Komatsu PC240-11,PC240LC-11,PC240NLC-11 Excavator Shop Manual PDF

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Komatsu PC240-11,PC240LC-11,PC240NLC-11 Hydraulic Excavator Shop Manual UENBM00332 – PDF DOWNLOAD

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Komatsu PC240-11,PC240LC-11,PC240NLC-11 Hydraulic Excavator Shop Manual UENBM00332 – PDF DOWNLOAD

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

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TABLE OF CONTENTS:

Komatsu PC240-11,PC240LC-11,PC240NLC-11 Hydraulic Excavator Shop Manual UENBM00332 – PDF DOWNLOAD

• SERIAL NUMBERS K70001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 21
FOREWORD, SAFETY, BASIC INFORMATION . 27
HOW TO READ THE SHOP MANUAL . 27
SAFETY NOTICE FOR OPERATION . 29
PRECAUTIONS TO PREVENT FIRE . 37
ACTIONS IF FIRE OCCURS 39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 41
PRECAUTIONS FOR DEF . 42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 42
PRECAUTIONS FOR ADDING 42
PRECAUTIONS FOR STORING . 42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 42
THE OTHER PRECAUTIONS . 42
STORE AdBlue/DEF 43
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 44
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 47
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 54
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 56
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 57
PRACTICAL USE OF KOMTRAX 58
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 61
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 63
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 73
HOW TO READ ELECTRICAL WIRE CODE 74
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 78
STANDARD TIGHTENING TORQUE TABLE 81
CONVERSION TABLE 88
01 SPECIFICATIONS . 93
CONTENTS 94
ABBREVIATION LIST . 95
SPECIFICATIONS 101
SPECIFICATION DRAWING . 101
SPECIFICATION DRAWING: PC240LC-11, PC240NLC-11 101
WORKING RANGE DRAWINGS 102
WORKING RANGE: PC240LC-11, PC240NLC-11 102
SPECIFICATIONS 103
SPECIFICATIONS: PC240LC-11, PC240NLC-11 . 103
WEIGHT TABLE 106
WEIGHT TABLE: PC240LC-11, PC240NLC-11 . 106
TABLE OF FUEL, COOLANT, AND LUBRICANTS 108
10 STRUCTURE AND FUNCTION . 109
CONTENTS 110
ABBREVIATION LIST . 114
UREA SCR SYSTEM . 120
LAYOUT DRAWING OF UREA SCR SYSTEM . 121
UREA SCR SYSTEM DIAGRAM . 126
FUNCTION OF UREA SCR SYSTEM . 127
FUNCTION OF AdBlue/DEF SYSTEM . 127
INDUCEMENT STRATEGY . 129
COMPONENT PARTS OF UREA SCR SYSTEM 137
AdBlue/DEF MIXING TUBE 137
SCR ASSEMBLY 137
AdBlue/DEF TANK . 140
AdBlue/DEF PUMP . 142
AdBlue/DEF INJECTOR . 143
AdBlue/DEF HOSE . 144
AdBlue/DEF TANK HEATING VALVE . 145
BOOT-UP SYSTEM 146
LAYOUT DRAWING OF BOOT-UP SYSTEM 146
SYSTEM OPERATING LAMP SYSTEM 148
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 148
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 148
BATTERY DISCONNECT SWITCH . 150
FUNCTION OF BATTERY DISCONNECT SWITCH . 150
ENGINE SYSTEM . 151
LAYOUT DRAWING OF ENGINE SYSTEM . 151
SPECIFICATIONS OF ENGINE SYSTEM . 152
FUNCTION OF ENGINE SYSTEM . 152
ENGINE CONTROL SYSTEM . 153
ENGINE CONTROL SYSTEM DIAGRAM . 153
FUNCTION OF ENGINE CONTROL SYSTEM . 154
AUTO-DECELERATION SYSTEM 156
AUTO-DECELERATION SYSTEM DIAGRAM 156
FUNCTION OF AUTO-DECELERATION SYSTEM 156
OPERATION OF AUTO-DECELERATION SYSTEM . 157
ENGINE AUTOMATIC WARM-UP SYSTEM . 158
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 158
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 159
OVERHEAT PREVENTION SYSTEM 160
OVERHEAT PREVENTION SYSTEM DIAGRAM 160
FUNCTION OF OVERHEAT PREVENTION SYSTEM 161
TURBOCHARGER PROTECTION SYSTEM 163
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 163
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 164
AUTOMATIC IDLE STOP SYSTEM 165
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 165
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 165
COMPONENT PARTS OF ENGINE SYSTEM 168
VGT . 168
EGR SYSTEM 172
EGR VALVE . 174
EGR COOLER 176
KCCV SYSTEM . 177
KCCV VENTILATOR . 179
KDPF 181
COOLING SYSTEM 186
LAYOUT DRAWING OF COOLING SYSTEM 186
SPECIFICATIONS OF COOLING SYSTEM 187
CONTROL SYSTEM 188
LAYOUT DRAWING OF CONTROL SYSTEM 188
MACHINE MONITOR SYSTEM 191
MACHINE MONITOR SYSTEM DIAGRAM 191
KomVision SYSTEM 192
LAYOUT DRAWING OF KOMVISION SYSTEM 192
KomVision SYSTEM DIAGRAM 194
FUNCTION OF KomVision SYSTEM 194
KOMTRAX SYSTEM 196
KOMTRAX SYSTEM DIAGRAM 196
FUNCTION OF KOMTRAX SYSTEM 196
PPC LEVERS 197
LH PPC LEVER 197
RH PPC LEVER 198
AUTOMATIC GREASE SYSTEM . 199
OUTLINE OF AUTO GREASE SYSTEM . 199
COMPONENT PARTS OF CONTROL SYSTEM . 214
MACHINE MONITOR . 214
KomVision CONTROLLER 227
KomVision CAMERA 231
KOMTRAX TERMINAL 231
PUMP CONTROLLER . 234
RESISTOR FOR PC-EPC VALVE . 238
CAN TERMINATING RESISTOR 238
PPC OIL PRESSURE SWITCH . 239
ENGINE CONTROLLER . 240
FUEL CONTROL DIAL . 246
SENSOR 248
STRUCTURE OF AMBIENT PRESSURE SENSOR 248
FUNCTION OF AMBIENT PRESSURE SENSOR . 248
STRUCTURE OF ENGINE OIL PRESSURE SWITCH . 248
FUNCTION OF ENGINE OIL PRESSURE SWITCH 249
STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR . 249
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR 249
STRUCTURE OF COOLANT TEMPERATURE SENSOR . 250
FUNCTION OF COOLANT TEMPERATURE SENSOR 250
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR . 250
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR 251
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR . 251
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR 251
STRUCTURE OF COMMON RAIL PRESSURE SENSOR 252
FUNCTION OF COMMON RAIL PRESSURE SENSOR . 252
STRUCTURE OF EGR VALVE LIFT SENSOR 252
FUNCTION OF EGR VALVE LIFT SENSOR . 252
STRUCTURE OF VGT SPEED SENSOR . 253
FUNCTION OF KVGT SPEED SENSOR . 253
STRUCTURE OF KVGT POSITION SENSOR . 253
FUNCTION OF KVGT POSITION SENSOR 254
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR . 254
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR 255
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR . 255
STRUCTURE OF CRANKCASE PRESSURE SENSOR 255
FUNCTION OF CRANKCASE PRESSURE SENSOR . 256
STRUCTURE OF ENGINE OIL LEVEL SENSOR 256
STRUCTURE OF AIR CLEANER CLOGGING SENSOR 256
FUNCTION OF AIR CLEANER CLOGGING SENSOR . 257
STRUCTURE OF WATER-IN-FUEL SENSOR . 257
FUNCTION OF WATER-IN-FUEL SENSOR 257
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 257
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 258
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH . 258
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 258
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 259
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 259
STRUCTURE OF OVERLOAD CAUTION SENSOR 259
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 259
FUNCTION OF OVERLOAD CAUTION SENSOR . 259
HYDRAULIC SYSTEM 260
LAYOUT DRAWING OF HYDRAULIC SYSTEM 260
CLSS 266
STRUCTURE OF CLSS . 266
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 268
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 269
PRESSURE COMPENSATION CONTROL . 282
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 285
