Komatsu HYDRAULIC EXCAVATOR PC290LC -11 PC290NLC -11 Shop Manual UENBM00350 PDF

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Komatsu HYDRAULIC EXCAVATOR PC290LC -11 PC290NLC -11 Shop Manual UENBM00350  – PDF DOWNLOAD

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Komatsu HYDRAULIC EXCAVATOR PC290LC -11 PC290NLC -11 Shop Manual UENBM00350  – PDF DOWNLOAD

Language : EnglishK
Pages :2652
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu HYDRAULIC EXCAVATOR PC290LC -11 PC290NLC -11 Shop Manual UENBM00350  – PDF DOWNLOAD

SERIAL NUMBERS 35001 and up
K70001 and up

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

TABLE OF CONTENTS:

Komatsu HYDRAULIC EXCAVATOR PC290LC -11 PC290NLC -11 Shop Manual UENBM00350  – PDF DOWNLOAD

SERIAL NUMBERS 35001 and up
K70001 and up

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 45
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 51
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 53
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 54
PRACTICAL USE OF KOMTRAX 55
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 56
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 56
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 57
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 58
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 60
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 64
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 65
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 70
HOW TO READ ELECTRICAL WIRE CODE 71
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 75
STANDARD TIGHTENING TORQUE TABLE 78
CONVERSION TABLE 85
01 SPECIFICATIONS 91
CONTENTS 92
ABBREVIATION LIST 93
SPECIFICATIONS 98
SPECIFICATION DRAWING 98
SPECIFICATION DRAWING: PC290LC-11, PC290NLC-11 98
WORKING RANGE DRAWINGS 99
WORKING RANGE: PC290LC-11, PC290NLC-11 99
SPECIFICATIONS 100
SPECIFICATIONS: PC290LC-11, PC290NLC-11 100
WEIGHT TABLE 103
WEIGHT TABLE: PC290LC-11, PC290NLC-11 103
TABLE OF FUEL, COOLANT, AND LUBRICANTS 105
10 STRUCTURE AND FUNCTION 107
CONTENTS 108
ABBREVIATION LIST 111
UREA SCR SYSTEM 116
LAYOUT DRAWING OF UREA SCR SYSTEM 117
UREA SCR SYSTEM DIAGRAM 122
FUNCTION OF UREA SCR SYSTEM 123
FUNCTION OF AdBlue/DEF SYSTEM 123
INDUCEMENT STRATEGY 125
COMPONENT PARTS OF UREA SCR SYSTEM 132
AdBlue/DEF MIXING TUBE 132
SCR ASSEMBLY 132
AdBlue/DEF TANK 135
AdBlue/DEF PUMP 137
AdBlue/DEF INJECTOR 138
AdBlue/DEF HOSE 139
AdBlue/DEF TANK HEATING VALVE 140
BOOT-UP SYSTEM 141
LAYOUT DRAWING OF BOOT-UP SYSTEM 141
SYSTEM OPERATING LAMP SYSTEM 143
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 143
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 143
BATTERY DISCONNECT SWITCH 144
FUNCTION OF BATTERY DISCONNECT SWITCH 144
ENGINE SYSTEM 145
LAYOUT DRAWING OF ENGINE SYSTEM 145
SPECIFICATIONS OF ENGINE SYSTEM 146
FUNCTION OF ENGINE SYSTEM 146
ENGINE CONTROL SYSTEM 147
ENGINE CONTROL SYSTEM DIAGRAM 147
FUNCTION OF ENGINE CONTROL SYSTEM 148
AUTO-DECELERATION SYSTEM 150
AUTO-DECELERATION SYSTEM DIAGRAM 150
FUNCTION OF AUTO-DECELERATION SYSTEM 150
OPERATION OF AUTO-DECELERATION SYSTEM 151
ENGINE AUTOMATIC WARM-UP SYSTEM 152
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 152
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 153
OVERHEAT PREVENTION SYSTEM 154
OVERHEAT PREVENTION SYSTEM DIAGRAM 154
FUNCTION OF OVERHEAT PREVENTION SYSTEM 155
TURBOCHARGER PROTECTION SYSTEM 157
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 157
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 158
AUTOMATIC IDLE STOP SYSTEM 159
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 159
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 159
COMPONENT PARTS OF ENGINE SYSTEM 162
KVGT 162
EGR SYSTEM 165
EGR VALVE 167
EGR COOLER 169
KCCV SYSTEM 170
KCCV VENTILATOR 172
KDPF 174
COOLING SYSTEM 179
LAYOUT DRAWING OF COOLING SYSTEM 179
SPECIFICATIONS OF COOLING SYSTEM 180
CONTROL SYSTEM 181
LAYOUT DRAWING OF CONTROL SYSTEM 181
MACHINE MONITOR SYSTEM 184
MACHINE MONITOR SYSTEM DIAGRAM 184
KOMTRAX SYSTEM 185
KOMTRAX SYSTEM DIAGRAM 185
FUNCTION OF KOMTRAX SYSTEM 185
PPC LEVERS 186
LH PPC LEVER 186
RH PPC LEVER 187
AUTOMATIC GREASE SYSTEM 188
OUTLINE OF AUTO GREASE SYSTEM 188
COMPONENT PARTS OF CONTROL SYSTEM 203
MACHINE MONITOR 203
KOMTRAX TERMINAL 216
PUMP CONTROLLER 218
RESISTOR FOR PC-EPC VALVE 222
CAN TERMINATING RESISTOR 223
PPC OIL PRESSURE SWITCH 223
ENGINE CONTROLLER 225
FUEL CONTROL DIAL 231
232
STRUCTURE OF ENGINE OIL PRESSURE SWITCH 232
FUNCTION OF ENGINE OIL PRESSURE SWITCH 233
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 233
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 234
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 234
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 234
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 234
FUNCTION OF AUTO GREASE PRESSURE SWITCH 234
STRUCTURE OF OVERLOAD CAUTION SENSOR 234
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 235
FUNCTION OF OVERLOAD CAUTION SENSOR 235
HYDRAULIC SYSTEM 236
LAYOUT DRAWING OF HYDRAULIC SYSTEM 236
CLSS 242
STRUCTURE OF CLSS 242
OPERATION OF UNLOAD VALVE AND LS PRESSURE 244
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 245
PRESSURE COMPENSATION CONTROL 258
ENGINE AND PUMP COMBINED CONTROL SYSTEM 260
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 260
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 261
PUMP AND VALVE CONTROL SYSTEM 266
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 266
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 267
COMPONENT PARTS OF HYDRAULIC SYSTEM 269
HYDRAULIC TANK 269
MAIN PUMP 270
PC-EPC VALVE 295
PILOT OIL FILTER 297
CONTROL VALVE 297
WORK EQUIPMENT SYSTEM 354
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 354
STRUCTURE OF VALVE CONTROL 359
ONE-TOUCH POWER MAXIMIZING SYSTEM 361
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 361
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 362
PPC LOCK SYSTEM 363
PPC LOCK SYSTEM DIAGRAM 363
FUNCTION OF PPC LOCK SYSTEM 363
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 364
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 364
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 364
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 365
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 366
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 366
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 368
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 369
WORK EQUIPMENT AND SWING PPC VALVE 369
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 374
SOLENOID VALVE 380
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 383
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 385
ATT EPC VALVE ASSEMBLY 388
RETURN OIL FILTER 389
QUICK COUPLER CONTROL VALVE 391
PILOT CIRCUIT ACCUMULATOR 393
ATTACHMENT CIRCUIT ACCUMULATOR 394
SWING SYSTEM 395
LAYOUT DRAWING OF SWING SYSTEM 395
SWING CONTROL SYSTEM DIAGRAM 399
FUNCTION OF SWING CONTROL SYSTEM 399
COMPONENT PARTS OF SWING SYSTEM 403
SWING MOTOR 403
SWING MACHINERY 414
SWING CIRCLE 415
TRAVEL SYSTEM 417
LAYOUT DRAWING OF TRAVEL SYSTEM 417
TRAVEL CONTROL SYSTEM DIAGRAM 421
FUNCTION OF TRAVEL CONTROL SYSTEM 421
COMPONENT PARTS OF TRAVEL SYSTEM 423
TRAVEL MOTOR 423
FINAL DRIVE 435
TRAVEL PPC VALVE 436
CENTER SWIVEL JOINT 441
UNDERCARRIAGE AND FRAME 443
LAYOUT DRAWING OF UNDERCARRIAGE 443
SPECIFICATIONS OF UNDERCARRIAGE 444
WORK EQUIPMENT 445
STRUCTURE OF WORK EQUIPMENT 445
FUNCTION OF WORK EQUIPMENT 446
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 447
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 447
BUCKET CLEARANCE ADJUSTMENT SHIM 448
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 448
CAB AND ITS ATTACHMENTS 449
ROPS CAB 449
STRUCTURE OF ROPS CAB 449
FUNCTION OF ROPS CAB 449
CAB MOUNT 450
STRUCTURE OF CAB MOUNT 450
FUNCTION OF CAB MOUNT 450
CAB TIPPING STOPPER 451
STRUCTURE OF CAB TIPPING STOPPER 451
FUNCTION OF CAB TIPPING STOPPER 451
20 STANDARD VALUE TABLE 453
CONTENTS 454
ABBREVIATION LIST 455
STANDARD VALUE TABLE FOR ENGINE 460
STANDARD VALUE TABLE FOR ENGINE: PC290LC-11, PC290NLC-11 460
STANDARD VALUE TABLE FOR MACHINE 464
STANDARD VALUE TABLE FOR MACHINE: PC290LC-11, PC290NLC-11 464
