KOMATSU PC240LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SEN05538-02) – PDF DOWNLOAD

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KOMATSU PC240LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SEN05538-02)

KOMATSU PC240LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SEN05538-02) – PDF DOWNLOAD:

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KOMATSU PC240LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SEN05538-02)

• This shop manual contains the necessary technical information for services performed in a workshop.For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
• This section contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added.
01. Specification
• This section explains the specifications of the machine.
10. Structure and function
• This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table
• This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge failures in troubleshooting.
30. Testing and adjusting
• This section explains measuring tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are explained in “Standard value table”.
40. Troubleshooting
• This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be explained in both of the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
• This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard
• This section gives maintenance standard values of each component.The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80. Appendix
• The section contains the equipment which can not be classified in the other sections. This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment.
90. Diagrams and drawings
• This section gives hydraulic circuit diagrams and electrical circuit diagrams.

TABLE OF CONTENTS:

KOMATSU PC240LC-10 HYDRAULIC EXCAVATOR SERVICE REPAIR MANUAL (SEN05538-02)

Index
00 Index and foreword 00-1
Index 00-2
Foreword, safety and general information 00-13
Important safety notice 00-13
How to read the shop manual 00-18
Explanation of terms for maintenance standard 00-20
Handling of hydraulic equipment 00-22
Method of disconnecting and connecting push-pull type coupler 00-24
Handling of electrical equipment 00-27
How to read electric wire code 00-35
Precautions when performing operation 00-38
Standard tightening torque table 00-41
List of abbreviation 00-45
Conversion table 00-50
01 Specification 01-2
Specifications 01-3
Specification drawings 01-3
Working range drawings 01-4
Specifications 01-5
Weight table 01-8
Table of fuel, coolant and lubricants 01-9
10 Structure and function 10-2
Engine and cooling system 10-3
Engine related parts 10-3
Cooling system 10-5
Power train 10-7
Power train 10-7
Swing circle 10-9
Swing machinery 10-10
Final drive 10-12
Undercarriage and frame 10-14
Track frame and idler cushion 10-14
Hydraulic system 10-16
Hydraulic equipment layout drawing 10-16
Valve control 10-18
Hydraulic tank 10-20
CLSS 10-22
Main pump 10-27
Control valve 10-51
Swing motor 10-105
Travel motor 10-116
PPC valve 10-129
Solenoid valve 10-150
Attachment circuit selector valve (for high pressure circuit) 10-153
Attachment circuit selector valve (for low pressure circuit) 10-155
Center swivel joint 10-158
Accumulator 10-160
Work equipment 10-161
Work equipment 10-161
Work equipment shim 10-162
Bucket play adjustment shim 10-163
Cab and its attachments 10-164
Cab mount and cab tipping stopper 10-164
ROPS cab 10-165
Electrical system 10-166
Electrical control system 10-166
Machine monitor system 10-209
KOMTRAX system 10-230
Sensors 10-232
20 Standard value table 20-2
Standard service value table 20-3
Standard value table for engine related parts 20-3
Standard value table for chassis related parts 20-4
Posture of machine for measuring performance and measurement procedure 20-13
30 Testing Adjusting 30-2
General information on testing and adjusting 30-3
Tools for testing and adjusting 30-3
Sketch of tools for testing and adjusting 30-7
Engine and cooling system 30-9
Checking engine speed 30-9
Measuring boost pressure 30-10
Measuring exhaust gas color 30-11
Measuring and adjusting valve clearance 30-13
Measuring compression pressure 30-16
Measuring blowby pressure 30-20
Measuring engine oil pressure 30-21
Measuring EGR valve and KVGToil pressure 30-22
Measuring fuel pressure 30-23
Measuring fuel delivery, return and leakage 30-29