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 285
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 286
PUMP AND VALVE CONTROL SYSTEM . 291
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 291
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 292
COMPONENT PARTS OF HYDRAULIC SYSTEM . 294
HYDRAULIC TANK 294
MAIN PUMP . 296
PC-EPC VALVE 320
PILOT OIL FILTER 322
CONTROL VALVE . 322
WORK EQUIPMENT SYSTEM . 379
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 379
STRUCTURE OF VALVE CONTROL 384
ONE-TOUCH POWER MAXIMIZING SYSTEM . 386
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 386
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 387
PPC LOCK SYSTEM . 388
PPC LOCK SYSTEM DIAGRAM . 388
FUNCTION OF PPC LOCK SYSTEM . 388
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 389
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 389
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 389
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 390
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 391
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 391
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 393
TOOL CONTROL SYSTEM . 394
TOOL CONTROL SYSTEM DIAGRAM . 394
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 396
WORK EQUIPMENT AND SWING PPC VALVE 396
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 401
SOLENOID VALVE 407
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 410
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 412
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE . 415
2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE . 417
ATTACHMENT BYPASS SOLENOID VALVE 420
ATT EPC VALVE ASSEMBLY 422
PILOT CIRCUIT ACCUMULATOR . 423
ATTACHMENT CIRCUIT ACCUMULATOR 424
SWING SYSTEM 425
LAYOUT DRAWING OF SWING SYSTEM 425
SWING CONTROL SYSTEM DIAGRAM 429
FUNCTION OF SWING CONTROL SYSTEM 429
COMPONENT PARTS OF SWING SYSTEM . 433
SWING MOTOR . 433
SWING MACHINERY . 444
SWING CIRCLE 445
TRAVEL SYSTEM . 447
LAYOUT DRAWING OF TRAVEL SYSTEM . 447
TRAVEL CONTROL SYSTEM DIAGRAM . 451
FUNCTION OF TRAVEL CONTROL SYSTEM . 451
COMPONENT PARTS OF TRAVEL SYSTEM 453
TRAVEL MOTOR 453
FINAL DRIVE . 466
TRAVEL PPC VALVE 467
CENTER SWIVEL JOINT . 472
UNDERCARRIAGE AND FRAME . 474
LAYOUT DRAWING OF UNDERCARRIAGE . 474
SPECIFICATIONS OF UNDERCARRIAGE . 475
WORK EQUIPMENT 476
STRUCTURE OF WORK EQUIPMENT . 476
FUNCTION OF WORK EQUIPMENT 477
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 478
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 478
BUCKET CLEARANCE ADJUSTMENT SHIM 479
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 479
CAB AND ITS ATTACHMENTS . 480
ROPS CAB 480
STRUCTURE OF ROPS CAB . 480
FUNCTION OF ROPS CAB 480
CAB MOUNT . 481
STRUCTURE OF CAB MOUNT 481
FUNCTION OF CAB MOUNT . 481
CAB TIPPING STOPPER . 482
STRUCTURE OF CAB TIPPING STOPPER 482
FUNCTION OF CAB TIPPING STOPPER . 482
20 STANDARD VALUE TABLE . 483
CONTENTS 484
ABBREVIATION LIST . 485
STANDARD VALUE TABLE FOR ENGINE . 491
STANDARD VALUE TABLE FOR ENGINE: PC240LC-11, PC240NLC-11 491
STANDARD VALUE TABLE FOR MACHINE 495
STANDARD VALUE TABLE FOR MACHINE: PC240LC-11, PC240NLC-11 . 495
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 508
STANDARD VALUE TABLE FOR ELECTRICAL . 512
STANDARD VALUE TABLE FOR ELECTRICAL . 512
30 TESTING AND ADJUSTING 523
CONTENTS 524
ABBREVIATION LIST . 527
RELATED INFORMATION ON TESTING AND ADJUSTING 533
TOOLS FOR TESTING AND ADJUSTING . 533
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 540
ENGINE AND COOLING SYSTEM . 542
TEST ENGINE SPEED . 542
METHOD FOR TESTING ENGINE SPEED . 542
TEST BOOST PRESSURE . 545
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 545
METHOD FOR TESTING BOOST PRESSURE . 546
TEST EXHAUST GAS COLOR 547
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 547
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 548
TEST AND ADJUST VALVE CLEARANCE . 550
METHOD FOR TESTING VALVE CLEARANCE 550
METHOD FOR ADJUSTING VALVE CLEARANCE 551
TEST COMPRESSION PRESSURE . 553
METHOD FOR TESTING COMPRESSION PRESSURE . 553
TEST BLOWBY PRESSURE 558
METHOD FOR TESTING BLOWBY PRESSURE 558
TEST ENGINE OIL PRESSURE 560
METHOD FOR TESTING ENGINE OIL PRESSURE 560
TEST EGR VALVE AND VGT OIL PRESSURE . 561
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 561
TEST FUEL PRESSURE 563
METHOD FOR TESTING FUEL PRESSURE 564
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 569
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 570
BLEEDING AIR FROM FUEL SYSTEM . 576
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 576
TEST FUEL CIRCUIT FOR LEAKAGE . 577
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 577
HANDLE CYLINDER CUT-OUT MODE OPERATION 579
HANDLE NO-INJECTION CRANKING OPERATION 580
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 581
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 581
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 581
REPLACING FAN BELT 583
METHOD FOR REPLACING FAN BELT . 583
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 584
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 584
TEST SCR RELATED FUNCTIONS 585
TEST AdBlue/DEF PUMP RAISED PRESSURE 588
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 591
TEST AdBlue/DEF LINE HEATER RELAY 1 . 595
TEST AdBlue/DEF LINE HEATER RELAY 2 . 598
TEST AdBlue/DEF PUMP HEATER RELAY . 600
TEST AdBlue/DEF TANK HEATER VALVE . 603
TEST DENITRATION EFFICIENCY OF SCR 606
CLEAN AdBlue/DEF TANK . 610
METHOD FOR CLEANING AdBlue/DEF TANK . 610
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 614
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 614
POWER TRAIN . 616
TEST SWING CIRCLE BEARING CLEARANCE . 616
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 616
UNDERCARRIAGE AND FRAME . 617
TEST AND ADJUST TRACK TENSION . 617
METHOD FOR TESTING TRACK TENSION 617
METHOD FOR ADJUSTING TRACK TENSION 617
HYDRAULIC SYSTEM 619
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 619
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 619
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 625
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 626
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 632
TEST OIL PRESSURE OF CONTROL CIRCUIT 635
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 635
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 637
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 637
TEST PC-EPC VALVE OUTLET PRESSURE . 638
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 639
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 641
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 641
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 642
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 645
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 646
METHOD FOR ADJUSTING LS VALVE . 647
TEST OUTLET PRESSURE OF SOLENOID VALVE 648
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 648
OPERATING CONDITION OF SOLENOID VALVE . 649