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 477
STANDARD VALUE TABLE FOR ELECTRICAL 481
STANDARD VALUE TABLE FOR ELECTRICAL 481
30 TESTING AND ADJUSTING 491
CONTENTS 492
ABBREVIATION LIST 495
RELATED INFORMATION ON TESTING AND ADJUSTING 500
TOOLS FOR TESTING AND ADJUSTING 500
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 506
ENGINE AND COOLING SYSTEM 508
TEST ENGINE SPEED 508
METHOD FOR TESTING ENGINE SPEED 508
TEST BOOST PRESSURE 511
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 511
METHOD FOR TESTING BOOST PRESSURE 512
TEST EXHAUST GAS COLOR 513
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 513
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 514
TEST AND ADJUST VALVE CLEARANCE 516
METHOD FOR TESTING VALVE CLEARANCE 516
METHOD FOR ADJUSTING VALVE CLEARANCE 517
TEST COMPRESSION PRESSURE 518
METHOD FOR TESTING COMPRESSION PRESSURE 518
TEST BLOWBY PRESSURE 523
METHOD FOR TESTING BLOWBY PRESSURE 523
TEST ENGINE OIL PRESSURE 525
METHOD FOR TESTING ENGINE OIL PRESSURE 525
TEST EGR VALVE AND KVGT OIL PRESSURE 526
METHOD FOR TESTING EGR VALVE AND KVGT OIL PRESSURE 526
TEST FUEL PRESSURE 528
METHOD FOR TESTING FUEL PRESSURE 529
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 534
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 535
BLEEDING AIR FROM FUEL SYSTEM 540
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 540
TEST FUEL CIRCUIT FOR LEAKAGE 541
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 541
HANDLE CYLINDER CUT-OUT MODE OPERATION 543
HANDLE NO-INJECTION CRANKING OPERATION 544
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 545
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 545
REPLACING FAN BELT 546
METHOD FOR REPLACING FAN BELT 546
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 547
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 547
TEST SCR RELATED FUNCTIONS 548
TEST AdBlue/DEF PUMP RAISED PRESSURE 551
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 553
TEST AdBlue/DEF LINE HEATER RELAY 1 556
TEST AdBlue/DEF LINE HEATER RELAY 2 559
TEST AdBlue/DEF PUMP HEATER RELAY 561
TEST AdBlue/DEF TANK HEATER VALVE 564
TEST DENITRATION EFFICIENCY OF SCR 567
CLEAN AdBlue/DEF TANK 570
METHOD FOR CLEANING AdBlue/DEF TANK 570
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 574
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 574
POWER TRAIN 576
TEST SWING CIRCLE BEARING CLEARANCE 576
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 576
UNDERCARRIAGE AND FRAME 577
TEST AND ADJUST TRACK TENSION 577
METHOD FOR TESTING TRACK TENSION 577
METHOD FOR ADJUSTING TRACK TENSION 577
HYDRAULIC SYSTEM 579
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 579
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 579
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 580
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 581
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 587
TEST OIL PRESSURE OF CONTROL CIRCUIT 590
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 590
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 592
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 592
TEST PC-EPC VALVE OUTLET PRESSURE 593
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 594
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 595
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 595
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL 596
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 599
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE 600
METHOD FOR ADJUSTING LS VALVE 601
TEST OUTLET PRESSURE OF SOLENOID VALVE 602
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 602
OPERATING CONDITION OF SOLENOID VALVE 603
TEST PPC VALVE OUTLET PRESSURE 606
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 606
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 608
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 608
TEST PUMP SWASH PLATE SENSOR 609
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 609
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 610
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 610
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 610
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 611
TEST OIL LEAKAGE 612
TEST OIL LEAKAGE OF BOOM CYLINDER 612
TEST OIL LEAKAGE OF ARM CYLINDER 612
TEST OIL LEAKAGE OF BUCKET CYLINDER 613
METHOD FOR TESTING OIL LEAKAGE OF SWING MOTOR 613
METHOD FOR TESTING OIL LEAKAGE OF TRAVEL MOTOR 613
BLEED AIR FROM HYDRAULIC CIRCUIT 615
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 616
CAB AND ITS ATTACHMENTS 618
TEST CAB TIPPING STOPPER 618
METHOD FOR TESTING CAB TIPPING STOPPER 618
METHOD FOR ADJUSTING MIRRORS 619
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 619
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 620
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 621
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 622
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 623
ELECTRICAL SYSTEM 625
ELECTRICAL SYSTEM 626
SET AND OPERATE MACHINE MONITOR 626
OPERATOR MODE 629
SERVICE MODE 634
METHOD FOR STARTING UP KOMTRAX TERMINAL 706
ADJUST REARVIEW CAMERA ANGLE 711
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 711
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 714
HANDLE BATTERY DISCONNECT SWITCH 715
TEST DIODES 716
METHOD FOR TESTING DIODE USING DIGITAL TESTER 716
METHOD FOR TESTING DIODE USING ANALOG TESTER 716
Pm CLINIC 717
Pm CLINIC SERVICE 717
Pm CLINIC CHECK SHEET 721
40 TROUBLESHOOTING 733
CONTENTS 734
ABBREVIATION LIST 745
RELATED INFORMATION ON TROUBLESHOOTING 750
GENERAL TROUBLESHOOTING POINTS 750
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 751
SEQUENCE OF EVENTS IN TROUBLESHOOTING 763
CHECKS BEFORE TROUBLESHOOTING 765
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 767
WALK-AROUND CHECK 767
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 769
CHECK FUEL LEVEL AND TYPE 769
CHECK IMPURE INGREDIENT IN FUEL 769
CHECK FUEL PREFILTER 770
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 770
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE 771
CHECK MAIN FILTER 772
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 774
CHECK COOLANT LEVEL (RESERVOIR TANK) 775
CHECK CLOGGING OF AIR CLEANER 775
OUTER ELEMENT – CLEAN 776
ELEMENTS – REPLACE 778
CHECK HYDRAULIC OIL LEVEL 779
CHECK HYDRAULIC OIL STRAINER 780
CHECK HYDRAULIC FILTER 781
CHECK OIL LEVEL IN SWING MACHINERY CASE 782
CHECK OIL LEVEL IN DAMPER CASE 783
CHECK OIL LEVEL IN FINAL DRIVE CASE 783
BLEED AIR FROM FUEL SYSTEM 784
BLEED AIR FROM HYDRAULIC SYSTEM 784
ELECTRICAL EQUIPMENT – CHECK METHOD 784
AUTOMATIC GREASE SYSTEM 792
FINDING MALFUNCTIONS 792
MALFUNCTION FINDING PROCEDURES 794
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 796
PROCEDURE FOR TESTING AND TROUBLESHOOTING 806
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 809
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 813
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 815
CONNECTOR LIST AND LAYOUT 818
CONNECTOR CONTACT IDENTIFICATION 831
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 871
FUSE LOCATION TABLE 877
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 880
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 884
FAILURE CODES TABLE 886
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 903
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit 903
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit 904
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit 905
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit 907
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit 909
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit 910
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit 911
FAILURE CODE [879EMC] Ventilation Damper Malfunction 913
FAILURE CODE [879FMC] Air Mix Damper Malfunction 914
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range 915
FAILURE CODE [989L00] Engine Controller Lock Caution 1 917
FAILURE CODE [989M00] Engine Controller Lock Caution 2 918
FAILURE CODE [989N00] Engine Controller Lock Caution 3 919
FAILURE CODE [A1U0N3] HC Desorb Request 1 920
FAILURE CODE [A1U0N4] HC Desorb Request 2 922