Bleeding air from fuel system 30-34
Checking fuel circuit for leakage 30-36
Handling cylinder cutout mode operation 30-37
Handling no injection cranking operation 30-38
Checking and adjusting air conditioner compressor belt tension 30-39
Replacing fan belt 30-40
Power train 30-41
Testing swing circle bearing clearance 30-41
Undercarriage and frame 30-42
Testing and adjusting track shoe tension 30-42
Hydraulic system 30-43
Releasing remaining pressure from hydraulic circuit 30-43
Measuring and adjusting of oil pressure in work equipment, swing, and travel circuits 30-44
Measuring oil pressure in control circuit 30-48
Measuring and adjusting oil pressure in pump PC control circuit 30-49
Measuring and adjusting oil pressure in pump LS control circuit 30-52
Measuring solenoid valve output pressure 30-57
Measuring PPC valve output pressure 30-60
Adjusting play of work equipment and swing PPC valves 30-62
Testing pump swash plate sensor 30-63
Isolating the parts causing hydraulic drift in work equipment 30-64
Measuring oil leakage 30-65
Bleeding air from hydraulic circuit 30-68
Cab and its attachments 30-70
Checking cab tipping stopper 30-70
Adjusting mirrors 30-71
Electrical system 30-73
Special functions of machine monitor 30-73
Angle adjustment of rear view camera 30-142
Handling voltage circuit of engine controller 30-144
Handling battery disconnect switch 30-145
Testing diodes 30-146
Pm clinic 30-147
Pm clinic service 30-147
40 Troubleshooting 40-8
General information on troubleshooting 40-9
Instruction on troubleshooting 40-9
How to proceed troubleshooting 40-11
Testing before troubleshooting 40-12
Testing procedure before troubleshooting 40-14
Preparation work for troubleshooting of electrical system 40-42
Classification and procedure for troubleshooting 40-46
Symptom of probable failure and troubleshooting No 40-49
Information mentioned in troubleshooting table 40-52
Diagnostic procedure for wiring harness open curcuit of pressure sensor system 40-55
Connector list and layout 40-57
Connector contact identification 40-68
T-branch box and T-branch adapter table 40-105
Fuse list and location 40-111
Precautions for cleaning and replacing KDPF (KCSF, KDOC) 40-113
Failure codes table 40-115
Troubleshooting by failure code (Display of code) 40-124
Failure code [879AKA] A/C Inner Sensor Open Circuit 40-124
Failure code [879AKB] A/C Inner Sensor Short Circuit 40-125
Failure code [879BKA] A/C Outer Sensor Open Circuit 40-126
Failure code [879BKB] A/C Outer Sensor Short Circuit 40-127
Failure code [879CKA] Ventilating Sensor Open Circuit 40-128
Failure code [879CKB] Ventilating Sensor Short Circuit 40-129
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 40-130
Failure code [879EMC] Ventilation Damper Abnormality 40-131
Failure code [879FMC] Air Mix Damper Abnormality 40-132
Failure code [879GKX] Refrigerant Abnormality 40-133
Failure code [989L00] Engine Controller Lock Caution1 40-134
Failure code [989M00] Engine Controller Lock Caution2 40-135
Failure code [989N00] Engine Controller Lock Caution3 40-136
Failure code [A1U0N3] HC desorb request1 40-137
Failure code [A1U0N4] HC desorb request2 40-139
Failure code [AA10NX] Air Cleaner Clogging 40-141
Failure code [AB00KE] Charge Voltage Low 40-143
Failure code [B@BAZG] Engine Oil Pressure Low 40-145
Failure code [B@BAZK] Eng Oil Level Low 40-146
Failure code [B@BCNS] Engine Coolant Overheat 40-147
Failure code [B@BCZK] Radiator Coolant Level Low 40-148
Failure code [B@HANS] Hyd Oil Overheat 40-150
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 40-151
Failure code [CA122] Chg Air Press Sensor High Error 40-152
Failure code [CA123] Chg Air Press Sensor Low Error 40-154
Failure code [CA131] Throttle Sensor High Error 40-156
Failure code [CA132] Throttle Sensor Low Error 40-158
Failure code [CA144] Coolant Temp Sens High Error 40-160
Failure code [CA145] Coolant Temp Sens Low Error 40-162
Failure code [CA153] Chg Air Temp Sensor High Error 40-164
Failure code [CA154] Chg Air Temp Sensor Low Error 40-166
Failure code [CA187] Sensor 2 Supply Volt Low Error 40-168
Failure code [CA221] Ambient Press Sensor High Error 40-170
Failure code [CA222] Ambient Press Sensor Low Error 40-172
Failure code [CA227] Sensor 2 Supply Volt High Error 40-174
Failure code [CA234] Eng Overspeed 40-175