TEST PPC VALVE OUTLET PRESSURE 652
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 652
TEST ATTACHMENT CIRCUIT OIL PRESSURE 654
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 654
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 656
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 656
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 657
TEST PUMP SWASH PLATE SENSOR 659
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 659
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 660
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 660
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 660
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 661
TEST OIL LEAKAGE 662
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 662
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 662
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 663
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 664
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 664
BLEED AIR FROM HYDRAULIC CIRCUIT 665
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 667
CAB AND ITS ATTACHMENTS . 669
TEST CAB TIPPING STOPPER 669
METHOD FOR TESTING CAB TIPPING STOPPER 669
METHOD FOR ADJUSTING MIRRORS 670
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 670
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 671
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 672
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 673
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 674
ELECTRICAL SYSTEM . 676
ELECTRICAL SYSTEM . 677
SET AND OPERATE MACHINE MONITOR . 677
OPERATOR MODE . 680
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 681
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 681
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 682
CHECKING FUNCTION OF SERVICE METER 682
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 682
SERVICE MODE 685
SERVICE MODE 685
METHOD FOR OPERATING SERVICE MODE . 687
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 689
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 695
ABNORMALITY RECORD MENU . 706
METHOD FOR CONFIRMING MAINTENANCE RECORD 711
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 712
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 716
DEFAULT MENU 717
DIAGNOSTIC TESTS MENU . 728
ADJUSTMENT MENU . 738
METHOD FOR PERFORMING NO-INJECTION CRANKING . 772
KOMTRAX SETTINGS MENU . 773
METHOD FOR DISPLAYING SERVICE MESSAGE . 775
METHOD FOR STARTING UP KOMTRAX TERMINAL . 777
ADJUST REARVIEW CAMERA ANGLE 782
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 782
ADJUST KomVision CAMERA ANGLE . 785
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 786
ADJUST KomVision RELATED ITEMS 790
SETTING OF KomVision (MAIN SETTING) . 790
SETTING OF KomVision (CAMERA SETTING) . 792
SETTING OF KomVision (CAMERA CALIBRATION) . 792
KomVision screen – Check 12 m visibility 806
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 809
HANDLE BATTERY DISCONNECT SWITCH 810
TEST DIODES . 811
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 811
METHOD FOR TESTING DIODE USING ANALOG TESTER 811
Pm CLINIC . 812
Pm CLINIC SERVICE . 812
Pm CLINIC SERVICE . 814
Pm CLINIC CHECK SHEET . 818
40 TROUBLESHOOTING 829
CONTENTS 830
ABBREVIATION LIST . 841
RELATED INFORMATION ON TROUBLESHOOTING 847
GENERAL TROUBLESHOOTING POINTS 847
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 848
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 860
CHECKS BEFORE TROUBLESHOOTING . 862
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 864
WALK-AROUND CHECK . 864
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 866
CHECK FUEL LEVEL AND TYPE . 866
CHECK IMPURE INGREDIENT IN FUEL . 866
CHECK FUEL PREFILTER 867
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 867
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 868
CHECK MAIN FILTER . 869
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 871
CHECK COOLANT LEVEL (RESERVOIR TANK) 872
CHECK CLOGGING OF AIR CLEANER . 872
OUTER ELEMENT – CLEAN . 873
ELEMENTS – REPLACE 875
CHECK HYDRAULIC OIL LEVEL . 876
CHECK HYDRAULIC OIL STRAINER 877
CHECK HYDRAULIC FILTER 878
CHECK OIL LEVEL IN SWING MACHINERY CASE . 879
CHECK OIL LEVEL IN DAMPER CASE 880
CHECK OIL LEVEL IN FINAL DRIVE CASE . 880
BLEED AIR FROM FUEL SYSTEM 881
BLEED AIR FROM HYDRAULIC SYSTEM . 881
ELECTRICAL EQUIPMENT – CHECK METHOD . 881
AUTOMATIC GREASE SYSTEM . 889
FINDING MALFUNCTIONS 889
MALFUNCTION FINDING PROCEDURES 891
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM . 893
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 903
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 906
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 910
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 912
CONNECTOR LIST AND LAYOUT . 915
CONNECTOR CONTACT IDENTIFICATION 928
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 968
FUSE LOCATION TABLE . 974
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 976
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 980
FAILURE CODE TABLE 982
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .1000
FAILURE CODE [879AKA] .1000
FAILURE CODE [879AKB] .1001
FAILURE CODE [879BKA] .1002
FAILURE CODE [879BKB] .1004
FAILURE CODE [879CKA] .1006
FAILURE CODE [879CKB] .1007
FAILURE CODE [879DKZ] .1008
FAILURE CODE [879EMC] .1010
FAILURE CODE [879FMC] .1011
FAILURE CODE [879GKX] .1012
FAILURE CODE [989L00] .1014
FAILURE CODE [989M00] .1015
FAILURE CODE [989N00] .1016
FAILURE CODE [A1U0N3] .1017
FAILURE CODE [A1U0N4] .1019
FAILURE CODE [A900FR] .1021
FAILURE CODE [A900N6] .1022
FAILURE CODE [A900NY] .1023
FAILURE CODE [AA10NX] .1024
FAILURE CODE [AB00KE] .1026
FAILURE CODE [AQ10N3] .1029
FAILURE CODE [AS00N3] .1031
FAILURE CODE [AS00R2] .1033
FAILURE CODE [AS00R3] .1034
FAILURE CODE [AS00R4] .1035
FAILURE CODE [AS00R5] .1036
FAILURE CODE [AS00R6] .1037
FAILURE CODE [AS00ZK] .1038
FAILURE CODE [AS10KM] .1039
FAILURE CODE [AS10NR] .1040
FAILURE CODE [AS10NT] .1041
FAILURE CODE [B@BAZG] .1042
FAILURE CODE [B@BAZK] .1043
FAILURE CODE [B@BCNS] .1045
FAILURE CODE [B@BCQA] .1046
FAILURE CODE [B@BCZK] .1048
FAILURE CODE [B@HANS] .1050
FAILURE CODE [CA115] 1051
FAILURE CODE [CA122] 1052
FAILURE CODE [CA123] 1054
FAILURE CODE [CA131] 1056
FAILURE CODE [CA132] 1058
FAILURE CODE [CA144] 1060
FAILURE CODE [CA145] 1062
FAILURE CODE [CA153] 1064
FAILURE CODE [CA154] 1067
FAILURE CODE [CA187] 1069
FAILURE CODE [CA221] 1071
FAILURE CODE [CA222] 1073
FAILURE CODE [CA227] 1075
FAILURE CODE [CA234] 1076
FAILURE CODE [CA238] 1077
FAILURE CODE [CA239] 1079
FAILURE CODE [CA249] 1081
FAILURE CODE [CA256] 1083
FAILURE CODE [CA271] 1085
FAILURE CODE [CA272] 1087
FAILURE CODE [CA322] 1089
FAILURE CODE [CA323] 1091
FAILURE CODE [CA324] 1093
FAILURE CODE [CA325] 1095
FAILURE CODE [CA331] 1097
FAILURE CODE [CA332] 1099
FAILURE CODE [CA343] 1101
FAILURE CODE [CA351] 1102
FAILURE CODE [CA352] 1103
FAILURE CODE [CA356] 1106
FAILURE CODE [CA357] 1108
FAILURE CODE [CA386] 1110
FAILURE CODE [CA428] 1111
FAILURE CODE [CA429] 1113
