253] KDOC Temperature Error - Non Regeneration.................................................................1239 FAILURE CODE [CA3254] KDOC Outlet Temperature High Error 1......................................................................1242 FAILURE CODE [CA3255] KDPF Temperature Error - Non Regeneration.................................................................1245 FAILURE CODE [CA3256] KDPF Outlet Temperature High Error 1......................................................................1249 FAILURE CODE [CA3311] KDOC Outlet Temperature High Error 2......................................................................1251 FAILURE CODE [CA3312] KDPF Outlet Temperature High Error 2......................................................................1253 FAILURE CODE [CA3313] KDOC Inlet Temperature Sensor Low Error...................................................................1256 FAILURE CODE [CA3314] KDOC Inlet Temperature Sensor High Error..................................................................1258 FAILURE CODE [CA3315] KDOC Inlet Temperature Sensor In Range Error..............................................................1259 FAILURE CODE [CA3316] KDOC Outlet Temperature Sensor Low Error..................................................................1261 FAILURE CODE [CA3317] KDOC Outlet Temperature Sensor High Error.................................................................1263 FAILURE CODE [CA3318] KDOC Outlet Temperature Sensor In Range Error.............................................................1264 FAILURE CODE [CA3319] KDPF Outlet Temperature Sensor High Error.................................................................1266 FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Error..................................................................1267 FAILURE CODE [CA3322] KDPF Outlet Temperature Sensor In Range Error.............................................................1269 FAILURE CODE [CA3419] MAF Sensor Supply Voltage High Error......................................................................1271 FAILURE CODE [CA3421] MAF Sensor Supply Voltage Low Error.......................................................................1273 FAILURE CODE [CA3497] AdBlue/DEF Level Low Error 1..............................................................................1275 FAILURE CODE [CA3498] AdBlue/DEF Level Low Error 2..............................................................................1276 FAILURE CODE [CA3543] AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low)....................................................1277 FAILURE CODE [CA3545] SCR Outlet NOx Sensor Unstable Error......................................................................1283 FAILURE CODE [CA3547] AdBlue/DEF Level Low Error 4..............................................................................1285 FAILURE CODE [CA3558] AdBlue/DEF Pump Voltage High Error........................................................................1286 FAILURE CODE [CA3559] AdBlue/DEF Pump Voltage Low Error.........................................................................1288 FAILURE CODE [CA3562] AdBlue/DEF LineHeater Relay 1 Voltage High Error..........................................................1290 FAILURE CODE [CA3563] AdBlue/DEF LineHeater Relay 1 Voltage Low Error...........................................................1292 FAILURE CODE [CA3567] AdBlue/DEF Injector Open Circuit Error or Short Circuit Error.............................................1295 FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction...........................................................................1298 FAILURE CODE [CA3571] AdBlue/DEF Pump Pressure Sensor High Error................................................................1302 FAILURE CODE [CA3572] AdBlue/DEF Pump Pressure Sensor Low Error.................................................................1304 FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Error....................................................................1306 FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Error...................................................................1308 FAILURE CODE [CA3577] AdBlue/DEF FCV Voltage High Error.........................................................................1310 FAILURE CODE [CA3578] AdBlue/DEF FCV Voltage Low Error..........................................................................1312 FAILURE CODE [CA3582] SCR Catalyst Efficiency Low Error 1.......................................................................1314 FAILURE CODE [CA3583] SCR Outlet NOx Sensor Heater Warming up Error.............................................................1320 FAILURE CODE [CA3596] AdBlue/DEF Pump Pressure Unstable Error...................................................................1322 FAILURE CODE [CA3649] Turbo Outlet NOx Sensor Heater Warming up Error...........................................................1324 FAILURE CODE [CA3681] SCR Outlet NOx Sensor Power Voltage Error.................................................................1326 FAILURE CODE [CA3682] Turbo Outlet NOx Sensor Power Voltage Error...............................................................1331 FAILURE CODE [CA3713] AdBlue/DEF Line Heater 1 Voltage High Error...............................................................1337 FAILURE CODE [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error..............................................................1340 FAILURE CODE [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Error............................................................1341 FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error....................................................................1342 FAILURE CODE [CA3741] Common Rail Pressure Valve Trip Error.....................................................................1345 FAILURE CODE [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error..............................................................1346 FAILURE CODE [CA3751] SCR Catalyst Degradation Error............................................................................1348 FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degradation Error...........................................................1350 FAILURE CODE [CA3866] AdBlue/DEF Low Concentration Error 2......................................................................1352 FAILURE CODE [CA3867] AdBlue/DEF Low Concentration Error 1......................................................................1355 FAILURE CODE [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout Error.............................................................1358 FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error..............................................................................1362 FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error.....................................................................1364 FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error....................................................................1368 FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Error..................................................................1370 FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error...................................................................1372 FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error......................................................................1374 FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error......................................................................1377 FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error.....................................................................1379 FAILURE CODE [CA4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error...................................................1381 FAILURE CODE [CA4152] SCR Temperature Sensor Datalink Timeout Error.............................................................1385 FAILURE CODE [CA4155] AdBlue/DEF Pump Heater Relay Voltage High Error...........................................................1389 FAILURE CODE [CA4156] AdBlue/DEF Pump Heater Relay Voltage Low Error............................................................1392 FAILURE CODE [CA4157] AdBlue/DEF FCV Malfunction................................................................................1395 FAILURE CODE [CA4158] KDOC and KDPF Temperature Sensor Internal Circuit Error...................................................1397 FAILURE CODE [CA4159] SCR Temperature Sensor Internal Circuit Error.............................................................1398 FAILURE CODE [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error...................................................1399 FAILURE CODE [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error....................................................1402 FAILURE CODE [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error...............................................1405 FAILURE CODE [CA4164] SCR Temperature Sensor ECU Voltage High Error.............................................................1407 FAILURE CODE [CA4165] SCR Temperature Sensor ECU Voltage Low Error..............................................................1409 FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Temperature Error.........................................................1411 FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error.....................................................................1413 FAILURE CODE [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error....................................................................1416 FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error.............................................................................1418 FAILURE CODE [CA4249] AdBlue/DEF Pump Temperature Sensor 1 In Range Error.......................................................1421 FAILURE CODE [CA4251] AdBlue/DEF Pump Temperature Sensor 2 In Range Error.......................................................1423 FAILURE CODE [CA4259] KDOC and KDPF Temperature Sensor Power Interrupt Error....................................................1425 FAILURE CODE [CA4261] SCR Temperature Sensor Power Interrupt Error..............................................................1428 FAILURE CODE [CA4277] AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error.............................................1431 FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error.......................................................................1434 FAILURE CODE [CA4459] AdBlue/DEF LineHeater Relay 2 Voltage High Error..........................................................1437 FAILURE CODE [CA4461] AdBlue/DEF LineHeater Relay 2 Voltage Low Error...........................................................1440 FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error.................................................................................1443 FAILURE CODE [CA4731] AdBlue/DEF Temperature Sensor Transmission Data Error.....................................................1447 FAILURE CODE [CA4732] AdBlue/DEF Level Sensor Transmission Data Error...........................................................1448 FAILURE CODE [CA4739] AdBlue/DEF Level Sensor Internal Circuit Error............................................................1449 FAILURE CODE [CA4768] Fuel in AdBlue/DEF Tank Error.............................................................................1450 FAILURE CODE [CA4769] AdBlue/DEF Level Measurement Impossible...................................................................1452 FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error.......................................................................1455 FAILURE CODE [CA4952] System Operating Lamp Short Circuit (Engine Controller)...................................................1458 FAILURE CODE [CA5115] AdBlue/DEF Line Heater 1 Voltage Low Error................................................................1460 FAILURE CODE [CA5179] Engine Room Temperature Sensor High Error.................................................................1463 FAILURE CODE [CA5181] Engine Room Temperature Sensor Low Error..................................................................1465 FAILURE CODE [CA5383] Ash Accumulation High Error...............................................................................1467 FAILURE CODE [D110KB] Battery Relay Output Short Circuit........................................................................1469 FAILURE CODE [D19JKZ] Personal Code Relay Open Circuit or Short Circuit.........................................................1471 FAILURE CODE [D811MC] KOMTRAX Malfunction.......................................................................................1474 FAILURE CODE [D862KA] GPS Antenna Open Circuit..................................................................................1475 FAILURE CODE [D8ALKA] System Operating Lamp Open Circuit (KOMTRAX)..............................................................1476 FAILURE CODE [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX).............................................................1478 FAILURE CODE [D8AQKR] CAN 2 Defective Communication (KOMTRAX)...................................................................1480 FAILURE CODE [DA20MC] Pump Controller Malfunction...............................................................................1482 FAILURE CODE [DA22KK] Pump Controller Solenoid Power Voltage Low Error..........................................................1483 FAILURE CODE [DA25KP] 5V Sensor 1 Power Voltage Low Error.......................................................................1486 FAILURE CODE [DA29KQ] Model Selection Signal Mismatch (Pump Controller).........................................................1489 FAILURE CODE [DA2LKA] System Operating Lamp Open Circuit (Pump Controller)......................................................1491 FAILURE CODE [DA2LKB] System Operating Lamp Short Circuit (Pump Controller).....................................................1493 FAILURE CODE [DA2QKR] Controller Area Network 2 Defective Communication (Pump Controller).......................................1495 FAILURE CODE [DA2RKR] Controller Area Network 1 Defective Communication (Pump Controller).......................................1498 FAILURE CODE [DAF0MB] Monitor ROM Abnormality...................................................................................1499 FAILURE CODE [DAF0MC] Monitor Malfunction.......................................................................................1500 FAILURE CODE [DAF8KB] Camera Power Supply Short Circuit.........................................................................1501 FAILURE CODE [DAF9KQ] Model Selection Signal Mismatch (Monitor).................................................................1503 FAILURE CODE [DAFGMC] GPS Module Malfunction....................................................................................1504 FAILURE CODE [DAFLKA] System Operating Lamp Open Circuit (Monitor)..............................................................1505 FAILURE CODE [DAFLKB] System Operating Lamp Short Circuit (Monitor).............................................................1507 FAILURE CODE [DAFQKR] CAN 2 Defective Communication (Monitor)...................................................................1509 FAILURE CODE [DAZ9KQ] Model Selection Signal Mismatch (A/C).....................................................................1510 FAILURE CODE [DAZQKR] CAN 2 Defective Communication (A/C ECU)...................................................................1511 FAILURE CODE [DB2QKR] CAN 2 Defective Communication (Engine Controller).........................................................1516 FAILURE CODE [DB2RKR] CAN 1 Defective Communication (Engine Controller).........................................................1521 FAILURE CODE [DDNRKA] W/E Lever Lock SW Open Circuit............................................................................1526 FAILURE CODE [DDNRKY] W/E Lever Lock SW Short Circuit...........................................................................1528 FAILURE CODE [DDNS00] Lock Lever Auto Lock Release SW On........................................................................1530 FAILURE CODE [DGH2KB] Hydraulic Oil Temperature Sensor Ground Fault.............................................................1532 FAILURE CODE [DHA4KA] Air Cleaner Clog Sensor Open Circuit......................................................................1534 FAILURE CODE [DHAAMA] KDPF Differential Pressure Sensor Frozen..................................................................1536 FAILURE CODE [DHACMA] KDPF Outlet Pressure Sensor Frozen........................................................................1538 FAILURE CODE [DHPAMA] Front Pump Pressure Sensor Defective Function.............................................................1540 FAILURE CODE [DHPBMA] Rear Pump Pressure Sensor Defective Function..............................................................1543 FAILURE CODE [DHS3MA] Arm IN PPC Pressure Sensor Defective Function.............................................................1546 FAILURE CODE [DHS4MA] Bucket CURL PPC Pressure Sensor Defective Function........................................................1549 FAILURE CODE [DHS8MA] Boom RAISE PPC Pressure Sensor Defective Function.........................................................1552 FAILURE CODE [DHS9MA] Boom LOWER PPC Pressure Sensor Defective Function.........................................................1555 FAILURE CODE [DHSAMA] Swing Right PPC Pressure Sensor Defective Function........................................................1558 FAILURE CODE [DHSBMA] Swing Left PPC Pressure Sensor Defective Function.........................................................1561 FAILURE CODE [DHSCMA] Arm OUT PPC Pressure Sensor Defective Function............................................................1564 FAILURE CODE [DHSDMA] Bucket DUMP PPC Pressure Sensor Defective Function........................................................1567 FAILURE CODE [DHSFMA] Travel Forward Left PPC Pressure Sensor Defective Function................................................1570 FAILURE CODE [DHSGMA] Travel Forward Right PPC Pressure Sensor Defective Function...............................................1573 FAILURE CODE [DHSHMA] Travel Reverse Left PPC Pressure Sensor Defective Function................................................1576 FAILURE CODE [DHSJMA] Travel Reverse Right PPC Pressure Sensor Defective Function...............................................1579 FAILURE CODE [DKR0MA] Front Pump Swash Plate Sensor Defective Function..........................................................1582 FAILURE CODE [DKR1MA] Rear Pump Swash Plate Sensor Defective Function...........................................................1585 FAILURE CODE [DKULKA] PPC Lock Relay Open Circuit...............................................................................1588 FAILURE CODE [DKULKB] PPC Lock Relay Short Circuit..............................................................................1590 FAILURE CODE [DKULKY] PPC Lock Relay Hot Short Circuit..........................................................................1592 FAILURE CODE [DR21KX] Camera 2 Picture Reverse Drive Input Out of Range.........................................................1593 FAILURE CODE [DR31KX] Camera 3 Picture Reverse Drive Input Out of Range.........................................................1595 FAILURE CODE [DV20KB] Travel Alarm Short Circuit................................................................................1597 FAILURE CODE [DW43KA] Travel Speed Solenoid Open Circuit........................................................................1599 FAILURE CODE [DW43KB] Travel Speed Solenoid Short Circuit.......................................................................1601 FAILURE CODE [DW43KY] Travel Speed Solenoid Hot Short Circuit...................................................................1603 FAILURE CODE [DW45KA]Swing Parking Brake Solenoid Open Circuit..................................................................1605 FAILURE CODE [DW45KB] Swing Parking Brake Solenoid Short Circuit................................................................1608 FAILURE CODE [DW45KY] Swing Parking Brake Solenoid Hot Short Circuit............................................................1611 FAILURE CODE [DW4CKY] PPC Lock Solenoid Hot Short Circuit.......................................................................1613 FAILURE CODE [DW91KA] Travel Junction Solenoid Open Circuit.....................................................................1614 FAILURE CODE [DW91KB] Travel Junction Solenoid Short Circuit....................................................................1616 FAILURE CODE [DW91KY] Travel Junction Solenoid Hot Short Circuit................................................................1618 FAILURE CODE [DWA2KA] Attachment Single or 2-Way Change Solenoid Open Circuit...................................................1620 FAILURE CODE [DWA2KB] Attachment Single or 2-Way Change Solenoid Short Circuit..................................................1622 FAILURE CODE [DWA2KY] Attachment Single or 2-Way Change Solenoid Hot Short Circuit..............................................1624 FAILURE CODE [DWK0KA] 2-Stage Relief Solenoid Open Circuit......................................................................1626 FAILURE CODE [DWK0KB] 2-Stage Relief Solenoid Open Circuit......................................................................1628 FAILURE CODE [DWK0KY] 2-Stage Relief Solenoid Hot Short Circuit.................................................................1630 FAILURE CODE [DWK2KA] Variable Back Pressure Solenoid Open Circuit..............................................................1632 FAILURE CODE [DWK2KB] Variable Back Pressure Solenoid Short Circuit.............................................................1634 FAILURE CODE [DWK2KY] Variable Back Pressure Solenoid Hot Short Circuit.........................................................1636 FAILURE CODE [DWK8KA] Swing Pressure Cutoff Solenoid Open Circuit...............................................................1638 FAILURE CODE [DWK8KB] Swing Pressure Cutoff Solenoid Short Circuit..............................................................1640 FAILURE CODE [DWK8KY] Swing Pressure Cutoff Solenoid Hot Short Circuit..........................................................1642 FAILURE CODE [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit...................................................................1644 FAILURE CODE [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit..................................................................1647 FAILURE CODE [DXA9KA] Rear Pump PC-EPC Solenoid Open Circuit....................................................................1649 FAILURE CODE [DXA9KB] Rear Pump PC-EPC Solenoid Short Circuit...................................................................1652 FAILURE CODE [DXE0KA] LS-EPC Solenoid Open Circuit..............................................................................1654 