Failure code [CA238] Ne Speed Sensor Supply Volt Error 40-176
Failure code [CA239] Ne Speed Sens Supply Volt High Error 40-177
Failure code [CA271] IMV/PCV1 Short Error 40-178
Failure code [CA272] IMV/PCV1 Open Error 40-180
Failure code [CA295] Ambient Press Sens In Range Error 40-181
Failure code [CA322] Inj #1(L#1) Open/Short Error 40-182
Failure code [CA323] Inj #5(L#5) Open/Short Error 40-184
Failure code [CA324] Inj #3(L#3) Open/Short Error 40-186
Failure code [CA325] Inj #6(L#6) Open/Short Error 40-188
Failure code [CA331] Inj #2(L#2) Open/Short Error 40-190
Failure code [CA332] Inj #4(L#4) Open/Short Error 40-192
Failure code [CA343] ECM Critical Internal Failure 40-194
Failure code [CA351] Injectors Drive Circuit Error 40-195
Failure code [CA352] Sensor 1 Supply Volt Low Error 40-196
Failure code [CA356] Mass Air Flow Sensor High Error 40-198
Failure code [CA357] Mass Air Flow Sensor Low Error 40-200
Failure code [CA386] Sensor 1 Supply Volt High Error 40-202
Failure code [CA428] Water in Fuel Sensor High Error 40-203
Failure code [CA429] Water in Fuel Sensor Low Error 40-205
Failure code [CA435] Eng Oil Press Sw Error 40-207
Failure code [CA441] Battery Voltage Low Error 40-208
Failure code [CA442] Battery Voltage High Error 40-210
Failure code [CA449] Rail Press Very High Error 40-211
Failure code [CA451] Rail Press Sensor High Error 40-212
Failure code [CA452] Rail Press Sensor Low Error 40-214
Failure code [CA488] Chg Air Temp High Torque Derate 40-215
Failure code [CA515] Rail Press Sens Sup Volt High Error 40-216
Failure code [CA516] Rail Press Sens Sup Volt Low Error 40-218
Failure code [CA553] Rail Press High Error 40-220
Failure code [CA555] Crankcase Press High Error 1 40-221
Failure code [CA556] Crankcase Press High Error 2 40-222
Failure code [CA559] Rail Press Low Error 40-223
Failure code [CA595] Turbo Speed High Error 2 40-225
Failure code [CA687] Turbo Speed Low Error 40-226
Failure code [CA689] Eng Ne Speed Sensor Error 40-228
Failure code [CA691] Intake Air Temp Sens High Error 40-230
Failure code [CA692] Intake Air Temp Sens Low Error 40-232
Failure code [CA697] ECM Int Temp Sensor High Error 40-234
Failure code [CA698] ECM Int Temp Sensor Low Error 40-235
Failure code [CA731] Eng Bkup Speed Sens Phase Error 40-236
Failure code [CA778] Eng Bkup Speed Sensor Error 40-237
Failure code [CA1117] Persistent Data Lost Error 40-241
Failure code [CA1664] KDOC Malfunction 40-242
Failure code [CA1691] Regeneration Ineffective 40-244
Failure code [CA1695] Sensor 5 Supply Volt Low Error 40-246
Failure code [CA1696] Sensor 5 Supply Volt High Error 40-248
Failure code [CA1843] Crankcase Press Sens High Error 40-250
Failure code [CA1844] Crankcase Press Sens Low Error 40-252
Failure code [CA1879] KDPF Delta P Sensor High Error 40-254
Failure code [CA1881] KDPF Delta P Sensor Low Error 40-256
Failure code [CA1883] KDPF Delta P Sens In Range Error 40-258
Failure code [CA1921] KDPF Soot Load High Error 1 40-261
Failure code [CA1922] KDPF Soot Load High Error 2 40-263
Failure code [CA1942] Crankcase Press Sens In Range Error 40-267
Failure code [CA1993] KDPF Delta Pressure Low Error 40-268
Failure code [CA2185] Throt Sensor Sup Volt High Error 40-269
Failure code [CA2186] Throt Sensor Sup Volt Low Error 40-270
Failure code [CA2249] Rail Press Very Low Error 40-271
Failure code [CA2271] EGR Valve Pos Sens High Error 40-272
Failure code [CA2272] EGR Valve Pos Sens Low Error 40-274
Failure code [CA2288] Turbo Speed High Error 1 40-277
Failure code [CA2311] IMV Solenoid Error 40-278
Failure code [CA2349] EGR Valve Solenoid Open Error 40-279
Failure code [CA2353] EGR Valve Solenoid Short Error 40-281
Failure code [CA2357] EGR Differential Pressure 40-283
Failure code [CA2373] Exh Manifold Press Sens Volt 40-284
Failure code [CA2374] Exhaust Manifold Press Sens Low Error 40-286
Failure code [CA2375] EGR Orifice Temp Sens High Error 40-288
Failure code [CA2376] EGR Orifice Temp Sens Low Error 40-290
Failure code [CA2381] KVGT Pos Sens High Error 40-292
Failure code [CA2382] KVGT Pos Sens Low Error 40-294
Failure code [CA2383] KVGT Solenoid Open Error 40-296
Failure code [CA2386] KVGT Solenoid Short Error 40-298
Failure code [CA2387] KVGT Servo Error 40-300
Failure code [CA2554] Exh Manifold Press Sens In Range Error 40-301