FAILURE CODE [CA435] 1115
FAILURE CODE [CA441] 1117
FAILURE CODE [CA442] 1119
FAILURE CODE [CA449] 1120
FAILURE CODE [CA451] 1121
FAILURE CODE [CA452] 1123
FAILURE CODE [CA488] 1125
FAILURE CODE [CA515] 1126
FAILURE CODE [CA516] 1128
FAILURE CODE [CA553] 1130
FAILURE CODE [CA555] 1131
FAILURE CODE [CA556] 1132
FAILURE CODE [CA559] 1133
FAILURE CODE [CA595] 1136
FAILURE CODE [CA687] 1137
FAILURE CODE [CA689] 1139
FAILURE CODE [CA691] 1142
FAILURE CODE [CA692] 1144
FAILURE CODE [CA697] 1146
FAILURE CODE [CA698] 1147
FAILURE CODE [CA731] 1148
FAILURE CODE [CA778] 1150
FAILURE CODE [CA1117] .1155
FAILURE CODE [CA1664] .1156
FAILURE CODE [CA1669] .1158
FAILURE CODE [CA1673] .1159
FAILURE CODE [CA1677] .1160
FAILURE CODE [CA1678] .1161
FAILURE CODE [CA1682] .1162
FAILURE CODE [CA1683] .1164
FAILURE CODE [CA1684] .1166
FAILURE CODE [CA1686] .1168
FAILURE CODE [CA1691] .1169
FAILURE CODE [CA1694] .1172
FAILURE CODE [CA1695] .1175
FAILURE CODE [CA1696] .1176
FAILURE CODE [CA1712] .1178
FAILURE CODE [CA1713] .1181
FAILURE CODE [CA1714] .1183
FAILURE CODE [CA1715] .1184
FAILURE CODE [CA1776] .1185
FAILURE CODE [CA1777] .1188
FAILURE CODE [CA1843] .1191
FAILURE CODE [CA1844] .1193
FAILURE CODE [CA1879] .1196
FAILURE CODE [CA1881] .1198
FAILURE CODE [CA1883] .1200
FAILURE CODE [CA1885] .1203
FAILURE CODE [CA1887] .1205
FAILURE CODE [CA1921] .1207
FAILURE CODE [CA1922] .1210
FAILURE CODE [CA1942] .1215
FAILURE CODE [CA1993] .1216
FAILURE CODE [CA2185] .1219
FAILURE CODE [CA2186] .1220
FAILURE CODE [CA2249] .1222
FAILURE CODE [CA2271] .1223
FAILURE CODE [CA2272] .1226
FAILURE CODE [CA2288] .1229
FAILURE CODE [CA2311] .1230
FAILURE CODE [CA2349] .1231
FAILURE CODE [CA2353] .1234
FAILURE CODE [CA2357] .1236
FAILURE CODE [CA2381] .1237
FAILURE CODE [CA2382] .1240
FAILURE CODE [CA2383] .1243
FAILURE CODE [CA2386] .1246
FAILURE CODE [CA2387] .1248
FAILURE CODE [CA2555] .1249
FAILURE CODE [CA2556] .1252
FAILURE CODE [CA2637] .1255
FAILURE CODE [CA2639] .1257
FAILURE CODE [CA2771] .1260
FAILURE CODE [CA2777] .1266
FAILURE CODE [CA2976] .1269
FAILURE CODE [CA3133] .1271
FAILURE CODE [CA3134] .1274
FAILURE CODE [CA3135] .1276
FAILURE CODE [CA3142] .1279
FAILURE CODE [CA3143] .1280
FAILURE CODE [CA3144] .1281
FAILURE CODE [CA3146] .1283
FAILURE CODE [CA3147] .1284
FAILURE CODE [CA3148] .1285
FAILURE CODE [CA3151] .1287
FAILURE CODE [CA3165] .1293
FAILURE CODE [CA3229] .1295
FAILURE CODE [CA3231] .1297
FAILURE CODE [CA3232] .1299
FAILURE CODE [CA3235] .1303
FAILURE CODE [CA3239] .1305
FAILURE CODE [CA3241] .1308
FAILURE CODE [CA3242] .1311
FAILURE CODE [CA3251] .1314
FAILURE CODE [CA3253] .1316
FAILURE CODE [CA3254] .1319
FAILURE CODE [CA3255] .1322
FAILURE CODE [CA3256] .1326
FAILURE CODE [CA3311] .1328
FAILURE CODE [CA3312] .1330
FAILURE CODE [CA3313] .1333
FAILURE CODE [CA3314] .1334
FAILURE CODE [CA3315] .1335
FAILURE CODE [CA3316] .1337
FAILURE CODE [CA3317] .1338
FAILURE CODE [CA3318] .1339
FAILURE CODE [CA3319] .1341
FAILURE CODE [CA3321] .1342
FAILURE CODE [CA3322] .1344
FAILURE CODE [CA3419] .1346
FAILURE CODE [CA3421] .1348
FAILURE CODE [CA3497] .1350
FAILURE CODE [CA3498] .1351
FAILURE CODE [CA3543] .1352
FAILURE CODE [CA3545] .1359
FAILURE CODE [CA3547] .1361
FAILURE CODE [CA3558] .1362
FAILURE CODE [CA3559] .1364
FAILURE CODE [CA3562] .1366
FAILURE CODE [CA3563] .1368
FAILURE CODE [CA3567] .1371
FAILURE CODE [CA3568] .1374
FAILURE CODE [CA3571] .1378
FAILURE CODE [CA3572] .1380
FAILURE CODE [CA3574] .1382
FAILURE CODE [CA3575] .1384
FAILURE CODE [CA3577] .1386
FAILURE CODE [CA3578] .1388
FAILURE CODE [CA3582] .1390
FAILURE CODE [CA3583] .1396
FAILURE CODE [CA3596] .1398
FAILURE CODE [CA3649] .1400
FAILURE CODE [CA3681] .1402
FAILURE CODE [CA3682] .1407
FAILURE CODE [CA3713] .1413
FAILURE CODE [CA3717] .1416
FAILURE CODE [CA3718] .1417
FAILURE CODE [CA3725] .1418
FAILURE CODE [CA3741] .1421
FAILURE CODE [CA3748] .1422
FAILURE CODE [CA3751] .1424
FAILURE CODE [CA3755] .1426
FAILURE CODE [CA3866] .1428
FAILURE CODE [CA3867] .1432
FAILURE CODE [CA3868] .1435
FAILURE CODE [CA3899] .1439
FAILURE CODE [CA3911] .1441
FAILURE CODE [CA3912] .1445
FAILURE CODE [CA3932] .1447
FAILURE CODE [CA3933] .1449
FAILURE CODE [CA3934] .1451
FAILURE CODE [CA3935] .1454
FAILURE CODE [CA3936] .1456
FAILURE CODE [CA4151] .1458
FAILURE CODE [CA4152] .1462
FAILURE CODE [CA4155] .1466
FAILURE CODE [CA4156] .1468
FAILURE CODE [CA4157] .1471
FAILURE CODE [CA4158] .1473
FAILURE CODE [CA4159] .1474
FAILURE CODE [CA4161] .1475
FAILURE CODE [CA4162] .1478
FAILURE CODE [CA4163] .1481
FAILURE CODE [CA4164] .1482
FAILURE CODE [CA4165] .1484
FAILURE CODE [CA4166] .1486
FAILURE CODE [CA4168] .1487
FAILURE CODE [CA4169] .1490
FAILURE CODE [CA4171] .1492
FAILURE CODE [CA4249] .1495
FAILURE CODE [CA4251] .1497
FAILURE CODE [CA4259] .1499
FAILURE CODE [CA4261] .1502
FAILURE CODE [CA4277] .1505
FAILURE CODE [CA4281] .1509
FAILURE CODE [CA4459] .1512
FAILURE CODE [CA4461] .1515
FAILURE CODE [CA4658] .1518
FAILURE CODE [CA4731] .1522
FAILURE CODE [CA4732] .1523
FAILURE CODE [CA4739] .1524
FAILURE CODE [CA4768] .1525
FAILURE CODE [CA4769] .1527
FAILURE CODE [CA4842] .1530
FAILURE CODE [CA4952] .1534
FAILURE CODE [CA5115] .1536
FAILURE CODE [CA5179] .1539
FAILURE CODE [CA5181] .1541
FAILURE CODE [CA5383] .1543
FAILURE CODE [D110KB] .1545
FAILURE CODE [D19JKZ] .1547
FAILURE CODE [D811MC] .1550
FAILURE CODE [D862KA] .1551
FAILURE CODE [D8ALKA] .1552
FAILURE CODE [D8ALKB] .1554
FAILURE CODE [D8AQKR] .1556
FAILURE CODE [DA20MC] .1558
FAILURE CODE [DA22KK] .1559
FAILURE CODE [DA25KP] .1562
FAILURE CODE [DA26KP] .1565
FAILURE CODE [DA29KQ] .1568
FAILURE CODE [DA2LKA] .1570
FAILURE CODE [DA2LKB] .1572
FAILURE CODE [DA2QKR] .1574
FAILURE CODE [DA2RKR] .1577
FAILURE CODE [DAF0KM] .1578
FAILURE CODE [DAF0MB] .1579
FAILURE CODE [DAF0MC] .1580
FAILURE CODE [DAF8KB] .1581
FAILURE CODE [DAF9KQ] .1583
FAILURE CODE [DAFGMC] .1584
FAILURE CODE [DAFLKA] .1585
FAILURE CODE [DAFLKB] .1587
FAILURE CODE [DAFQKR] .1589
FAILURE CODE [DAZ9KQ] .1590
FAILURE CODE [DAZQKR] .1591
FAILURE CODE [DB2QKR] .1596
FAILURE CODE [DBP0KM] .1601
FAILURE CODE [DBP0KT] .1602
FAILURE CODE [DB2RKR] .1603
FAILURE CODE [DBP5KB] .1608
FAILURE CODE [DBP5KY] .1611
FAILURE CODE [DBPQKR] .1614
FAILURE CODE [DDNRKA] .1619
FAILURE CODE [DDNRKY] .1621
FAILURE CODE [DDNS00] .1623
FAILURE CODE [DFB1KZ] .1625
FAILURE CODE [DFB2KZ] .1628
FAILURE CODE [DFB3L8] .1631
FAILURE CODE [DFB4L8] .1633
FAILURE CODE [DFB5KZ] .1635
FAILURE CODE [DFB6KZ] .1638
FAILURE CODE [DGH2KA] .1641
FAILURE CODE [DGH2KB] .1643
FAILURE CODE [DHA4KA] .1645
FAILURE CODE [DHAAMA] .1647
FAILURE CODE [DHACMA] .1649
FAILURE CODE [DHPAMA] .1651
FAILURE CODE [DHPBMA] .1654
FAILURE CODE [DHS3MA] .1657
FAILURE CODE [DHS4MA] .1660
FAILURE CODE [DHS8MA] .1663
FAILURE CODE [DHS9MA] .1666
FAILURE CODE [DHSAMA] .1669
FAILURE CODE [DHSBMA] .1672
FAILURE CODE [DHSCMA] .1675
FAILURE CODE [DHSDMA] .1678
FAILURE CODE [DHSFMA] .1681
FAILURE CODE [DHSGMA] .1684
FAILURE CODE [DHSHMA] .1687
FAILURE CODE [DHSJMA] .1690
FAILURE CODE [DHX1MA] .1693