FAILURE CODE [DXE0KB] LS-EPC Solenoid Short Circuit.............................................................................1656 FAILURE CODE [DXE4KA] Attachment Flow Regulating EPC Solenoid Open Circuit......................................................1658 FAILURE CODE [DXE4KB] Attachment Flow Regulating EPC Solenoid Short Circuit.....................................................1660 FAILURE CODE [DXE4KY] Attachment Flow EPC Hot Short Circuit.....................................................................1662 FAILURE CODE [DXE5KA] Merge-divider Main Solenoid Open Circuit..................................................................1663 FAILURE CODE [DXE5KB] Merge-divider Main Solenoid Short Circuit.................................................................1665 FAILURE CODE [DXE6KA] Merge-divider LS Solenoid Open Circuit....................................................................1667 FAILURE CODE [DXE6KB] Merge-divider LS Solenoid Short Circuit...................................................................1669 FAILURE CODE [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid Open Circuit....................................................1671 FAILURE CODE [DXE7KB] Attachment Flow Regulating EPC 2 Solenoid Short Circuit...................................................1673 FAILURE CODE [DXE7KY] Attachment Flow Regulating EPC 2 Hot Short Circuit........................................................1675 FAILURE CODE [DXE8KA] Attachment Flow Regulating EPC 3 Solenoid Open Circuit....................................................1677 FAILURE CODE [DXE8KB] Attachment Flow Regulating EPC 3 Solenoid Short Circuit...................................................1679 FAILURE CODE [DXE8KY] Attachment Flow Regulating EPC 3 Hot Short Circuit........................................................1681 FAILURE CODE [DXE9KA] Attachment Flow Regulating EPC 4 Solenoid Open Circuit....................................................1683 FAILURE CODE [DXE9KB] Attachment Flow Regulating EPC 4 Solenoid Short Circuit...................................................1685 FAILURE CODE [DXE9KY] Attachment Flow Regulating EPC 4 Hot Short Circuit........................................................1687 FAILURE CODE [DXEAKA] Attachment Flow Regulating EPC 5 Solenoid Open Circuit....................................................1689 FAILURE CODE [DXEAKB] Attachment Flow Regulating EPC 5 Solenoid Short Circuit...................................................1691 FAILURE CODE [DXEAKY] Attachment Flow Regulating EPC 5 Hot Short Circuit........................................................1693 FAILURE CODE [DY20KA]Wiper Motor Open Circuit...................................................................................1695 FAILURE CODE [DY20MA] Wiper Motor Defective Function............................................................................1698 FAILURE CODE [DY2CKB] Washer Motor Short Circuit................................................................................1700 FAILURE CODE [DY2DKB] Wiper Motor (Normal Rotation) Short Circuit...............................................................1703 FAILURE CODE [DY2EKB] Wiper Motor (Reverse Rotation) Short Circuit..............................................................1705 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).......................................................................................1707 E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)...............................................................................1707 E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK......................................................................................1713 E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK...................................................................................1716 E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP...........................................................1718 E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING.............................................1720 E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW..........1723 E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW....1724 E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING...............................................1725 E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING................................................1726 E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING...................................................1727 E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..............................................................1728 E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING................................................................1729 E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...........................................................1730 E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING................................................1731 E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.......................................................1732 E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.................................................1733 E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM...................................................................1734 E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL.......................................................................1736 E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM.............................................1737 E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE........................................1738 E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM..............................................1739 E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE.............................................1741 E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED.....................................................................1742 E-24 FUNCTION SWITCH DOES NOT OPERATE...........................................................................................1743 E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)...................................................................1744 E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF....................1745 E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER....................................................................1746 E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED.......................................1747 E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED..........................................1748 E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE.................................................1749 E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE................................................1750 E-32 ALARM BUZZER CANNOT BE CANCELED............................................................................................1752 E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION...................................................1753 E-34 SERVICE MODE CANNOT BE SELECTED............................................................................................1754 E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE............................................................1755 E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK.............................................................1757 E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING.............................................1758 E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE.............................1761 E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR.......................1763 E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED.......................................................................1765 E-41 ALARM DOES NOT SOUND DURING TRAVEL.........................................................................................1766 E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED......................................................................1768 E-43 HORN DOES NOT SOUND........................................................................................................1769 E-44 HORN DOES NOT STOP SOUNDING................................................................................................1773 E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF...................................................1775 E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE...........................................................1776 E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE......................................................1778 E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION....................................................1779 E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION....................................................1780 E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.......................................................1781 E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................................1782 E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...................................................1783 E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...................................................1784 E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.........................................................1785 E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................................1786 E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.......................................................1787 E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED.............................................................................1789 E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY...................................................................................1790 E-59 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED................................................................................1791 E-60 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE..................................................................................1793 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE).......................................................................1794 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE).........................................................................1794 SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS................................................................................1795 FAILURE MODE AND CAUSE TABLE....................................................................................................1797 H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK............................................................................1806 H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER...................................................................1807 H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR................................................................................1810 H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP...........................................................................1811 H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS..................................................................................1812 H-6 SPEED OR POWER OF BOOM IS LOW...............................................................................................1814 H-7 ARM SPEED OR POWER IS