Failure code [CA2555] Grid Htr Relay Volt Low Error 40-302
Failure code [CA2556] Grid Htr Relay Volt High Error 40-304
Failure code [CA2637] KDOC Face Plugging 40-306
Failure code [CA2639] Manual Stationary Regeneration Request 40-308
Failure code [CA2961] EGR Orifice Temp High Error 1 40-310
Failure code [CA2973] Chg Air Press Sensor In Range Error 40-311
Failure code [CA3133] KDPF Outlet Press Sens High Error 40-312
Failure code [CA3134] KDPF Outlet Press Sens Low Error 40-314
Failure code [CA3135] KDPF Outlet Press Sens In Range Error 40-316
Failure code [CA3251] DOC Inlet Temp High Error 40-319
Failure code [CA3253] KDOC Temp Error – Non Regeneration 40-322
Failure code [CA3254] KDOC Outlet Temp High Error 1 40-323
Failure code [CA3255] KDPF Temp Error – Non Regeneration 40-326
Failure code [CA3256] KDPF Outlet Temp High Error 1 40-327
Failure code [CA3311] KDOC Outlet Temp High Error 2 40-328
Failure code [CA3312] KDPF Outlet Temp High Error 2 40-329
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 40-331
Failure code [CA3314] KDOC Inlet Temp Sens High Error 40-334
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error 40-338
Failure code [CA3316] KDOC Outlet Temp Sens Low Error 40-342
Failure code [CA3317] KDOC Outlet Temp Sens High Error 40-345
Failure code [CA3318] KDOC Inlet Temp Sens In Range Error 40-349
Failure code [CA3319] KDPF Outlet Temp Sens High Error 40-353
Failure code [CA3321] KDPF Outlet Temp Sens Low Error 40-357
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 40-360
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 40-364
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 40-365
Failure code [CA3741] Rail Press Valve Trip Error 40-367
Failure code [D110KB] Battery Relay Output Voltage 40-368
Failure code [D19JKZ] Personal Code Relay Abnormality 40-370
Failure code [D811MC] KOMTRAX Error 40-373
Failure code [D862KA] GPS Antenna Open Circuit 40-374
Failure code [D8ALKA] Operating Lamp Open Circuit(KOMTRAX)
40-375
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) 40-377
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 40-378
Failure code [DA20MC] Pump Controller 40-379
Failure code [DA22KK] Pump Solenoid Power Low Error 40-380
Failure code [DA25KP] 5V Sensor 1 Power Abnormality 40-382
Failure code [DA29KQ] Model Selection Abnormality 40-385
Failure code [DA2LKA] Operating Lamp Open Circuit(Pump Con) 40-387
Failure code [DA2LKB] Operating Lamp Short Circuit(Pump Con) 40-389
Failure code [DA2QKR] CAN2 Discon (Pump Con) 40-390
Failure code [DA2QKR] CAN1 Discon (Pump Con) 40-392
Failure code [DAF0MB] Monitor ROM Abnormality 40-393
Failure code [DAF0MC] Monitor Error 40-394
Failure code [DAF8KB] Camera Power Supply Short Circuit 40-395
Failure code [DAF9KQ] Model Selection Abnormality 40-397
Failure code [DAFGMC] GPS Module Error 40-398
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) 40-399
Failure code [DAFLKB] Operating Lamp Short Circuit(Monitor) 40-401
Failure code [DAFQKR] CAN2 Discon (Monitor) 40-402
Failure code [DAZ9KQ] A/C Model Selection Abnormality 40-403
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) 40-404
Failure code [DB2QKR] CAN2 Discon (Engine Con) 40-408
Failure code [DB2RKR] CAN1 Discon (Engine Con) 40-413
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit 40-417
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit 40-419
Failure code [DHPAMA] F Pump Press Sensor Abnormality 40-420
Failure code [DHPBMA] R Pump Press Sensor Abnormality 40-423
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality 40-426
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality 40-428
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality 40-431
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality 40-434
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality 40-437
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality 40-440
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality 40-443
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality 40-446
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality 40-449
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality 40-452
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality 40-455
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality 40-458
Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality 40-461
Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality 40-464
Failure code [DR21KX] Camera 2 Picture Rev Drive Abnormality 40-467
Failure code [DR31KX] Camera 3 Picture Rev Drive Abnormality 40-469
Failure code [DV20KB] Travel Alarm Short Circuit 40-471
Failure code [DW43KA] Travel Speed Sol Open Circuit 40-473
Failure code [DW43KB] Travel Speed Sol Short Circuit 40-475
Failure code [DW45KA] Swing Brake Sol Open Circuit 40-477
Failure code [DW45KB] Swing Brake Sol Short Circuit 40-479
Failure code [DW91KA] Travel Junction Sol Open Circuit 40-482
Failure code [DW91KB] Travel Junction Sol Short Circuit 40-484
Failure code [DWA2KA] Attachment Sol Open Circuit 40-486
Failure code [DWA2KB] Attachment Sol Short Circuit 40-488
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit 40-490
Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit 40-492
Failure code [DWK2KA] Variable Back Press Sol Open Circuit 40-494
Failure code [DWK2KB] Variable Back Press Sol Short Circuit 40-496
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit 40-498
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit 40-500
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit 40-502
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit 40-504
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit 40-506
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit 40-508
Failure code [DXE0KA] LS-EPC Sol Open Circuit 40-510
Failure code [DXE0KB] LS-EPC Sol Short Circuit 40-512
Failure code [DXE4KA] Attachment Flow EPC Open Circuit 40-514
Failure code [DXE4KB] Attachment Flow EPC Short Circuit 40-516
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit 40-518
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit 40-520
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit 40-522
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit 40-524
Failure code [DY20KA] Wiper Working Abnormality 40-526
Failure code [DY20MA] Wiper Parking Abnormality 40-528
Failure code [DY2CKB] Washer Drive Short Circuit 40-530
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit 40-532
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit 40-534
Troubleshooting of electrical system (E-mode) 40-536
E-1 Engine does not start (Engine does not rotate) 40-536
E-2 Manual preheating system does not work 40-542
E-3 Automatic preheating system does not work 40-545
E-4 Preheating monitor does not light up when preheater is operated 40-547
E-5 When starting switch is turned to ON position, machine monitor displays nothing 40-549
E-6 When starting switch is turned to ON position (before starting engine), engine oil level
monitor lights up in yellow 40-552
E-7 When starting switch is turned to ON position (before starting engine), radiator coolant
level monitor lights up in yellow 40-553
E-8 Coolant temperature monitor lights up in white while engine is running 40-554
E-9 Hydraulic oil temperature monitor lights up in white while engine is running 40-555
E-10 Charge level monitor lights up while engine is running 40-556
E-11 Fuel level monitor lights up in red while engine is running 40-557
E-12 Air cleaner clogging monitor lights up in yellow while engine is running 40-558
E-13 Water separator monitor lights up while engine is running 40-559
E-14 Coolant temperature monitor lights up in red while engine is running 40-560
E-15 Hydraulic oil temperature monitor lights up in red while engine is running 40-561
E-16 Engine oil pressure monitor lights up in red while engine is running 40-562
E-17 Fuel gauge indicate either full or empty and does not move 40-563
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty) 40-564
E-19 Coolant temperature gauge indicate either Min or Max and does not move 40-565
E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min nor
Max) 40-566
E-21 Hydraulic oil temperature gauge indicate either Min or Max and does not move 40-567
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min
nor Max) 40-569
E-23 Content of display on machine monitor is different from that of actual machine 40-570
E-24 Machine monitor does not display some items 40-571
E-25 Function switch does not work 40-572
E-26 Automatic preheating system does not work (In cold season) 40-573
E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration
switch is operated 40-574