FAILURE CODE [A900FR] Abrupt Engine Stop by Auto Idling Stop 3 924
FAILURE CODE [A900N6] Abrupt Engine Stop by Auto Idling Stop 1 925
FAILURE CODE [A900NY] Abrupt Engine Stop by Auto Idling Stop 2 926
FAILURE CODE [AA10NX] Air Cleaner Clogging 927
FAILURE CODE [AB00KE] Charge Voltage Low 929
FAILURE CODE [AQ10N3] Manual Stationary Regeneration Request (KDOC Face Plugging) 932
FAILURE CODE [AS00N3] Manual Stationary Regeneration Request (SCR) 934
FAILURE CODE [AS00R2] Warning 2 (SCR Device Abnormality) 936
FAILURE CODE [AS00R3] Inducement 1 (SCR Device Abnormality) 937
FAILURE CODE [AS00R4] Inducement 2 (SCR Device Abnormality) 938
FAILURE CODE [AS00R5] Inducement 3 (SCR Device Abnormality) 939
FAILURE CODE [AS00R6] Temporary Recovery of Inducement 940
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Error 5 941
FAILURE CODE [AS10KM] AdBlue/DEF Injector Overheat Warning 942
FAILURE CODE [AS10NR] AdBlue/DEF Injector High Temperature Warning 943
FAILURE CODE [AS10NT] AdBlue/DEF Injector Overheat Caution 944
FAILURE CODE [B@BAZG] Engine Oil Pressure Low 945
FAILURE CODE [B@BAZK] Eng Oil Level Low 946
FAILURE CODE [B@BCNS] Eng Water Overheat 948
FAILURE CODE [B@BCZK] Eng Water Level Low 949
FAILURE CODE [B@HANS] Hyd Oil Overheat 951
FAILURE CODE [CA115] Engine NE and Backup Speed Sensor Error 952
FAILURE CODE [CA122] Charge Air Pressure Sensor High Error 953
FAILURE CODE [CA123] Charge Air Pressure Sensor Low Error 955
FAILURE CODE [CA131] Throttle Sensor High Error 957
FAILURE CODE [CA132] Throttle Sensor Low Error 959
FAILURE CODE [CA144] Coolant Temperature Sensor High Error 961
FAILURE CODE [CA145] Coolant Temperature Sensor Low Error 963
FAILURE CODE [CA153] Charge Air Temperature Sensor High Error 965
FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error 968
FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error 970
FAILURE CODE [CA221] Ambient Pressure Sensor High Error 972
FAILURE CODE [CA222] Ambient Pressure Sensor Low Error 974
FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error 976
FAILURE CODE [CA234] Engine Overspeed 977
FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error 978
FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Error 980
FAILURE CODE [CA249] Ambient Air Temp Sensor High Error 982
FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error 984
FAILURE CODE [CA271] IMV or PCV 1 Short Circuit Error 986
FAILURE CODE [CA272] IMV or PCV 1 Open Circuit Error 988
FAILURE CODE [CA322] Injector #1 (L#1) Open Circuit Error or Short Circuit Error 990
FAILURE CODE [CA323] Injector #5 (L#5) Open Circuit Error or Short Circuit Error 992
FAILURE CODE [CA324] Injector #3 (L#3) Open Circuit Error or Short Circuit Error 994
FAILURE CODE [CA325] Injector #6 (L#6) Open Circuit Error or Short Circuit Error 996
FAILURE CODE [CA331] Injector #2 (L#2) Open Circuit Error or Short Circuit Error 998
FAILURE CODE [CA332] Injector #4 (L#4) Open Circuit Error or Short Circuit Error1000
FAILURE CODE [CA343] Engine Controller Internal Failure1002
FAILURE CODE [CA351] Injectors Drive Circuit Error1003
FAILURE CODE [CA352] Sensor 1 Supply Voltage Low Error1004
FAILURE CODE [CA356] MAF Sensor High Error1007
FAILURE CODE [CA357] MAF Sensor Low Error1009
FAILURE CODE [CA386] Sensor 1 Supply Voltage High Error1011
FAILURE CODE [CA428] Water in Fuel Sensor High Error1012
FAILURE CODE [CA429] Water in Fuel Sensor Low Error1014
FAILURE CODE [CA435] Engine Oil Pressure SW Error1016
FAILURE CODE [CA441] Battery Voltage Low Error1018
FAILURE CODE [CA442] Battery Voltage High Error1020
FAILURE CODE [CA449] Common Rail Pressure High Error 21021
FAILURE CODE [CA451] Common Rail Pressure Sensor High Error1022
FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error1024
FAILURE CODE [CA488] Charge Air Temperature High Torque Derate1026
FAILURE CODE [CA515] Common Rail Pressure Sensor Supply Voltage High Error1027
FAILURE CODE [CA516] Common Rail Pressure Sensor Supply Voltage Low Error1029
FAILURE CODE [CA553] Common Rail Pressure High Error 11031
FAILURE CODE [CA555] Crankcase Pressure High Error 11032
FAILURE CODE [CA556] Crankcase Pressure High Error 21033
FAILURE CODE [CA559] Common Rail Pressure Low Error 11034
FAILURE CODE [CA595] Turbocharger Speed High Error 21037
FAILURE CODE [CA687] Turbocharger Speed Low Error1038
FAILURE CODE [CA689] Engine NE Speed Sensor Error1040
FAILURE CODE [CA691] Intake Air Temperature Sensor High Error1043
FAILURE CODE [CA692] Intake Air Temperature Sensor Low Error1045
FAILURE CODE [CA697] Engine Controller Internal Temperature Sensor High Error1047
FAILURE CODE [CA698] Engine Controller Internal Temperature Sensor Low Error1048
FAILURE CODE [CA731] Engine Backup Speed Sensor Phase Error1049
FAILURE CODE [CA778] Engine Backup Speed Sensor Error1051
FAILURE CODE [CA1117] Engine Controller Partial Data Lost Error1056
FAILURE CODE [CA1664] KDOC Abnormality1057
FAILURE CODE [CA1669] AdBlue/DEF Level Sensor Voltage High Error1059
FAILURE CODE [CA1673] AdBlue/DEF Level Low Error 31060
FAILURE CODE [CA1677] AdBlue/DEF Temperature Sensor Low Error1061
FAILURE CODE [CA1678] AdBlue/DEF Temperature Sensor High Error1062
FAILURE CODE [CA1682] AdBlue/DEF Pump Priming Error1063
FAILURE CODE [CA1683] AdBlue/DEF Tank Heating Valve Voltage High Error1065
FAILURE CODE [CA1684] AdBlue/DEF Tank Heating Valve Voltage Low Error1067
FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High Error1069
FAILURE CODE [CA1691] Defective Regeneration1070
FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error1073
FAILURE CODE [CA1695] Sensor 5 Supply Voltage High Error1076
FAILURE CODE [CA1696] Sensor 5 Supply Voltage Low Error1077
FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error1079
FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Error1082
FAILURE CODE [CA1714] AdBlue/DEF Quality Sensor Out of Calibration Error1084
FAILURE CODE [CA1715] AdBlue/DEF Quality Sensor Internal Circuit Error1085
FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error1086
FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error1089
FAILURE CODE [CA1843] Crankcase Pressure Sensor High Error1092
FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error1094
FAILURE CODE [CA1879] KDPF Differential Pressure Sensor High Error1097
FAILURE CODE [CA1881] KDPF Differential Pressure Sensor Low Error1099
FAILURE CODE [CA1883] KDPF Differential Pressure Sensor In Range Error1101
FAILURE CODE [CA1885] Turbo Outlet NOx Sensor Circuit Error1104
FAILURE CODE [CA1887] SCR Outlet NOx Sensor Circuit Error1106
FAILURE CODE [CA1921] KDPF Soot Accumulation High Error 11108
FAILURE CODE [CA1922] KDPF Soot Accumulation High Error 21111
FAILURE CODE [CA1942] Crankcase Pressure Sensor In Range Error1116
FAILURE CODE [CA1993] KDPF Differential Pressure Low Error1117
FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error1120
FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error1121
FAILURE CODE [CA2249] Common Rail Pressure Low Error 21123
FAILURE CODE [CA2271] EGR Valve Position Sensor High Error1124
FAILURE CODE [CA2272] EGR Valve Position Sensor Low Error1127
FAILURE CODE [CA2288] Turbocharger Speed High Error 11130
FAILURE CODE [CA2311] lMV Solenoid Error1131
FAILURE CODE [CA2349] EGR Valve Solenoid Open Circuit Error1132
FAILURE CODE [CA2353] EGR Valve Solenoid Short Circuit Error1135
FAILURE CODE [CA2357] EGR Valve Servo Error1137
FAILURE CODE [CA2381] KVGT Position Sensor High Error1138
FAILURE CODE [CA2382] KVGT Position Sensor Low Error1141
FAILURE CODE [CA2383] KVGT Solenoid Open Circuit Error1144
FAILURE CODE [CA2386] KVGT Solenoid Short Circuit Error1147
FAILURE CODE [CA2387] KVGT Servo Error1149
FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error1150
FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error1153
FAILURE CODE [CA2637] KDOC Face Plugging1156
FAILURE CODE [CA2639] Manual Stationary Regeneration Request1158
FAILURE CODE [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error1161
FAILURE CODE [CA2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable1167
FAILURE CODE [CA2976] AdBlue/DEF Pump Temperature Sensor Signal Error1170
FAILURE CODE [CA3133] KDPF Outlet Pressure Sensor High Error1172
FAILURE CODE [CA3134] KDPF Outlet Pressure Sensor Low Error1175