FAILURE CODE [DKR0MA] .1696
FAILURE CODE [DKR1MA] .1699
FAILURE CODE [DKULKA] .1702
FAILURE CODE [DKULKB] .1704
FAILURE CODE [DKULKY] .1706
FAILURE CODE [DR10KA] .1708
FAILURE CODE [DR12KA] .1711
FAILURE CODE [DR20KA] .1713
FAILURE CODE [DR21KX] .1715
FAILURE CODE [DR30KA] .1717
FAILURE CODE [DR31KX] .1719
FAILURE CODE [DR40KA] .1721
FAILURE CODE [DUMBKA] .1723
FAILURE CODE [DUMBKB] .1725
FAILURE CODE [DV20KB] .1727
FAILURE CODE [DW43KA] .1729
FAILURE CODE [DW43KB] .1731
FAILURE CODE [DW43KY] .1733
FAILURE CODE [DW45KA] .1735
FAILURE CODE [DW45KB] .1738
FAILURE CODE [DW45KY] .1741
FAILURE CODE [DW4CKY] .1743
FAILURE CODE [DW91KA] .1745
FAILURE CODE [DW91KB] .1747
FAILURE CODE [DW91KY] .1749
FAILURE CODE [DWA2KA] .1751
FAILURE CODE [DWA2KB] .1753
FAILURE CODE [DWA2KY] .1755
FAILURE CODE [DWK0KA] .1757
FAILURE CODE [DWK0KB] .1759
FAILURE CODE [DWK0KY] .1761
FAILURE CODE [DWK2KA] .1763
FAILURE CODE [DWK2KB] .1765
FAILURE CODE [DWK2KY] .1767
FAILURE CODE [DWK8KA] .1769
FAILURE CODE [DWK8KB] .1771
FAILURE CODE [DWK8KY] .1773
FAILURE CODE [DXA8KA] .1775
FAILURE CODE [DXA8KB] .1777
FAILURE CODE [DXA9KA] .1779
FAILURE CODE [DXA9KB] .1781
FAILURE CODE [DXE0KA] .1783
FAILURE CODE [DXE0KB] .1784
FAILURE CODE [DXE4KA] .1786
FAILURE CODE [DXE4KB] .1788
FAILURE CODE [DXE4KY] .1790
FAILURE CODE [DXE5KA] .1792
FAILURE CODE [DXE5KB] .1794
FAILURE CODE [DXE6KA] .1796
FAILURE CODE [DXE6KB] .1798
FAILURE CODE [DXE7KA] .1800
FAILURE CODE [DXE7KB] .1802
FAILURE CODE [DXE7KY] .1804
FAILURE CODE [DXE8KA] .1806
FAILURE CODE [DXE8KB] .1808
FAILURE CODE [DXE8KY] .1810
FAILURE CODE [DXE9KA] .1812
FAILURE CODE [DXE9KB] .1814
FAILURE CODE [DXE9KY] .1816
FAILURE CODE [DXEAKA] .1818
FAILURE CODE [DXEAKB] .1820
FAILURE CODE [DXEAKY] .1822
FAILURE CODE [DY20KA] .1824
FAILURE CODE [DY20MA] .1826
FAILURE CODE [DY2CKB] .1828
FAILURE CODE [DY2DKB] .1831
FAILURE CODE [DY2EKB] .1833
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1835
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1835
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1841
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1844
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1846
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1848
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1851
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1852
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1853
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1854
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1855
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1856
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1857
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1858
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1859
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1860
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1861
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1862
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1864
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1865
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1866
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1867
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1869
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1870
E-24 FUNCTION SWITCH DOES NOT OPERATE .1871
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1872
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1873
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1874
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1875
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1876
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1877
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1878
E-32 ALARM BUZZER CANNOT BE CANCELED 1880
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1881
E-34 SERVICE MODE CANNOT BE SELECTED 1882
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1883
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1886
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1888
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1891
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1893
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1896
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1897
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1899
E-43 HORN DOES NOT SOUND 1900
E-44 HORN DOES NOT STOP SOUNDING 1903
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1905
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1906
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1908
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1909
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1910
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1911
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1912
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1913
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1914
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1915
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1916
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1917
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1919
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1920
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1921
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1921
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1922
FAILURE MODE AND CAUSE TABLE 1924
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1933
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1934
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1937
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1938
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1939
H-6 SPEED OR POWER OF BOOM IS LOW .1941
H-7 ARM SPEED OR POWER IS LOW .1945
H-8 BUCKET SPEED OR POWER IS LOW 1950
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1953
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1954
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1956
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .1958
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .1959
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1960
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1961
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1962
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .1963
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1964
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1965
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1966
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .1967
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .1969
H-23 TRAVEL SPEED IS LOW 1972
H-24 ONE OF TRACKS DOES NOT RUN .1974
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1975
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1976
H-27 SWINGS ONLY IN ONE DIRECTION .1977
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .1978
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1979
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1980