E-28 Auto-deceleration is not actuated or canceled when lever is operated 40-575
E-29 Working mode selector screen selection screen is not diplayed when working mode
switch is operated 40-577
E-30 Engine or hydraulic pump setting does not change when working mode is
changed 40-578
E-31 Travel speed monitor does not change when travel speed switch is operated 40-579
E-32 Travel speed does not change when travel speed is shifted 40-580
E-33 Alarm buzzer does not stop sounding 40-581
E-34 When starting switch is turned to OFF position, service meter is not displayed 40-582
E-35 Service mode cannot be selected 40-583
E-36 Any of work equipment, swing and travel does not work 40-584
E-37 Any of work equipment, swing and travel can not be locked 40-586
E-38 Machine can not swing while swing brake cancel switch is canceled 40-587
E-39 Swing brake does not operate while swing brake cancel switch is locked 40-589
E-40 One-touch power maximizing function does not work or monitor is not displayed 40-591
E-41 One-touch power maximizing function cannot be released 40-593
E-42 Travel alarm does not sound when machine travels 40-594
E-43 Travel alarm does not stop sounding when machine stops 40-595
E-44 Horn does not sound 40-596
E-45 Horn does not stop sounding 40-598
E-46 Wiper monitor does not light up or go out when wipper switch is operated 40-599
E-47 Wiper does not operate when wipper switch is operated 40-600
E-48 Window washer does not operate when window washer switch is operated 40-602
E-49 BOOM LOWER indication is not displayed properly with monitoring function 40-603
E-50 ARM DUMP indication is not displayed properly with monitoring function 40-604
E-51 ARM IN indication is not displayed properly with monitoring function 40-605
E-52 BOOM RAISE indication is not displayed properly with monitoring function 40-606
E-54 BUCKET DUMP indication is not displayed properly with monitoring function 40-608
E-55 SWING indication is not displayed properly with monitoring function 40-609
E-56 TRAVEL indication is not displayed properly with monitoring function 40-610
E-57 Service is not displayed properly with monitoring function 40-611
E-58 Attachment hydraulic circuit cannot be changed 40-614
E-59 KOMTRAX system does not work properly 40-615
Troubleshooting of hydraulic and mechanical system (H-mode) 40-616
Information mentioned in troubleshooting table (H mode) 40-616
System chart for hydraulic system 40-617
Failure mode and cause table 40-619
H-1 All of work equipment, swing and travel operation lacks speed or power 40-627
H-2 Engine speed lowers significantly or engine stalls 40-630
H-3 Any of work equipment, swing and travel does not work 40-632
H-4 Unusual sound is heard from around hydraulic pump 40-633
H-5 Fine control performance or response is poor 40-634
H-6 Boom operation lacks speed or power 40-635
H-7 Arm operation lacks speed or power 40-637
H-8 Bucket operation lacks speed or power 40-639
H-9 Work equipment does not move in single operation 40-640
H-10 Hydraulic drift of boom is large 40-641
H-11 Hydraulic drift of arm is large 40-642
H-12 Hydraulic drift of bucket is large 40-643
H-13 Time lag of work equipment is large 40-644
H-14 When part of work equipment is relieved singly, other parts of work equipment
move 40-646
E-15 One-touch power maximizing function does not work 40-647
H-16 In combined operation of work equipment, equipment having heavier load moves
slower 40-648
H-17 In combined operations of swing and boom RAISE, boom rising speed is low 40-649
H-18 In combined operations of swing and travel, travel speed drops largely 40-650
H-19 Machine does not travel straight 40-651
H-20 Travel speed is too low 40-652
H-21 Machine is hard to steer or travel power is low 40-654
H-22 Travel speed does not change, or travel speed is too low or high 40-656
H-23 One of tracks dose not run 40-657
H-24 Upper structure does not swing to the right or left 40-658
H-25 Upper structure swing only to the right or left 40-659
H-26 Swing acceleration is poor or swing speed is low (both right and left) 40-660
H-27 Swing acceleration is poor or swing speed is low (either right or left) 40-661
H-28 Upper structure overruns excessively when it stops swinging (both right and
left) 40-662
H-29 Upper structure overruns excessively when it stops swinging (either right or left) 40-663