FAILURE CODE [CA3135] KDPF Outlet Pressure Sensor In Range Error1177
FAILURE CODE [CA3142] SCR Temperature Sensor High Error1180
FAILURE CODE [CA3143] SCR Temperature Sensor Low Error1181
FAILURE CODE [CA3144] SCR Temperature Sensor In Range Error1182
FAILURE CODE [CA3146] SCR Outlet Temperature Sensor High Error1184
FAILURE CODE [CA3147] SCR Outlet Temperature Sensor Low Error1185
FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range Error1186
FAILURE CODE [CA3151] SCR Catalyst Efficiency Low Error 21188
FAILURE CODE [CA3165] SCR Outlet Temperature High Error1194
FAILURE CODE [CA3229] SCR Temperature High Error1196
FAILURE CODE [CA3231] SCR Temperature High Error – Non Regeneration1198
FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error1200
FAILURE CODE [CA3235] SCR Outlet Temperature High Error – Non Regeneration1204
FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error1206
FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error1209
FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error1212
FAILURE CODE [CA3251] KDOC Inlet Temperature High Error1215
FAILURE CODE [CA3253] KDOC Temperature Error – Non Regeneration1217
FAILURE CODE [CA3254] KDOC Outlet Temperature High Error 11220
FAILURE CODE [CA3255] KDPF Temperature Error – Non Regeneration1223
FAILURE CODE [CA3256] KDPF Outlet Temperature High Error 11227
FAILURE CODE [CA3311] KDOC Outlet Temperature High Error 21229
FAILURE CODE [CA3312] KDPF Outlet Temperature High Error 21231
FAILURE CODE [CA3313] KDOC Inlet Temperature Sensor Low Error1234
FAILURE CODE [CA3314] KDOC Inlet Temperature Sensor High Error1236
FAILURE CODE [CA3315] KDOC Inlet Temperature Sensor In Range Error1237
FAILURE CODE [CA3316] KDOC Outlet Temperature Sensor Low Error1239
FAILURE CODE [CA3317] KDOC Outlet Temperature Sensor High Error1241
FAILURE CODE [CA3318] KDOC Outlet Temperature Sensor In Range Error1242
FAILURE CODE [CA3319] KDPF Outlet Temperature Sensor High Error1244
FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Error1245
FAILURE CODE [CA3322] KDPF Outlet Temperature Sensor In Range Error1247
FAILURE CODE [CA3419] MAF Sensor Supply Voltage High Error1249
FAILURE CODE [CA3421] MAF Sensor Supply Voltage Low Error1251
FAILURE CODE [CA3497] AdBlue/DEF Level Low Error 11253
FAILURE CODE [CA3498] AdBlue/DEF Level Low Error 21254
FAILURE CODE [CA3543] AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low)1255
FAILURE CODE [CA3545] SCR Outlet NOx Sensor Unstable Error1261
FAILURE CODE [CA3547] AdBlue/DEF Level Low Error 41263
FAILURE CODE [CA3558] AdBlue/DEF Pump Voltage High Error1264
FAILURE CODE [CA3559] AdBlue/DEF Pump Voltage Low Error1266
FAILURE CODE [CA3562] AdBlue/DEF LineHeater Relay 1 Voltage High Error1268
FAILURE CODE [CA3563] AdBlue/DEF LineHeater Relay 1 Voltage Low Error1270
FAILURE CODE [CA3567] AdBlue/DEF Injector Open Circuit Error or Short Circuit Error1273
FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction1276
FAILURE CODE [CA3571] AdBlue/DEF Pump Pressure Sensor High Error1280
FAILURE CODE [CA3572] AdBlue/DEF Pump Pressure Sensor Low Error1282
FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Error1284
FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Error1286
FAILURE CODE [CA3577] AdBlue/DEF FCV Voltage High Error1288
FAILURE CODE [CA3578] AdBlue/DEF FCV Voltage Low Error1290
FAILURE CODE [CA3582] SCR Catalyst Efficiency Low Error 11292
FAILURE CODE [CA3583] SCR Outlet NOx Sensor Heater Warming up Error1298
FAILURE CODE [CA3596] AdBlue/DEF Pump Pressure Unstable Error1300
FAILURE CODE [CA3649] Turbo Outlet NOx Sensor Heater Warming up Error1302
FAILURE CODE [CA3681] SCR Outlet NOx Sensor Power Voltage Error1304
FAILURE CODE [CA3682] Turbo Outlet NOx Sensor Power Voltage Error1309
FAILURE CODE [CA3713] AdBlue/DEF Line Heater 1 Voltage High Error1315
FAILURE CODE [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error1318
FAILURE CODE [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Error1319
FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error1320
FAILURE CODE [CA3741] Rail Press Valve Trip Error1323
FAILURE CODE [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error1324
FAILURE CODE [CA3751] SCR Catalyst Degradation Error1326
FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degradation Error1328
FAILURE CODE [CA3866] AdBlue/DEF Low Concentration Error 21330
FAILURE CODE [CA3867] AdBlue/DEF Low Concentration Error 11333
FAILURE CODE [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout Error1336
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error1340
FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error1342
FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error1346
FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Error1348
FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error1350
FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error1352
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error1355
FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error1357
FAILURE CODE [CA4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error1359
FAILURE CODE [CA4152] SCR Temperature Sensor Datalink Timeout Error1363
FAILURE CODE [CA4155] AdBlue/DEF Pump Heater Relay Voltage High Error1367
FAILURE CODE [CA4156] AdBlue/DEF Pump Heater Relay Voltage Low Error1370
FAILURE CODE [CA4157] AdBlue/DEF FCV Malfunction1373
FAILURE CODE [CA4158] KDOC and KDPF Temperature Sensor Internal Circuit Error1375
FAILURE CODE [CA4159] SCR Temperature Sensor Internal Circuit Error1376
FAILURE CODE [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error1377
FAILURE CODE [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error1380
FAILURE CODE [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error1383
FAILURE CODE [CA4164] SCR Temperature Sensor ECU Voltage High Error1385
FAILURE CODE [CA4165] SCR Temperature Sensor ECU Voltage Low Error1387
FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Temperature Error1389
FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error1391
FAILURE CODE [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error1394
FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error1396
FAILURE CODE [CA4249] AdBlue/DEF Pump Temperature Sensor 1 In Range Error1399
FAILURE CODE [CA4251] AdBlue/DEF Pump Temperature Sensor 2 In Range Error1401
FAILURE CODE [CA4259] KDOC and KDPF Temperature Sensor Power Interrupt Error1403
FAILURE CODE [CA4261] SCR Temperature Sensor Power Interrupt Error1406
FAILURE CODE [CA4277] AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error1409
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error1412
FAILURE CODE [CA4459] AdBlue/DEF LineHeater Relay 2 Voltage High Error1415
FAILURE CODE [CA4461] AdBlue/DEF LineHeater Relay 2 Voltage Low Error1418
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error1421
FAILURE CODE [CA4731] AdBlue/DEF Temperature Sensor Transmission Data Error1425
FAILURE CODE [CA4732] AdBlue/DEF Level Sensor Transmission Data Error1426
FAILURE CODE [CA4739] AdBlue/DEF Level Sensor Internal Circuit Error1427
FAILURE CODE [CA4768] Fuel in AdBlue/DEF Tank Error1428
FAILURE CODE [CA4769] AdBlue/DEF Level Measurement Impossible1430
FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error1433
FAILURE CODE [CA4952] System Operating Lamp Short Circuit (Engine Controller)1436
FAILURE CODE [CA5115] AdBlue/DEF Line Heater 1 Voltage Low Error1438
FAILURE CODE [CA5179] Engine Room Temperature Sensor High Error1441
FAILURE CODE [CA5181] Engine Room Temperature Sensor Low Error1443
FAILURE CODE [CA5383] Ash Accumulation High Error1445
FAILURE CODE [D110KB] Battery Relay Output Short Circuit1447
FAILURE CODE [D19JKZ] Personal Code Relay Open Circuit or Short Circuit1449
FAILURE CODE [D811MC] KOMTRAX Malfunction1452
FAILURE CODE [D862KA] GPS Antenna Open Circuit1453
FAILURE CODE [D8ALKA] System Operating Lamp Open Circuit (KOMTRAX)1454
FAILURE CODE [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX)1456
FAILURE CODE [D8AQKR] CAN 2 Defective Communication (KOMTRAX)1458
FAILURE CODE [DA20MC] Pump Controller Malfunction1460
FAILURE CODE [DA22KK] Pump Controller Solenoid Power Voltage Low Error1461