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1981
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .1982
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .1983
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .1984
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1985
H-36 Quick coupler cylinder will not extend .1986
H-37 Quick coupler cylinder will not retract (but buzzer doesnot sound) .1988
H-38 Buzzer does not sound (but quick coupler cylinder doesretract) .1990
H-39 Quick coupler cylinder extends and retracts slowly .1992
TROUBLESHOOTING OF ENGINE (S-MODE) 1993
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1993
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1994
S-1 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1995
S-2 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1996
S-3 ENGINE STARTABILITY IS POOR .1998
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2000
S-6 ENGINE STOPS DURING OPERATION .2002
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2004
S-8 ENGINE LACKS POWER 2005
S-9 KDPF GETS CLOGGED IN A SHORT TIME .2007
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2009
S-11 OIL BECOMES CONTAMINATED QUICKLY .2010
S-4 FUEL CONSUMPTION IS EXCESSIVE .2011
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2012
S-14 OIL PRESSURE DROPS .2013
S-15 FUEL MIXES INTO ENGINE OIL .2015
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2016
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2017
S-18 UNUSUAL NOISE IS HEARD .2018
S-19 VIBRATION IS EXCESSIVE .2019
S-5 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2020
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2021
S-22 ACTIVE REGENERATION TAKES TIME .2023
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2024
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2025
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2027
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2028
50 DISASSEMBLY AND ASSEMBLY .2029
CONTENTS 2030
ABBREVIATION LIST .2035
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2041
HOW TO READ THIS MANUAL .2041
COATING MATERIALS LIST 2043
SPECIAL TOOLS LIST 2047
SKETCHES OF SPECIAL TOOLS .2059
ENGINE AND COOLING SYSTEM .2065
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2065
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2065
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2068
REMOVE AND INSTALL INJECTOR ASSEMBLY 2072
METHOD FOR REMOVING INJECTOR ASSEMBLY .2072
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2077
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2085
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2086
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2095
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2111
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2111
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2112
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2115
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2115
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2118
REMOVE AND INSTALL STARTER ASSEMBLY .2123
METHOD FOR REMOVING STARTER ASSEMBLY 2123
METHOD FOR INSTALLING STARTER ASSEMBLY 2125
REMOVE AND INSTALL ALTERNATOR BELT 2127
METHOD FOR REMOVING ALTERNATOR BELT .2127
METHOD FOR INSTALLING ALTERNATOR BELT .2129
REMOVE AND INSTALL RADIATOR ASSEMBLY 2131
METHOD FOR REMOVING RADIATOR ASSEMBLY .2131
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2133
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2135
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2135
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2138
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2141
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2141
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2142
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2144
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2145
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2153
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2164
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2164
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2167
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2171
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2171
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2172
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2175
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2175
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2176
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2177
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2177
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2179
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2185
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2185
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2189
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2195
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2195
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2200
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2206
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2206
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2211
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2217
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2217
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2217
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2219
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2219
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2219
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2221
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2221
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2223
REMOVE AND INSTALL KDPF ASSEMBLY 2226
METHOD FOR REMOVING KDPF ASSEMBLY .2226
METHOD FOR INSTALLING KDPF ASSEMBLY .2228
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2230
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2231
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2234
REMOVE AND INSTALL SCR ASSEMBLY .2239
METHOD FOR REMOVING SCR ASSEMBLY 2239
METHOD FOR INSTALLING SCR ASSEMBLY 2241
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2243
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2243
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2249
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2255
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2255
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2262
REMOVE AND INSTALL KCCV ASSEMBLY 2270
METHOD FOR REMOVING KCCV ASSEMBLY .2270
METHOD FOR INSTALLING KCCV ASSEMBLY .2273
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2277
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2277
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2282
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2287
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2287
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2289
REMOVE AND INSTALL AdBlue/DEF PUMP 2291
METHOD FOR REMOVING AdBlue/DEF PUMP .2291