LOW...................................................................................................1820 H-8 BUCKET SPEED OR POWER IS LOW................................................................................................1825 H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION............................................................................1828 H-10 HYDRAULIC DRIFT OF BOOM IS LARGE...........................................................................................1829 H-11 HYDRAULIC DRIFT OF ARM IS LARGE............................................................................................1831 H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE.........................................................................................1833 H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES...........................................1834 H-14 TIME LAG OF WORK EQUIPMENT IS LARGE........................................................................................1835 H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE.......................................................................1836 H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE..................................................................................1837 H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED.......................................................................................1838 H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED...........................................................................1839 H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER........................................1840 H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY......................................................1841 H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW....................................................1842 H-22 MACHINE DOES NOT TRAVEL STRAIGHT...........................................................................................1843 H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW.......................................................................1845 H-24 TRAVEL SPEED IS LOW........................................................................................................1848 H-25 ONE OF TRACKS DOES NOT RUN.................................................................................................1850 H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST..........................................................1852 H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT..................................................................1853 H-28 SWINGS ONLY IN ONE DIRECTION...............................................................................................1854 H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)...............................................1855 H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION........................................1856 H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)..........................................1857 H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)......................1858 H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING.........................................................................1859 H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING...........................................................1860 H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED).....................................................1861 H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)....................................................1862 H-37 Quick coupler cylinder will not extend.....................................................................................1863 H-38 Quick coupler cylinder will not retract (but buzzer does not sound)........................................................1865 H-39 Buzzer does not sound (but quick coupler cylinder does retract)............................................................1867 H-40 Quick coupler cylinder extends and retracts slowly.........................................................................1869 TROUBLESHOOTING OF ENGINE (S-MODE)..................................................................................................1870 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE).........................................................................1870 S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION......................................................1871 S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT..................................................................................1872 S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)..............................1873 S-4 ENGINE STARTABILITY IS POOR.................................................................................................1875 S-5 ENGINE DOES NOT PICK UP SMOOTHLY............................................................................................1877 S-6 ENGINE STOPS DURING OPERATION...............................................................................................1879 S-7 ENGINE RUNS ROUGH OR IS UNSTABLE............................................................................................1881 S-8 ENGINE LACKS POWER..........................................................................................................1882 S-9 KDPF GETS CLOGGED IN A SHORT TIME...........................................................................................1884 S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE........................................................................................1886 S-11 OIL BECOMES CONTAMINATED QUICKLY...........................................................................................1887 S-12 FUEL CONSUMPTION IS EXCESSIVE..............................................................................................1888 S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)......................................................1889 S-14 OIL PRESSURE DROPS.........................................................................................................1890 S-15 FUEL MIXES INTO ENGINE OIL.................................................................................................1892 S-16 WATER MIXES INTO ENGINE OIL (MILKY)........................................................................................1893 S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)...........................................................................1894 S-18 UNUSUAL NOISE IS HEARD.....................................................................................................1895 S-19 VIBRATION IS EXCESSIVE.....................................................................................................1896 S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT.......................................................................................1897 S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY.................................................................................1898 S-22 ACTIVE REGENERATION TAKES TIME.............................................................................................1900 S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION........................................................................1901 S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE........................................................................................1902 S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)...................................................................................1904 S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)..................................................................1905 50 DISASSEMBLY AND ASSEMBLY.............................................................................................................1907 CONTENTS............................................................................................................................1908 ABBREVIATION LIST...................................................................................................................1913 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY.....................................................................................1918 HOW TO READ THIS MANUAL.........................................................................................................1918 COATING MATERIALS LIST..........................................................................................................1920 SPECIAL TOOLS LIST..............................................................................................................1925 SKETCHES OF SPECIAL TOOLS.......................................................................................................1940 ENGINE AND COOLING SYSTEM...........................................................................................................1948 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY.........................................................................................1948 METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY....................................................................................1948 METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY..................................................................................1953 REMOVE AND INSTALL INJECTOR ASSEMBLY............................................................................................1961 METHOD FOR REMOVING INJECTOR ASSEMBLY.......................................................................................1961 METHOD FOR INSTALLING INJECTOR ASSEMBLY.....................................................................................1968 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY.......................................................................................1980 METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY..................................................................................1981 METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY................................................................................1990 REMOVE AND INSTALL EGR VALVE ASSEMBLY...........................................................................................2008 METHOD FOR REMOVING EGR VALVE ASSEMBLY......................................................................................2008 METHOD FOR INSTALLING EGR VALVE ASSEMBLY....................................................................................2009 REMOVE AND INSTALL EGR COOLER ASSEMBLY..........................................................................................2011 METHOD FOR REMOVING EGR COOLER ASSEMBLY.....................................................................................2011 METHOD FOR INSTALLING EGR COOLER ASSEMBLY...................................................................................2012 REMOVE AND INSTALL STARTER ASSEMBLY.............................................................................................2015 METHOD FOR REMOVING STARTER ASSEMBLY........................................................................................2015 METHOD FOR INSTALLING STARTER ASSEMBLY......................................................................................2016 REMOVE AND INSTALL ALTERNATOR BELT..............................................................................................2017 METHOD FOR REMOVING ALTERNATOR BELT.........................................................................................2017 METHOD FOR