FAILURE CODE [DA25KP] 5V Sensor 1 Power Voltage Low Error1464
FAILURE CODE [DA29KQ] Model Selection Signal Mismatch (Pump Controller)1467
FAILURE CODE [DA2LKA] System Operating Lamp Open Circuit (Pump Controller)1469
FAILURE CODE [DA2LKB] System Operating Lamp Short Circuit (Pump Controller)1471
FAILURE CODE [DA2QKR] Controller Area Network 2 Defective Communication (Pump Controller)1473
FAILURE CODE [DA2RKR] Controller Area Network 1 Defective Communication (Pump Controller)1476
FAILURE CODE [DAF0MB] Monitor ROM Abnormality1477
FAILURE CODE [DAF0MC] Monitor Malfunction1478
FAILURE CODE [DAF8KB] Camera Power Supply Short Circuit1479
FAILURE CODE [DAF9KQ] Model Selection Signal Mismatch (Monitor)1481
FAILURE CODE [DAFGMC] GPS Module Malfunction1482
FAILURE CODE [DAFLKA] System Operating Lamp Open Circuit (Monitor)1483
FAILURE CODE [DAFLKB] System Operating Lamp Short Circuit (Monitor)1485
FAILURE CODE [DAFQKR] CAN 2 Defective Communication (Monitor)1487
FAILURE CODE [DAZ9KQ] Model Selection Signal Mismatch (A/C)1488
FAILURE CODE [DAZQKR] CAN 2 Defective Communication (A/C ECU)1489
FAILURE CODE [DB2QKR] CAN 2 Defective Communication (Engine Controller)1494
FAILURE CODE [DB2RKR] CAN 1 Defective Communication (Engine Controller)1499
FAILURE CODE [DDNRKA] W/E Lever Lock SW Open Circuit1504
FAILURE CODE [DDNRKY] W/E Lever Lock SW Short Circuit1506
FAILURE CODE [DDNS00] Lock Lever Auto Lock Release SW On1508
FAILURE CODE [DFB1KZ] Service Lever Potentio 1 Open or Short Circuit1510
FAILURE CODE [DFB2KZ] Service Lever Potentio 2 Open or Short Circuit1513
FAILURE CODE [DFB3L8] Service Lever 1 Potentiometer Error1516
FAILURE CODE [DFB4L8] Service Lever 2 Potentiometer Error1518
FAILURE CODE [DFB5KZ] Service Lever Sub Potentio 1 Open or Short Circuit1520
FAILURE CODE [DFB6KZ] Service Lever Sub Potentio 2 Open or Short Circuit1523
FAILURE CODE [DGH2KA] Hydraulic Oil Temperature Sensor Open Circuit1526
FAILURE CODE [DGH2KB] Hydraulic Oil Temperature Sensor Ground Fault1528
FAILURE CODE [DHA4KA] Air Cleaner Clog Sensor Open Circuit1530
FAILURE CODE [DHAAMA] KDPF Differential Pressure Sensor Frozen1532
FAILURE CODE [DHACMA] KDPF Outlet Pressure Sensor Frozen1534
FAILURE CODE [DHPAMA] Front Pump Pressure Sensor Defective Function1536
FAILURE CODE [DHPBMA] Rear Pump Pressure Sensor Defective Function1539
FAILURE CODE [DHS3MA] Arm IN PPC Pressure Sensor Defective Function1542
FAILURE CODE [DHS4MA] Bucket CURL PPC Pressure Sensor Defective Function1545
FAILURE CODE [DHS8MA] Boom RAISE PPC Pressure Sensor Defective Function1548
FAILURE CODE [DHS9MA] Boom LOWER PPC Pressure Sensor Defective Function1551
FAILURE CODE [DHSAMA] Swing Right PPC Pressure Sensor Defective Function1554
FAILURE CODE [DHSBMA] Swing Left PPC Pressure Sensor Defective Function1557
FAILURE CODE [DHSCMA] Arm OUT PPC Pressure Sensor Defective Function1560
FAILURE CODE [DHSDMA] Bucket DUMP PPC Pressure Sensor Defective Function1563
FAILURE CODE [DHSFMA] Travel Forward Left PPC Pressure Sensor Defective Function1566
FAILURE CODE [DHSGMA] Travel Forward Right PPC Pressure Sensor Defective Function1569
FAILURE CODE [DHSHMA] Travel Reverse Left PPC Pressure Sensor Defective Function1572
FAILURE CODE [DHSJMA] Travel Reverse Right PPC Pressure Sensor Defective Function1575
FAILURE CODE [DHX1MA] Overload Sensor Abnormality (Analog)1578
FAILURE CODE [DKR0MA] Front Pump Swash Plate Sensor Defective Function1581
FAILURE CODE [DKR1MA] Rear Pump Swash Plate Sensor Defective Function1584
FAILURE CODE [DKULKA] PPC Lock Relay Open Circuit1587
FAILURE CODE [DKULKB] PPC Lock Relay Short Circuit1589
FAILURE CODE [DKULKY] PPC Lock Relay Hot Short Circuit1591
FAILURE CODE [DR21KX] Camera 2 Picture Reverse Drive Input Out of Range1593
FAILURE CODE [DR31KX] Camera 3 Picture Reverse Drive Input Out of Range1595
FAILURE CODE [DV20KB] Travel Alarm Short Circuit1597
FAILURE CODE [DW43KA] Travel Speed Solenoid Open Circuit1599
FAILURE CODE [DW43KB] Travel Speed Solenoid Short Circuit1601
FAILURE CODE [DW43KY] Travel Speed Solenoid Hot Short Circuit1603
FAILURE CODE [DW45KA]Swing Parking Brake Solenoid Open Circuit1605
FAILURE CODE [DW45KB] Swing Parking Brake Solenoid Short Circuit1608
FAILURE CODE [DW45KY] Swing Parking Brake Solenoid Hot Short Circuit1611
FAILURE CODE [DW4CKY] PPC Lock Solenoid Hot Short Circuit1613
FAILURE CODE [DW91KA] Travel Junction Solenoid Open Circuit1615
FAILURE CODE [DW91KB] Travel Junction Solenoid Short Circuit1617
FAILURE CODE [DW91KY] Travel Junction Solenoid Hot Short Circuit1619
FAILURE CODE [DWA2KA] Attachment Single or 2-Way Change Solenoid Open Circuit1621
FAILURE CODE [DWA2KB] Attachment Single or 2-Way Change Solenoid Short Circuit1623
FAILURE CODE [DWA2KY] Attachment Single or 2-Way Change Solenoid Hot Short Circuit1625
FAILURE CODE [DWK0KA] 2-Stage Relief Solenoid Open Circuit1627
FAILURE CODE [DWK0KB] 2-Stage Relief Solenoid Open Circuit1629
FAILURE CODE [DWK0KY] 2-Stage Relief Solenoid Hot Short Circuit1631
FAILURE CODE [DWK2KA] Variable Back Pressure Solenoid Open Circuit1633
FAILURE CODE [DWK2KB] Variable Back Pressure Solenoid Short Circuit1635
FAILURE CODE [DWK2KY] Variable Back Pressure Solenoid Hot Short Circuit1637
FAILURE CODE [DWK8KA] Swing Pressure Cutoff Solenoid Open Circuit1639
FAILURE CODE [DWK8KB] Swing Pressure Cutoff Solenoid Short Circuit1641
FAILURE CODE [DWK8KY] Swing Pressure Cutoff Solenoid Hot Short Circuit1643
FAILURE CODE [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit1645
FAILURE CODE [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit1647
FAILURE CODE [DXA9KA] Rear Pump PC-EPC Solenoid Open Circuit1649
FAILURE CODE [DXA9KB] Rear Pump PC-EPC Solenoid Short Circuit1651
FAILURE CODE [DXE0KA] LS-EPC Solenoid Open Circuit1653
FAILURE CODE [DXE0KB] LS-EPC Solenoid Short Circuit1654
FAILURE CODE [DXE4KA] Attachment Flow Regulating EPC Solenoid Open Circuit1656
FAILURE CODE [DXE4KB] Attachment Flow Regulating EPC Solenoid Short Circuit1658
FAILURE CODE [DXE4KY] Attachment Flow EPC Hot Short Circuit1660
FAILURE CODE [DXE5KA] Merge-divider Main Solenoid Open Circuit1662
FAILURE CODE [DXE5KB] Merge-divider Main Solenoid Short Circuit1664
FAILURE CODE [DXE6KA] Merge-divider LS Solenoid Open Circuit1666
FAILURE CODE [DXE6KB] Merge-divider LS Solenoid Short Circuit1668
FAILURE CODE [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid Open Circuit1670
FAILURE CODE [DXE7KB] Attachment Flow Regulating EPC 2 Solenoid Short Circuit1672
FAILURE CODE [DXE7KY] Attachment Flow Regulating EPC 2 Hot Short Circuit1674
FAILURE CODE [DXE8KA] Attachment Flow Regulating EPC 3 Solenoid Open Circuit1676
FAILURE CODE [DXE8KB] Attachment Flow Regulating EPC 3 Solenoid Short Circuit1678
FAILURE CODE [DXE8KY] Attachment Flow Regulating EPC 3 Hot Short Circuit1680
FAILURE CODE [DXE9KA] Attachment Flow Regulating EPC 4 Solenoid Open Circuit1682
FAILURE CODE [DXE9KB] Attachment Flow Regulating EPC 4 Solenoid Short Circuit1684
FAILURE CODE [DXE9KY] Attachment Flow Regulating EPC 4 Hot Short Circuit1686
FAILURE CODE [DXEAKA] Attachment Flow Regulating EPC 5 Solenoid Open Circuit1688
FAILURE CODE [DXEAKB] Attachment Flow Regulating EPC 5 Solenoid Short Circuit1690
FAILURE CODE [DXEAKY] Attachment Flow Regulating EPC 5 Hot Short Circuit1692
FAILURE CODE [DY20KA]Wiper Motor Open Circuit1694
FAILURE CODE [DY20MA] Wiper Motor Defective Function1696
FAILURE CODE [DY2CKB] Washer Motor Short Circuit1698
FAILURE CODE [DY2DKB] Wiper Motor (Normal Rotation) Short Circuit1701
FAILURE CODE [DY2EKB] Wiper Motor (Reverse Rotation) Short Circuit1703
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)1705
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)1705
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK1711
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK1714
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP1716
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING1718
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW1721
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW1722
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING1723
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING1724
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING1725
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1726