METHOD FOR INSTALLING AdBlue/DEF PUMP .2293
REMOVE AND INSTALL AdBlue/DEF HOSE 2296
METHOD FOR REMOVING AdBlue/DEF HOSE .2296
METHOD FOR INSTALLING AdBlue/DEF HOSE .2304
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2310
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2310
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2311
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2313
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2313
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2315
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2318
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2318
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2319
POWER TRAIN .2320
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2320
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2320
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2321
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2323
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2323
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2327
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2336
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2336
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2339
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2342
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2342
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2346
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2353
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2353
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2353
UNDERCARRIAGE AND FRAME .2355
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2355
METHOD FOR SEPARATING TRACK ASSEMBLY 2355
METHOD FOR INSTALLING TRACK ASSEMBLY 2357
REMOVE AND INSTALL SPROCKET .2360
METHOD FOR REMOVING SPROCKET 2360
METHOD FOR INSTALLING SPROCKET 2360
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2362
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2362
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2363
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2364
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2364
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2365
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2369
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2370
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2371
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2372
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2373
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2374
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2376
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2376
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2378
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2380
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2380
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2382
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2385
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2385
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2388
HYDRAULIC SYSTEM 2392
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2392
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2392
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2394
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2397
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2398
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2399
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2400
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2400
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2403
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2406
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2406
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2409
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2412
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2412
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2419
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2427
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2427
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2429
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2433
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2433
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2433
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2435
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2435
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2436
REMOVE AND INSTALL QUICK COUPLER VALVE 2438
WORK EQUIPMENT 2440
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2440
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2440
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2444
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2450
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2450
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2453
CAB AND ITS ATTACHMENTS .2459
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2459
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2459
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2465
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2472
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2474
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2474
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2484
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2484
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2487
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2493
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2493
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2500
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2507
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2507
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2513
REMOVE AND INSTALL OPERATOR’S SEAT 2520
METHOD FOR REMOVING OPERATOR’S SEAT .2520
METHOD FOR INSTALLING OPERATOR’S SEAT .2522
REMOVE AND INSTALL SEAT BELT 2525
METHOD FOR REMOVING SEAT BELT .2525
METHOD FOR INSTALLING SEAT BELT .2526
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2527
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2527
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2532
ELECTRICAL SYSTEM .2541
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2541
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2541
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2543
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2544
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2544
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2548
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2553
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2553
METHOD FOR INSTALLING KomVision CONTROLLER 2554
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2556
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2556
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2559
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2562
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2562