INSTALLING ALTERNATOR BELT.......................................................................................2020 REMOVE AND INSTALL RADIATOR ASSEMBLY............................................................................................2023 METHOD FOR REMOVING RADIATOR ASSEMBLY.......................................................................................2023 METHOD FOR INSTALLING RADIATOR ASSEMBLY.....................................................................................2025 REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY................................................................................2027 METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY...........................................................................2027 METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY.........................................................................2029 REMOVE AND INSTALL AFTERCOOLER ASSEMBLY.........................................................................................2032 METHOD FOR REMOVING AFTERCOOLER ASSEMBLY....................................................................................2032 METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY..................................................................................2033 REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY................................................................................2035 METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY...........................................................................2036 METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY.........................................................................2047 REMOVE AND INSTALL ENGINE FRONT OIL SEAL........................................................................................2062 METHOD FOR REMOVING ENGINE FRONT OIL SEAL...................................................................................2062 METHOD FOR INSTALLING ENGINE FRONT OIL SEAL.................................................................................2066 REMOVE AND INSTALL ENGINE REAR OIL SEAL.........................................................................................2070 METHOD FOR REMOVING ENGINE REAR OIL SEAL....................................................................................2071 METHOD FOR INSTALLING ENGINE REAR OIL SEAL..................................................................................2072 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY.........................................................................................2079 METHOD FOR REMOVING ENGINE HOOD ASSEMBLY....................................................................................2079 METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY..................................................................................2080 REMOVE AND INSTALL FUEL TANK ASSEMBLY...........................................................................................2083 METHOD FOR REMOVING FUEL TANK ASSEMBLY......................................................................................2083 METHOD FOR INSTALLING FUEL TANK ASSEMBLY....................................................................................2087 REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY.....................................................................................2090 METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY................................................................................2090 METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY..............................................................................2096 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY.......................................................................2102 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY..................................................................2102 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY................................................................2108 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR.......................................................................................2113 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR..................................................................................2113 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR................................................................................2113 REMOVE AND INSTALL AdBlue/DEF TANK STRAINER.....................................................................................2115 METHOD FOR REMOVING AdBlue/DEF TANK STRAINER................................................................................2115 METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER..............................................................................2115 REMOVE AND INSTALL KDPF ASSEMBLY................................................................................................2116 METHOD FOR REMOVING KDPF ASSEMBLY...........................................................................................2116 METHOD FOR INSTALLING KDPF ASSEMBLY.........................................................................................2119 DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY.......................................................................................2123 METHOD FOR DISASSEMBLING KDPF ASSEMBLY......................................................................................2124 METHOD FOR ASSEMBLING KDPF ASSEMBLY.........................................................................................2127 REMOVE AND INSTALL SCR ASSEMBLY.................................................................................................2132 METHOD FOR REMOVING SCR ASSEMBLY............................................................................................2132 METHOD FOR INSTALLING SCR ASSEMBLY..........................................................................................2135 REMOVE AND INSTALL KDPF, SCR ASSEMBLY...........................................................................................2138 METHOD FOR REMOVING KDPF, SCR ASSEMBLY......................................................................................2139 METHOD FOR INSTALLING KDPF, SCR ASSEMBLY....................................................................................2145 REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET...................................................................................2152 METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET..............................................................................2152 METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET............................................................................2155 REMOVE AND INSTALL KCCV ASSEMBLY................................................................................................2160 METHOD FOR REMOVING KCCV ASSEMBLY...........................................................................................2160 METHOD FOR INSTALLING KCCV ASSEMBLY.........................................................................................2161 REMOVE AND INSTALL AdBlue/DEF MIXING TUBE.......................................................................................2163 METHOD FOR REMOVING AdBlue/DEF MIXING TUBE..................................................................................2164 METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE................................................................................2167 REMOVE AND INSTALL AdBlue/DEF INJECTOR..........................................................................................2171 METHOD FOR REMOVING AdBlue/DEF INJECTOR.....................................................................................2171 METHOD FOR INSTALLING AdBlue/DEF INJECTOR...................................................................................2174 REMOVE AND INSTALL AdBlue/DEF PUMP..............................................................................................2178 METHOD FOR REMOVING AdBlue/DEF PUMP.........................................................................................2178 METHOD FOR INSTALLING AdBlue/DEF PUMP.......................................................................................2181 REMOVE AND INSTALL AdBlue/DEF HOSE..............................................................................................2183 METHOD FOR REMOVING AdBlue/DEF HOSE.........................................................................................2184 METHOD FOR INSTALLING AdBlue/DEF HOSE.......................................................................................2190 REMOVE AND INSTALL AIR CLEANER ASSEMBLY.........................................................................................2198 METHOD FOR REMOVING AIR CLEANER ASSEMBLY....................................................................................2198 METHOD FOR INSTALLING AIR CLEANER ASSEMBLY..................................................................................2200 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY..........................................................................2202 METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY.....................................................................2202 METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY...................................................................2203 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...........................................................................2205 METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY......................................................................2205 METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY....................................................................2206 POWER TRAIN.........................................................................................................................2207 REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY........................................................................2207 METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...................................................................2207 METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY.................................................................2208 DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY...................................................................................2210 METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY...............................................................................2211 METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY..................................................................................2215 REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY.....................................................................2223 METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY................................................................2223 METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY..............................................................2224 DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY...............................................................................2226 METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY...........................................................................2226 METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY..............................................................................2229 