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1727
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1728
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1729
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1730
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING1731
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1732
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL1734
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1735
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE1736
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM1737
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE1739
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED1740
E-24 FUNCTION SWITCH DOES NOT OPERATE1741
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)1742
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF1743
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER1744
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED1745
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED1746
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE1747
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE1748
E-32 ALARM BUZZER CANNOT BE CANCELED1750
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION1751
E-34 SERVICE MODE CANNOT BE SELECTED1752
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE1753
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK1756
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING1758
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE1761
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR1763
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED1766
E-41 ALARM DOES NOT SOUND DURING TRAVEL1767
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED1769
E-43 HORN DOES NOT SOUND1770
E-44 HORN DOES NOT STOP SOUNDING1773
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF1775
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE1776
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE1778
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1779
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1780
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1781
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1782
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1783
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1784
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1785
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1786
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION1787
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED1789
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY1790
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)1791
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)1791
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS1792
FAILURE MODE AND CAUSE TABLE1794
H-1 ANY OF WORK EQUIPMENT, SWING AND TRAVEL DOES NOT WORK1803
H-2 ALL OF WORK EQUIPMENTS, SWING AND TRAVEL OPERATION LACK SPEED OR POWER1804
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR1807
H-4 UNUSUAL SOUND IS HEARD FROM AROUND HYDRAULIC PUMP1808
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS1809
H-6 SPEED OR POWER OF BOOM IS LOW1811
H-7 SPEED OR POWER OF ARM IS LOW1815
H-8 SPEED OR POWER OF BUCKET IS LOW1820
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION1823
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE1824
H-11 HYDRAULIC DRIFT OF ARM IS LARGE1826
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE1828
H-13 OTHER WORK EQUIPMENT MOVES WHEN ONE OF WORK EQUIPMENT IS RELIEVED1829
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE1830
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT WORK1831
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED1832
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CONTROLLED1833
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT , EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER1834
H-19 TRAVEL SPEED DROPS LARGELY IN COMBINED OPERATION OF SWING AND TRAVE1835
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW1836
H-21 MACHINE DOES NOT TRAVEL STRAIGHT1837
H-22 MACHINE IS HARD TO STEER OR TRAVEL POWER IS LOW1839
H-23 TRAVEL SPEED IS LOW1842
H-24 ONE OF TRACKS DOES NOT RUN1844
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO LOW OR HIGH1845
H-26 UPPER STRUCTURE DOES NOT SWING IN BOTH RIGHT AND LEFT DIRECTIONS1846
H-27 UPPER STRUCTURE SWING IN ONLY ONE DIRECTION1847
H-28 SWING ACCELERATION OR SWING SPEED OF UPPER STRUCTURE IS LOW IN BOTH RIGHT AND LEFT DIRECTIONS1848
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION1849
H-30 OVERRUN OF UPPER STRUCTURE IS LARGE IN BOTH RIGHT AND LEFT DIRECTIONS1850
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING IN ONLY ONE DIRECTION1851
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING1852
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING1853
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)1854
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)1855
H-36 Quick coupler cylinder will not extend1856
H-37 Quick coupler cylinder will not retract (but buzzer does not sound)1858
H-38 Buzzer does not sound (but quick coupler cylinder does retract)1860
H-39 Quick coupler cylinder extends and retracts slowly1862
TROUBLESHOOTING OF ENGINE (S-MODE)1863
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)1863
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION1864
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT1865
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)1866
S-4 ENGINE STARTABILITY IS POOR1868
S-5 ENGINE DOES NOT PICK UP SMOOTHLY1870
S-6 ENGINE STOPS DURING OPERATION1872
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE1874
S-8 ENGINE LACKS POWER1875
S-9 KDPF GETS CLOGGED IN A SHORT TIME1877
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE1879
S-11 OIL BECOMES CONTAMINATED QUICKLY1880
S-12 FUEL CONSUMPTION IS EXCESSIVE1881
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)1882
S-14 OIL PRESSURE DROPS1883
S-15 FUEL MIXES INTO ENGINE OIL1885
S-16 WATER MIXES INTO ENGINE OIL (MILKY)1886
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)1887
S-18 UNUSUAL NOISE IS HEARD1888
S-19 VIBRATION IS EXCESSIVE1889
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT1890
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY1891
S-22 ACTIVE REGENERATION TAKES TIME1893
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION1894
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE1895
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)1897
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)1898
50 DISASSEMBLY AND ASSEMBLY1899
CONTENTS1900
ABBREVIATION LIST1905
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY1910
HOW TO READ THIS MANUAL1910
COATING MATERIALS LIST1912
SPECIAL TOOLS LIST1917
SKETCHES OF SPECIAL TOOLS1929
ENGINE AND COOLING SYSTEM1935
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY1935
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY1935
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY1938
REMOVE AND INSTALL INJECTOR ASSEMBLY1942
METHOD FOR REMOVING INJECTOR ASSEMBLY1942
METHOD FOR INSTALLING INJECTOR ASSEMBLY1947
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY1955
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY1956
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY1965
REMOVE AND INSTALL EGR VALVE ASSEMBLY1981
METHOD FOR REMOVING EGR VALVE ASSEMBLY1981
METHOD FOR INSTALLING EGR VALVE ASSEMBLY1982
REMOVE AND INSTALL EGR COOLER ASSEMBLY1985
METHOD FOR REMOVING EGR COOLER ASSEMBLY1985
METHOD FOR INSTALLING EGR COOLER ASSEMBLY1988
REMOVE AND INSTALL STARTER ASSEMBLY1993
METHOD FOR REMOVING STARTER ASSEMBLY1993
METHOD FOR INSTALLING STARTER ASSEMBLY1995
REMOVE AND INSTALL ALTERNATOR BELT1997
METHOD FOR REMOVING ALTERNATOR BELT1997
METHOD FOR INSTALLING ALTERNATOR BELT1999
REMOVE AND INSTALL RADIATOR ASSEMBLY2001
METHOD FOR REMOVING RADIATOR ASSEMBLY2001
METHOD FOR INSTALLING RADIATOR ASSEMBLY2003
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY2005
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY2005
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY2008
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY2011