H-30 Shock is large when upper structure stops swinging 40-664
H-31 Large unusual noise is heard when upper structure stops swinging 40-665
H-32 Swing drift on a slope is large while swing holding brake is applied 40-666
H-33 Swing drift on a slope is large while swing holding brake is released 40-667
H-34 Attachment circuit cannot be changed while attachment is installed 40-668
H-35 Oil flow in attachment circuit cannot be controlled 40-669
Troubleshooting of engine (S-mode) 40-670
Information mentioned in troubleshooting table (S mode) 40-670
S-1 When starting switch is turned to START position, engine does not crank 40-671
S-2 When engine cranks, smoke does not come out 40-672
S-3 Engine does not start while fuel is injected (Incomplete combustion) 40-673
S-4 Startability is poor 40-674
S-5 Engine does not pick up smoothly 40-676
S-6 Engine stops during operation 40-677
S-7 Engine runs rough or is unstable 40-679
S-8 Engine lacks power 40-680
S-9 Exhaust smoke is black (KDPF clogs up early) 40-682
S-10 Engine oil consumption is too much 40-684
S-11 Oil becomes contaminated early 40-685
S-12 Fuel consumption is excessive 40-686
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 40-687
S-14 Engine oil pressure drops 40-688
S-15 Fuel is contaminated in engine oil 40-689
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white) 40-690
S-17 Coolant temperature rises too high (Overheating) 40-691
S-18 Unusual noise is heard 40-692
S-19 Vibration is excessive 40-693
S-20 Automatic regeneration is operated frequently 40-694
S-21 Active regeneration is operated for long 40-695
S-22 White smoke comes out in the process of active regeneration 40-696
50 Disassembly and assembly 50-3
General information on disassembly and assembly 50-4
How to read this manual 50-4
Coating materials list 50-6
Special tools list 50-10
Sketches of special tools 50-18
Engine and cooling system 50-21
Removal and installation of supply pump assembly 50-21
Removal and installation of injector assembly 50-26
Removal and installation of cylinder head assembly 50-35
Removal and installation of radiator assembly 50-55
Removal and installation of hydraulic oil cooler assembly 50-57
Removal and installation of aftercooler assembly 50-60
Removal and installation of engine and main pump assembly 50-62
Removal and installation of engine front oil seal 50-74
Removal and installation of engine rear oil seal 50-78
Removal and installation of fuel cooler assembly 50-81
Removal and installation of fuel tank assembly 50-82
Removal and installation of engine hood assembly 50-85
Removal and installation of KDPF assembly 50-88
Disassembly and assembly of KDPF 50-96
Removal and installation of KCCV assembly 50-104
Removal and installation of air cleaner assembly 50-107
Power train 50-110
Removal and installation of travel motor and final drive assembly 50-110
Disassembly and assembly of final drive 50-112
Removal and installation of swing motor and swing machinery assembly 50-120
Disassembly and assembly of swing machinery 50-123
Removal and installation of swing circle assembly 50-131
Undercarriage and frame 50-132
Separation and connection of track shoe assembly 50-132
Removal and installation of sprocket 50-135
Removal and installation of idler and idler cushion assembly 50-136
Disassembly and assembly of idler 50-137
Disassembly and assembly of idler cushion 50-140
Disassembly and assembly of track roller 50-142
Disassembly and assembly of carrier roller 50-145
Removal and installation of revolving frame assembly 50-148
Removal and installation of counterweight assembly 50-150
Hydraulic system 50-153
Removal and installation of center swivel joint assembly 50-153
Disassembly and assembly of center swivel joint 50-155
Removal and installation of hydraulic tank assembly 50-157
Removal and installation of main pump assembly 50-161
Removal and installation of control valve assembly 50-165
Disassembly and assembly of control valve 50-172
Disassembly and assembly of work equipment PPC valve 50-177
Disassembly and assembly of travel PPC valve 50-179
Work equipment 50-182
Removal and installation of work equipment assembly 50-182
Disassembly and assembly of work equipment cylinder 50-185
Cab and its attachments 50-191
Removal and installation of operator’s cab assembly 50-191