REMOVE AND INSTALL SWING CIRCLE ASSEMBLY........................................................................................2236 METHOD FOR REMOVING SWING CIRCLE ASSEMBLY...................................................................................2236 METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY.................................................................................2236 UNDERCARRIAGE AND FRAME.............................................................................................................2238 SEPARATION AND CONNECTION OF TRACK ASSEMBLY.....................................................................................2238 METHOD FOR SEPARATING TRACK ASSEMBLY........................................................................................2238 METHOD FOR INSTALLING TRACK ASSEMBLY........................................................................................2240 REMOVE AND INSTALL SPROCKET.....................................................................................................2243 METHOD FOR REMOVING SPROCKET................................................................................................2243 METHOD FOR INSTALLING SPROCKET..............................................................................................2243 REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY.............................................................................2245 METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY........................................................................2245 METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY......................................................................2246 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY.........................................................................................2247 METHOD FOR DISASSEMBLING IDLER ASSEMBLY.....................................................................................2247 METHOD FOR ASSEMBLING IDLER ASSEMBLY........................................................................................2248 DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY..............................................................................2252 METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY.............................................................................2252 METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY................................................................................2253 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY..................................................................................2255 METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY..............................................................................2256 METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY.................................................................................2257 DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY.................................................................................2259 METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY............................................................................2259 METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY...............................................................................2260 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY.....................................................................................2263 METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY................................................................................2263 METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY..............................................................................2265 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY.......................................................................................2268 METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY..................................................................................2268 METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY................................................................................2269 HYDRAULIC SYSTEM....................................................................................................................2272 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY.................................................................................2272 METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY............................................................................2272 METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY..........................................................................2273 DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY...........................................................................2276 METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY.......................................................................2277 METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY..........................................................................2278 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY......................................................................................2279 METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY.................................................................................2279 METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY...............................................................................2282 REMOVE AND INSTALL MAIN PUMP ASSEMBLY...........................................................................................2286 METHOD FOR REMOVING MAIN PUMP ASSEMBLY......................................................................................2286 METHOD FOR INSTALLING MAIN PUMP ASSEMBLY....................................................................................2289 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY.......................................................................................2292 METHOD FOR REMOVING CONTROL VALVE ASSEMBLY..................................................................................2292 METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY................................................................................2299 DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY.................................................................................2306 METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING..................................................................2307 METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY................................................................................2308 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY......................................................................2313 METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY..................................................................2313 METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY.....................................................................2314 DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY..............................................................................2316 METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY..........................................................................2316 METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY.............................................................................2317 REMOVE AND INSTALL QUICK COUPLER VALVE..........................................................................................2319 WORK EQUIPMENT......................................................................................................................2321 REMOVE AND INSTALL BUCKET ASSEMBLY..............................................................................................2321 METHOD FOR REMOVING BUCKET ASSEMBLY.........................................................................................2321 METHOD FOR INSTALLING BUCKET ASSEMBLY.......................................................................................2321 REMOVE AND INSTALL ARM ASSEMBLY.................................................................................................2323 METHOD FOR REMOVING ARM ASSEMBLY............................................................................................2323 METHOD FOR INSTALLING ARM ASSEMBLY..........................................................................................2324 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY......................................................................................2326 METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY.................................................................................2326 METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY...............................................................................2329 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY.......................................................................2332 METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY...................................................................2332 METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY......................................................................2335 CAB AND ITS ATTACHMENTS.............................................................................................................2342 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY......................................................................................2342 METHOD FOR REMOVING OPERATOR CAB ASSEMBLY...................................................................................2342 METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY.................................................................................2348 REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)...........................................................................2355 METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)......................................................................2357 METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)....................................................................2357 REMOVE AND INSTALL FRONT WINDOW ASSEMBLY........................................................................................2367 METHOD FOR REMOVING FRONT WINDOW ASSEMBLY...................................................................................2367 METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY.................................................................................2370 REMOVE AND INSTALL FLOOR FRAME ASSEMBLY.........................................................................................2376 METHOD FOR REMOVING FLOOR FRAME ASSEMBLY....................................................................................2377 METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY..................................................................................2383 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY................................................................................2391 METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY...........................................................................2391 METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY.........................................................................2396 REMOVE AND INSTALL OPERATOR'S SEAT..............................................................................................2402 