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY2011
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY2012
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY2014
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY2015
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY2023
REMOVE AND INSTALL ENGINE FRONT OIL SEAL2034
METHOD FOR REMOVING ENGINE FRONT OIL SEAL2034
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL2037
REMOVE AND INSTALL ENGINE REAR OIL SEAL2041
METHOD FOR REMOVING ENGINE REAR OIL SEAL2041
METHOD FOR INSTALLING ENGINE REAR OIL SEAL2042
REMOVE AND INSTALL FUEL COOLER ASSEMBLY2045
METHOD FOR REMOVING FUEL COOLER ASSEMBLY2045
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY2046
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY2047
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY2047
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY2049
REMOVE AND INSTALL FUEL TANK ASSEMBLY2055
METHOD FOR REMOVING FUEL TANK ASSEMBLY2055
METHOD FOR INSTALLING FUEL TANK ASSEMBLY2059
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY2063
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY2063
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY2068
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2074
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2074
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY2079
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR2085
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR2085
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR2085
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER2087
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER2087
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER2087
REMOVE AND INSTALL KDPF ASSEMBLY2088
METHOD FOR REMOVING KDPF ASSEMBLY2088
METHOD FOR INSTALLING KDPF ASSEMBLY2090
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY2092
METHOD FOR DISASSEMBLING KDPF ASSEMBLY2093
METHOD FOR ASSEMBLING KDPF ASSEMBLY2096
REMOVE AND INSTALL SCR ASSEMBLY2101
METHOD FOR REMOVING SCR ASSEMBLY2101
METHOD FOR INSTALLING SCR ASSEMBLY2103
REMOVE AND INSTALL KDPF, SCR ASSEMBLY2105
METHOD FOR REMOVING KDPF, SCR ASSEMBLY2105
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY2111
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET2117
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET2117
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET2124
REMOVE AND INSTALL KCCV ASSEMBLY2132
METHOD FOR REMOVING KCCV ASSEMBLY2132
METHOD FOR INSTALLING KCCV ASSEMBLY2134
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE2139
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE2139
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE2144
REMOVE AND INSTALL AdBlue/DEF INJECTOR2149
METHOD FOR REMOVING AdBlue/DEF INJECTOR2149
METHOD FOR INSTALLING AdBlue/DEF INJECTOR2151
REMOVE AND INSTALL AdBlue/DEF PUMP2153
METHOD FOR REMOVING AdBlue/DEF PUMP2153
METHOD FOR INSTALLING AdBlue/DEF PUMP2155
REMOVE AND INSTALL AdBlue/DEF HOSE2158
METHOD FOR REMOVING AdBlue/DEF HOSE2158
METHOD FOR INSTALLING AdBlue/DEF HOSE2165
REMOVE AND INSTALL AIR CLEANER ASSEMBLY2171
METHOD FOR REMOVING AIR CLEANER ASSEMBLY2171
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY2172
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY2174
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY2174
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY2176
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY2179
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY2179
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY2180
POWER TRAIN2181
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2181
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2181
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY2182
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY2183
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY2183
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY2187
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY2196
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY2196
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY2198
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY2202
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY2202
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY2206
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY2213
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY2213
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY2213
UNDERCARRIAGE AND FRAME2215
SEPARATION AND CONNECTION OF TRACK ASSEMBLY2215
METHOD FOR SEPARATING TRACK ASSEMBLY2215
METHOD FOR INSTALLING TRACK ASSEMBLY2217
REMOVE AND INSTALL SPROCKET2220
METHOD FOR REMOVING SPROCKET2220
METHOD FOR INSTALLING SPROCKET2220
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY2222
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY2222
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY2223
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY2224
METHOD FOR DISASSEMBLING IDLER ASSEMBLY2224
METHOD FOR ASSEMBLING IDLER ASSEMBLY2225
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY2229
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY2230
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY2231
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY2232
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY2233
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY2234
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY2236
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY2236
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY2237
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY2240
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY2240
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY2242
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY2244
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY2244
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY2247
HYDRAULIC SYSTEM2251
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY2251
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY2251
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY2253
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY2256
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2257
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY2258
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY2259
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY2259
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY2261
REMOVE AND INSTALL MAIN PUMP ASSEMBLY2264
METHOD FOR REMOVING MAIN PUMP ASSEMBLY2264
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY2267
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY2270
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY2270
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY2277
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY2285
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING2285
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY2287
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY2291
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2291
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY2291
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY2293
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY2293
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY2294
REMOVE AND INSTALL QUICK COUPLER VALVE2296
WORK EQUIPMENT2298
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY2298
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY2298
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY2302
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY2308
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2308
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY2311
CAB AND ITS ATTACHMENTS2317
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY2317
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY2317
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY2322
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)2329
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY2331
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY2331
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY2341