Removal and installation of operator cab glass (adhered glass) 50-196
Removal and installation of front window assembly 50-206
Removal and installation of floor frame assembly 50-212
Removal and installation of air conditioner unit assembly 50-218
Removal and installation of operator’s seat 50-222
Removal and installation of seat belt 50-224
Removal and installation of front wiper assembly 50-226
Electric system 50-233
Removal and installation of air conditioner compressor assembly 50-233
Removal and installation of air conditioner condenser assembly 50-236
Removal and installation of engine controller assembly 50-238
Removal and installation of pump controller assembly 50-240
Removal and installation of machine monitor assembly 50-243
Removal and installation of pump swash plate sensor 50-245
Removal and installation of Mass air flow and temperature sensor 50-246
Removal and installation of KOMTRAX terminal assembly 50-247
60 Maintenance standard 60-2
Engine and cooling system 60-3
Engine mount 60-3
Cooling system 60-4
Power train 60-5
Swing circle 60-5
Swing machinery 60-6
Final drive 60-8
Sprocket 60-10
Undercarriage and frame 60-12
Truck frame and idler cushion 60-12
Idler 60-14
Truck roller 60-16
Carrier roller 60-17
Truck shoe 60-18
Hydraulic system 60-23
Hydraulic tank 60-23
Main pump 60-24
Control valve 60-25
Swing motor 60-33
Travel motor 60-35
PPC valve 60-38
Solenoid valve 60-48
Attachment circuit selector valve (for high-pressure circuit) 60-49
Attachment circuit selector valve (for low-pressure circuit) 60-50
Center swivel joint 60-51
Work equipment 60-52
Work equipment cylinder 60-52
80 Appendix 80-2
Air conditioner 80-3
Precautions for refrigerant 80-3
Air conditioner component 80-4
Structure and function of refrigeration system 80-6
Overview of refrigeration system 80-7
Air conditioner unit 80-9
Dual pressure switch 80-15
Air conditioner controller 80-16
Air conditioner compressor 80-17
Air conditioner condenser 80-18
Sunlight sensor 80-20
Outside air temperature sensor 80-21
Inspection and troubleshooting procedure of air conditioner 80-22
Air conditioner circuit diagram and arrangement of connector pins 80-24
System diagram 80-26
Air conditioner controller input and output signals 80-27
Parts and connectors layout 80-29
Layout of air conditioner related parts and connectors 80-30
Testing air leakage (duct) 80-33
Testing with self-diagnosis function 80-36
How to enter air conditioner “Electrical Systems” screen in service mode of the machine
monitor 80-37
Testing vent (mode) changeover 80-39
Testing FRESH/RECIRC air changeover 80-41
Testing sunlight sensor 80-42
Testing (dual) pressure switch for refrigerant 80-43
Testing relay 80-45
Troubleshooting chart 1 80-46
Troubleshooting chart 2 80-47
Information mentioned in troubleshooting table 80-50
Failure code list related to air conditioner 80-51
Failure code [879AKA] A/C Inner Sensor Open Circuit 80-53
Failure code [879AKB] A/C Inner Sensor Short Circuit 80-54
Failure code [879BKA] A/C Outer Sensor Open Circuit 80-55
Failure code [879BKB] A/C Outer Sensor Short Circuit 80-57
Failure code [879CKA] Ventilating Sensor Open Circuit 80-59
Failure code [879CKB] Ventilating Sensor Short Circuit 80-60
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit 80-61
Failure code [879EMC] Ventilation Damper Abnormality 80-63
Failure code [879FMC] Air Mix Damper Abnormality 80-64
Failure code [879GKX] Refrigerant Abnormality 80-65
A-1 Troubleshooting for power supply system (The air conditioner does not operate) 80-66
A-2 Troubleshooting of compressor system (Air is not cooled) 80-68
A-3 Troubleshooting of blower motor system (Air does not come out or air flow is
abnormal) 80-71
A-4 Troubleshooting for FRESH/RECIRC air changeover 80-73
Troubleshooting with gauge pressure 80-75
Testing refrigerant pressure 80-77
Precautions for disconnecting and connecting refrigerant piping 80-80
Filling compressor oil 80-82
Desiccant replacement 80-84
90 Diagrams and drawings 90-2
Hydraulic circuit diagram 90-3
Symbols in hydraulic circuit diagram 90-3
Hydraulic circuit diagram 90-6
Electric circuit diagram 90-8
Symbols in electric circuit diagram 90-8
Electric circuit diagram 90-11
Electric circuit diagram for air conditioner unit 90-17
Index 1

PLEASE NOTE:

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