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2563
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2564
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2564
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2565
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2566
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2566
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2567
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2569
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2569
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2571
REMOVE AND INSTALL KomVision CAMERA .2574
METHOD FOR REMOVING KomVision CAMERA 2574
METHOD FOR INSTALLING KomVision CAMERA 2577
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2580
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2580
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2583
60 MAINTENANCE STANDARD .2587
CONTENTS 2588
ABBREVIATION LIST .2589
ENGINE AND COOLING SYSTEM .2595
MAINTENANCE STANDARD OF ENGINE MOUNT 2595
MAINTENANCE STANDARD OF COOLING SYSTEM 2596
POWER TRAIN .2597
MAINTENANCE STANDARD OF SWING CIRCLE 2597
MAINTENANCE STANDARD OF SWING MACHINERY .2598
MAINTENANCE STANDARD OF FINAL DRIVE .2600
MAINTENANCE STANDARD OF SPROCKET 2602
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2603
UNDERCARRIAGE AND FRAME .2605
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2605
MAINTENANCE STANDARD OF IDLER .2607
MAINTENANCE STANDARD OF TRACK ROLLER 2609
MAINTENANCE STANDARD OF CARRIER ROLLER 2610
MAINTENANCE STANDARD OF TRACK SHOE 2611
MAINTENANCE STANDARD OF TRIPLE SHOE .2614
MAINTENANCE STANDARD OF SWAMP SHOE 2615
MAINTENANCE STANDARD OF ROAD LINER 2616
HYDRAULIC SYSTEM 2617
MAINTENANCE STANDARD OF HYDRAULIC TANK 2617
MAINTENANCE STANDARD OF MAIN PUMP .2618
MAINTENANCE STANDARD OF LS-EPC VALVE 2619
MAINTENANCE STANDARD OF PC-EPC VALVE 2620
MAINTENANCE STANDARD OF SWING MOTOR .2621
MAINTENANCE STANDARD OF TRAVEL MOTOR 2624
MAINTENANCE STANDARD OF CONTROL VALVE .2627
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2637
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2640
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2643
MAINTENANCE STANDARD OF EPC VALVE .2644
MAINTENANCE STANDARD OF SOLENOID VALVE 2646
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 2647
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2649
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2650
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2651
WORK EQUIPMENT 2652
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2652
DIMENSION OF ARM 2657
DIMENSIONS OF BUCKET 2659
MAINTENANCE STANDARD OF BOOM CYLINDER .2661
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2662
MAINTENANCE STANDARD OF ARM CYLINDER 2663
MAINTENANCE STANDARD OF BUCKET CYLINDER .2664
80 APPENDIX .2665
CONTENTS 2666
ABBREVIATION LIST .2668
AIR CONDITIONER SYSTEM 2674
PRECAUTIONS FOR REFRIGERANT .2674
AIR CONDITIONER COMPONENT .2675
SPECIFICATIONS OF AIR CONDITIONER .2677
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2678
OUTLINE OF REFRIGERATION CYCLE 2679
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2681
AIR CONDITIONER UNIT 2681
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2681
FUNCTION OF AIR CONDITIONER UNIT 2683
COMPONENT PARTS OF AIR CONDITIONER UNIT .2685
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2686
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2686
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2686
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2686
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2687
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2687
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2687
FUNCTION OF DUAL PRESSURE SWITCH 2688
AIR CONDITIONER CONTROLLER 2689
STRUCTURE OF AIR CONDITIONER CONTROLLER .2689
COMPRESSOR 2690
STRUCTURE OF COMPRESSOR .2690
SPECIFICATIONS OF COMPRESSOR 2690
FUNCTION OF COMPRESSOR 2690
CONDENSER .2691
STRUCTURE OF CONDENSER 2691
SPECIFICATIONS OF CONDENSER .2691
FUNCTION OF CONDENSER .2691
SENSORS FOR AIR CONDITIONER SYSTEM 2693
STRUCTURE OF SUNLIGHT SENSOR 2693
FUNCTION OF SUNLIGHT SENSOR .2693
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2693
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2693
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2695
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2697
AIR CONDITIONER SYSTEM DIAGRAM 2699
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2700
FUNCTION OF AIR CONDITIONER CONTROLLER 2701
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2702
TESTING AIR LEAKAGE (DUCT) 2706
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2706
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2708
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2709
TEST VENT (MODE) CHANGEOVER .2710
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2710
TESTING FRESH/RECIRC AIR CHANGEOVER .2712
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2712
TEST SUNLIGHT SENSOR 2713
METHOD FOR TESTING SUNLIGHT SENSOR 2713
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2714
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2714
TEST RELAYS .2715
METHOD FOR TESTING RELAYS .2715
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2716
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2717
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2720
FAILURE CODE [879AKA] .2722
FAILURE CODE [879AKB] .2723
FAILURE CODE [879BKA] .2724
FAILURE CODE [879BKB] .2726
FAILURE CODE [879CKA] .2728
FAILURE CODE [879CKB] .2729
FAILURE CODE [879DKZ] .2730
FAILURE CODE [879EMC] .2732
FAILURE CODE [879FMC] .2733
FAILURE CODE [879GKX] .2734
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2736
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2738
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2741
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2743
TROUBLESHOOTING USING GAUGE PRESSURE 2745
CONNECTION OF SERVICE TOOL 2748
METHOD FOR CONNECTING SERVICE TOOL 2748
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2750
HANDLE COMPRESSOR OIL .2752
METHOD FOR REPLACING DESICCANT 2754
90 CIRCUIT DIAGRAMS .2757
CONTENTS 2758
ABBREVIATION LIST .2759
HYDRAULIC CIRCUIT DIAGRAM .2765
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2765
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2769
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2771
ELECTRICAL CIRCUIT DIAGRAM 2773
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2773
ELECTRICAL CIRCUIT DIAGRAM (1/8) 2777
ELECTRICAL CIRCUIT DIAGRAM (2/8) 2779
ELECTRICAL CIRCUIT DIAGRAM (3/8) 2781
ELECTRICAL CIRCUIT DIAGRAM (4/8) 2783
ELECTRICAL CIRCUIT DIAGRAM (5/8) 2785
ELECTRICAL CIRCUIT DIAGRAM (6/8) 2787
ELECTRICAL CIRCUIT DIAGRAM (7/8) 2789
ELECTRICAL CIRCUIT DIAGRAM (8/8) 2791
INDEX 2793

DESCRIPTION:

Komatsu PC240-11,PC240LC-11,PC240NLC-11 Hydraulic Excavator Shop Manual UENBM00332 – PDF DOWNLOAD

• SERIAL NUMBERS K70001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

G.B 31/12/24