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY2341
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY2344
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY2350
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY2350
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY2357
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY2364
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY2364
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY2369
REMOVE AND INSTALL OPERATOR’S SEAT2375
METHOD FOR REMOVING OPERATOR’S SEAT2375
METHOD FOR INSTALLING OPERATOR’S SEAT2377
REMOVE AND INSTALL SEAT BELT2380
METHOD FOR REMOVING SEAT BELT2380
METHOD FOR INSTALLING SEAT BELT2381
REMOVE AND INSTALL FRONT WIPER ASSEMBLY2382
METHOD FOR REMOVING FRONT WIPER ASSEMBLY2382
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY2387
ELECTRICAL SYSTEM2395
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY2395
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY2395
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY2396
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY2398
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY2398
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY2402
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY2407
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY2407
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY2410
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR2414
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR2414
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR2415
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR2416
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR2416
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR2416
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR2418
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR2418
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR2419
REMOVE AND INSTALL SCR TEMPERATURE SENSOR2420
METHOD FOR REMOVING SCR TEMPERATURE SENSOR2420
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR2422
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY2424
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY2424
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY2427
60 MAINTENANCE STANDARD2431
CONTENTS2432
ABBREVIATION LIST2433
ENGINE AND COOLING SYSTEM2438
MAINTENANCE STANDARD OF ENGINE MOUNT2438
MAINTENANCE STANDARD OF COOLING SYSTEM2439
POWER TRAIN2440
MAINTENANCE STANDARD OF SWING CIRCLE2440
MAINTENANCE STANDARD OF SWING MACHINERY2441
MAINTENANCE STANDARD OF FINAL DRIVE2443
MAINTENANCE STANDARD OF SPROCKET2445
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING2446
UNDERCARRIAGE AND FRAME2448
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION2448
MAINTENANCE STANDARD OF IDLER2450
MAINTENANCE STANDARD OF TRACK ROLLER2452
MAINTENANCE STANDARD OF CARRIER ROLLER2454
MAINTENANCE STANDARD OF TRACK SHOE2455
MAINTENANCE STANDARD OF TRIPLE SHOE2458
HYDRAULIC SYSTEM2459
MAINTENANCE STANDARD OF HYDRAULIC TANK2459
MAINTENANCE STANDARD OF MAIN PUMP2460
MAINTENANCE STANDARD OF LS-EPC VALVE2461
MAINTENANCE STANDARD OF PC-EPC VALVE2462
MAINTENANCE STANDARD OF SWING MOTOR2463
MAINTENANCE STANDARD OF TRAVEL MOTOR2466
MAINTENANCE STANDARD OF CONTROL VALVE2469
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE2479
MAINTENANCE STANDARD OF TRAVEL PPC VALVE2482
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)2485
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE2486
MAINTENANCE STANDARD OF SOLENOID VALVE2488
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)2489
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)2490
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT2491
WORK EQUIPMENT2492
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE2492
DIMENSION OF ARM2497
DIMENSIONS OF BUCKET2499
MAINTENANCE STANDARD OF BOOM CYLINDER2501
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON)2502
MAINTENANCE STANDARD OF ARM CYLINDER2503
MAINTENANCE STANDARD OF BUCKET CYLINDER2504
80 APPENDIX2505
CONTENTS2506
ABBREVIATION LIST2508
AIR CONDITIONER SYSTEM2513
PRECAUTIONS FOR REFRIGERANT2513
AIR CONDITIONER COMPONENT2514
SPECIFICATIONS OF AIR CONDITIONER2516
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE2517
OUTLINE OF REFRIGERATION CYCLE2518
COMPONENT PARTS OF AIR CONDITIONER SYSTEM2520
AIR CONDITIONER UNIT2520
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT2520
FUNCTION OF AIR CONDITIONER UNIT2522
COMPONENT PARTS OF AIR CONDITIONER UNIT2524
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT2525
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT2525
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT2525
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT2525
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2526
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2526
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT2526
FUNCTION OF DUAL PRESSURE SWITCH2527
AIR CONDITIONER CONTROLLER2528
STRUCTURE OF AIR CONDITIONER CONTROLLER2528
COMPRESSOR2529
STRUCTURE OF COMPRESSOR2529
SPECIFICATIONS OF COMPRESSOR2529
FUNCTION OF COMPRESSOR2529
CONDENSER2530
STRUCTURE OF CONDENSER2530
SPECIFICATIONS OF CONDENSER2530
FUNCTION OF CONDENSER2530
SENSORS FOR AIR CONDITIONER SYSTEM2532
STRUCTURE OF SUNLIGHT SENSOR2532
FUNCTION OF SUNLIGHT SENSOR2532
STRUCTURE OF AMBIENT TEMPERATURE SENSOR2532
FUNCTION OF AMBIENT TEMPERATURE SENSOR2532
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER2534
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER2536
AIR CONDITIONER SYSTEM DIAGRAM2538
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER2539
FUNCTION OF AIR CONDITIONER CONTROLLER2540
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS2541
TESTING AIR LEAKAGE (DUCT)2545
METHOD FOR TESTING AIR LEAKAGE (DUCT)2545
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION2547
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR2548
TEST VENT (MODE) CHANGEOVER2549
METHOD FOR TESTING VENT (MODE) CHANGEOVER2549
TESTING FRESH/RECIRC AIR CHANGEOVER2551
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER2551
TEST SUNLIGHT SENSOR2552
METHOD FOR TESTING SUNLIGHT SENSOR2552
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT2553
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT2553
TEST RELAYS2554
METHOD FOR TESTING RELAYS2554
AIR CONDITIONER TROUBLESHOOTING CHART 12555
AIR CONDITIONER TROUBLESHOOTING CHART 22556
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE2559
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit2561
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit2562
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit2563
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit2565
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit2567
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit2568
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit2569
FAILURE CODE [879EMC] Ventilation Damper Malfunction2571
FAILURE CODE [879FMC] Air Mix Damper Malfunction2572
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range2573
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)2575
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)2577
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)2580
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER2582
TROUBLESHOOTING USING GAUGE PRESSURE2584
CONNECTION OF SERVICE TOOL2587
METHOD FOR CONNECTING SERVICE TOOL2587
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS2589
HANDLE COMPRESSOR OIL2591
METHOD FOR REPLACING DESICCANT2593
90 CIRCUIT DIAGRAMS2595
CONTENTS2596
ABBREVIATION LIST2597
HYDRAULIC CIRCUIT DIAGRAM2602
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM2602
HYDRAULIC CIRCUIT DIAGRAM (1/2)2607
HYDRAULIC CIRCUIT DIAGRAM (2/2)2609
ELECTRICAL CIRCUIT DIAGRAM2611
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM2611
ELECTRICAL CIRCUIT DIAGRAM (1/8)2615
ELECTRICAL CIRCUIT DIAGRAM (2/8)2617
ELECTRICAL CIRCUIT DIAGRAM (3/8)2619
ELECTRICAL CIRCUIT DIAGRAM (4/8)2621
ELECTRICAL CIRCUIT DIAGRAM (5/8)2623
ELECTRICAL CIRCUIT DIAGRAM (6/8)2625
ELECTRICAL CIRCUIT DIAGRAM (7/8)2627
ELECTRICAL CIRCUIT DIAGRAM (8/8)2629
INDEX2631

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S.M 24/12/24