METHOD FOR REMOVING OPERATOR'S SEAT.........................................................................................2402 METHOD FOR INSTALLING OPERATOR'S SEAT.......................................................................................2404 REMOVE AND INSTALL SEAT BELT....................................................................................................2407 METHOD FOR REMOVING SEAT BELT...............................................................................................2407 METHOD FOR INSTALLING SEAT BELT.............................................................................................2408 REMOVE AND INSTALL FRONT WIPER ASSEMBLY.........................................................................................2409 METHOD FOR REMOVING FRONT WIPER ASSEMBLY....................................................................................2409 METHOD FOR INSTALLING FRONT WIPER ASSEMBLY..................................................................................2414 ELECTRICAL SYSTEM...................................................................................................................2422 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...................................................................................2422 METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY..............................................................................2422 METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY............................................................................2424 REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY.....................................................................................2428 METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY................................................................................2428 METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY..............................................................................2431 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY.....................................................................................2435 METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY................................................................................2435 METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY..............................................................................2438 REMOVE AND INSTALL PUMP SWASH PLATE SENSOR......................................................................................2442 METHOD FOR REMOVING PUMP SWASH PLATE SENSOR.................................................................................2442 METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR...............................................................................2442 REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR.........................................................................2444 METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR....................................................................2444 METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR..................................................................2445 REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR...............................................................................2446 METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR..........................................................................2446 METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR........................................................................2447 REMOVE AND INSTALL SCR TEMPERATURE SENSOR.......................................................................................2448 METHOD FOR REMOVING SCR TEMPERATURE SENSOR..................................................................................2448 METHOD FOR INSTALLING SCR TEMPERATURE SENSOR................................................................................2449 REMOVE AND INSTALL REARVIEW CAMERA..............................................................................................2451 METHOD FOR REMOVING REARVIEW CAMERA.........................................................................................2451 METHOD FOR INSTALLING REARVIEW CAMERA.......................................................................................2452 REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY....................................................................................2454 METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY...............................................................................2454 METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY.............................................................................2457 60 MAINTENANCE STANDARD.................................................................................................................2461 CONTENTS............................................................................................................................2462 ABBREVIATION LIST...................................................................................................................2463 ENGINE AND COOLING SYSTEM...........................................................................................................2468 MAINTENANCE STANDARD OF ENGINE MOUNT............................................................................................2468 MAINTENANCE STANDARD OF COOLING SYSTEM..........................................................................................2470 POWER TRAIN.........................................................................................................................2472 MAINTENANCE STANDARD OF SWING CIRCLE............................................................................................2472 MAINTENANCE STANDARD OF SWING MACHINERY.........................................................................................2473 MAINTENANCE STANDARD OF FINAL DRIVE.............................................................................................2475 MAINTENANCE STANDARD OF SPROCKET................................................................................................2477 MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING...............................................................2478 UNDERCARRIAGE AND FRAME.............................................................................................................2480 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION...........................................................................2480 MAINTENANCE STANDARD OF IDLER...................................................................................................2482 MAINTENANCE STANDARD OF TRACK ROLLER............................................................................................2484 MAINTENANCE STANDARD OF CARRIER ROLLER..........................................................................................2486 MAINTENANCE STANDARD OF TRACK SHOE..............................................................................................2487 MAINTENANCE STANDARD OF TRIPLE SHOE.............................................................................................2490 HYDRAULIC SYSTEM....................................................................................................................2491 MAINTENANCE STANDARD OF HYDRAULIC TANK..........................................................................................2491 MAINTENANCE STANDARD OF MAIN PUMP...............................................................................................2492 MAINTENANCE STANDARD OF SWING MOTOR.............................................................................................2494 MAINTENANCE STANDARD OF TRAVEL MOTOR............................................................................................2497 MAINTENANCE STANDARD OF CONTROL VALVE...........................................................................................2500 MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE......................................................................2510 MAINTENANCE STANDARD OF TRAVEL PPC VALVE........................................................................................2513 MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)..........................................................2516 MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE..........................................................2517 MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE...........................................................................2519 MAINTENANCE STANDARD OF SOLENOID VALVE..........................................................................................2521 MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE........................................................................2522 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE.......................................................................2524 MAINTENANCE STANDARD OF CENTER SWIVEL JOINT.....................................................................................2525 WORK EQUIPMENT......................................................................................................................2526 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE..................................................................................2526 DIMENSION OF ARM............................................................................................................2531 DIMENSIONS OF BUCKET........................................................................................................2533 MAINTENANCE STANDARD OF BOOM CYLINDER...........................................................................................2535 MAINTENANCE STANDARD OF ARM CYLINDER............................................................................................2536 MAINTENANCE STANDARD OF BUCKET CYLINDER.........................................................................................2537 80 APPENDIX.............................................................................................................................2539 CONTENTS............................................................................................................................2540 ABBREVIATION LIST...................................................................................................................2542 AIR CONDITIONER SYSTEM..............................................................................................................2547 PRECAUTIONS FOR REFRIGERANT.....................................................................................................2547 AIR CONDITIONER COMPONENT.......................................................................................................2548 SPECIFICATIONS OF AIR CONDITIONER...............................................................................................2550 CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE...............................................................................2551 OUTLINE OF REFRIGERATION CYCLE..................................................................................................2552 COMPONENT PARTS OF AIR CONDITIONER SYSTEM...........................................................................................2554 AIR CONDITIONER UNIT............................................................................................................2554 CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT...............................................................................2554 FUNCTION OF AIR CONDITIONER UNIT............................................................................................2556 COMPONENT PARTS OF AIR CONDITIONER UNIT.........................................................................................2558 FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT....................................................................2559 FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT...................................................................2559 FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT.................................................2559 FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT...................................................................2559 STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT..............................................................2560 FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...............................................................2560 OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...................................................................2560 FUNCTION OF DUAL PRESSURE SWITCH............................................................................................2561 AIR CONDITIONER CONTROLLER......................................................................................................2562 STRUCTURE OF AIR CONDITIONER CONTROLLER.....................................................................................2562 COMPRESSOR......................................................................................................................2563 STRUCTURE OF COMPRESSOR.....................................................................................................2563 SPECIFICATIONS OF COMPRESSOR................................................................................................2563 FUNCTION OF COMPRESSOR......................................................................................................2563 CONDENSER.......................................................................................................................2564 STRUCTURE OF CONDENSER......................................................................................................2564 SPECIFICATIONS OF CONDENSER.................................................................................................2564 FUNCTION OF CONDENSER.......................................................................................................2564 RECEIVER DRIER..................................................................................................................2565 STRUCTURE OF RECEIVER DRIER.................................................................................................2565 SPECIFICATIONS OF RECEIVER DRIER............................................................................................2565 FUNCTION OF RECEIVER DRIER..................................................................................................2565 SENSORS FOR AIR CONDITIONER SYSTEM..............................................................................................2566 STRUCTURE OF SUNLIGHT SENSOR................................................................................................2566 FUNCTION OF SUNLIGHT SENSOR.................................................................................................2566 STRUCTURE OF AMBIENT TEMPERATURE SENSOR.....................................................................................2566 FUNCTION OF AMBIENT TEMPERATURE SENSOR......................................................................................2566 EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER.........................................................2568 CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER...............................................................2570 AIR CONDITIONER SYSTEM DIAGRAM......................................................................................................2572 INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER..........................................................................2573 FUNCTION OF AIR CONDITIONER CONTROLLER......................................................................................2574 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS.......................................................2575 TESTING AIR LEAKAGE (DUCT)..........................................................................................................2579 METHOD FOR TESTING AIR LEAKAGE (DUCT)...........................................................................................2579 TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION...............................................................................2581 HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR..................................2582 TEST VENT (MODE) CHANGEOVER.........................................................................................................2583 METHOD FOR TESTING VENT (MODE) CHANGEOVER.......................................................................................2583 TESTING FRESH/RECIRC AIR CHANGEOVER.................................................................................................2585 METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER..................................................................................2585 TEST SUNLIGHT SENSOR................................................................................................................2586 METHOD FOR TESTING SUNLIGHT SENSOR..............................................................................................2586 TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT.........................................................................................2587 METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT.......................................................................2587 TEST RELAYS.........................................................................................................................2588 METHOD FOR TESTING RELAYS.......................................................................................................2588 AIR CONDITIONER TROUBLESHOOTING CHART 1.............................................................................................2589 AIR CONDITIONER TROUBLESHOOTING CHART 2.............................................................................................2590 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE......................................................................................2593 FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit.........................................................2595 FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit........................................................2596 FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit.................................................................2597 FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit................................................................2599 FAILURE CODE [879CKA] Ventilating Sensor Open Circuit...............................................................................2601 FAILURE CODE [879CKB] Ventilating Sensor Short Circuit..............................................................................2602 FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit.................................................................2603 FAILURE CODE [879EMC] Ventilation Damper Malfunction................................................................................2605 FAILURE CODE [879FMC] Air Mix Damper Malfunction....................................................................................2606 FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range................................................................2607 A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)......................................................2609 A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED).......................................................2611 A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)..............................................2614 A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER.................................................................................2616 TROUBLESHOOTING USING GAUGE PRESSURE................................................................................................2618 CONNECTION OF SERVICE TOOL..........................................................................................................2621 METHOD FOR CONNECTING SERVICE TOOL..............................................................................................2621 PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS.............................................2623 HANDLE COMPRESSOR OIL...............................................................................................................2625 90 CIRCUIT DIAGRAMS.....................................................................................................................2627 CONTENTS............................................................................................................................2628 ABBREVIATION LIST...................................................................................................................2629 HYDRAULIC CIRCUIT DIAGRAM...........................................................................................................2634 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM.......................................................................................2634 HYDRAULIC CIRCUIT DIAGRAM (1/2).................................................................................................2639 HYDRAULIC CIRCUIT DIAGRAM (2/2).................................................................................................2641 ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................2643 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM......................................................................................2643 ELECTRICAL CIRCUIT DIAGRAM (1/8)................................................................................................2647 ELECTRICAL CIRCUIT DIAGRAM (2/8)................................................................................................2649 ELECTRICAL CIRCUIT DIAGRAM (3/8)................................................................................................2651 ELECTRICAL CIRCUIT DIAGRAM (4/8)................................................................................................2653 ELECTRICAL CIRCUIT DIAGRAM (5/8)................................................................................................2655 ELECTRICAL CIRCUIT DIAGRAM (6/8)................................................................................................2657 ELECTRICAL CIRCUIT DIAGRAM (7/8)................................................................................................2659 ELECTRICAL CIRCUIT DIAGRAM (8/8)................................................................................................2661 INDEX...................................................................................................................................2663
DESCRIPTION:
KOMATSU PC360LC-11 PC360NLC-11 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00390 – PDF DOWNLOAD
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.
S.S 31/12/24
