Komatsu PC240LC-11 Hydraulic Excavator Shop Manual SEN06737-C8 PDF

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Komatsu PC240LC-11 Hydraulic Excavator Shop Manual SEN06737-C8  – PDF DOWNLOAD

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Komatsu PC240LC-11 Hydraulic Excavator Shop Manual SEN06737-C8  – PDF DOWNLOAD

Language : English
Pages : 2924
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC240LC-11 Hydraulic Excavator Shop Manual SEN06737-C8  – PDF DOWNLOAD

• SERIAL NUMBERS C70001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 22
FOREWORD, SAFETY, BASIC INFORMATION . 28
HOW TO READ THE SHOP MANUAL . 28
SAFETY NOTICE FOR OPERATION . 30
PRECAUTIONS TO PREVENT FIRE . 38
ACTIONS IF FIRE OCCURS 40
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 41
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 42
PRECAUTIONS FOR DEF . 43
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 43
PRECAUTIONS FOR ADDING 43
PRECAUTIONS FOR STORING . 43
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 43
THE OTHER PRECAUTIONS . 43
STORE Ad Blue/DEF 44
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 48
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 55
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 57
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 58
PRACTICAL USE OF KOMTRAX 59
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 62
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 64
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 68
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 74
HOW TO READ ELECTRICAL WIRE CODE 75
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 79
STANDARD TIGHTENING TORQUE TABLE 82
CONVERSION TABLE 89
01 SPECIFICATIONS . 95
CONTENTS 96
ABBREVIATION LIST . 97
SPECIFICATIONS 103
SPECIFICATION DRAWING . 103
SPECIFICATION DRAWING: PC240LC-11 . 103
WORKING RANGE DRAWINGS 105
WORKING RANGE: PC240LC-11 . 105
SPECIFICATIONS 106
SPECIFICATIONS: PC240LC-11 106
WEIGHT TABLE 109
WEIGHT TABLE: PC240LC-11 109
TABLE OF FUEL, COOLANT, AND LUBRICANTS 111
10 STRUCTURE AND FUNCTION . 113
CONTENTS 114
ABBREVIATION LIST . 117
UREA SCR SYSTEM . 123
LAYOUT DRAWING OF UREA SCR SYSTEM . 124
UREA SCR SYSTEM DIAGRAM . 129
FUNCTION OF UREA SCR SYSTEM . 130
FUNCTION OF AdBlue/DEF SYSTEM . 130
INDUCEMENT STRATEGY . 132
COMPONENT PARTS OF UREA SCR SYSTEM 146
AdBlue/DEF MIXING TUBE 146
SCR ASSEMBLY 146
AdBlue/DEF TANK . 149
AdBlue/DEF PUMP . 151
AdBlue/DEF INJECTOR . 152
AdBlue/DEF HOSE . 153
AdBlue/DEF TANK HEATING VALVE . 154
BOOT-UP SYSTEM 155
LAYOUT DRAWING OF BOOT-UP SYSTEM 155
SYSTEM OPERATING LAMP SYSTEM 157
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 157
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 157
OPERATION OF SYSTEM OPERATING LAMP SYSTEM . 157
BATTERY DISCONNECT SWITCH . 158
FUNCTION OF BATTERY DISCONNECT SWITCH . 158
ENGINE SYSTEM . 159
LAYOUT DRAWING OF ENGINE SYSTEM . 159
SPECIFICATIONS OF ENGINE SYSTEM . 160
FUNCTION OF ENGINE SYSTEM . 160
ENGINE CONTROL SYSTEM . 161
ENGINE CONTROL SYSTEM DIAGRAM . 161
OPERATION OF ENGINE CONTROL SYSTEM 162
AUTO-DECELERATION SYSTEM 164
AUTO-DECELERATION SYSTEM DIAGRAM 164
FUNCTION OF AUTO-DECELERATION SYSTEM 164
OPERATION OF AUTO-DECELERATION SYSTEM . 165
ENGINE AUTOMATIC WARM-UP SYSTEM . 166
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 166
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 167
OVERHEAT PREVENTION SYSTEM 168
OVERHEAT PREVENTION SYSTEM DIAGRAM 168
FUNCTION OF OVERHEAT PREVENTION SYSTEM 169
TURBOCHARGER PROTECTION SYSTEM 171
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 171
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 172
AUTOMATIC IDLE STOP SYSTEM 173
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 173
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 173
OPERATION OF AUTOMATIC IDLE STOP SYSTEM . 173
COMPONENT PARTS OF ENGINE SYSTEM 176
VGT . 176
EGR SYSTEM 180
EGR VALVE . 182
EGR COOLER 184
KCCV SYSTEM . 185
KCCV VENTILATOR . 187
KDPF 189
COOLING SYSTEM 194
LAYOUT DRAWING OF COOLING SYSTEM 194
SPECIFICATIONS OF COOLING SYSTEM 195
CONTROL SYSTEM 196
LAYOUT DRAWING OF CONTROL SYSTEM PARTS 196
MACHINE MONITOR SYSTEM 199
MACHINE MONITOR SYSTEM DIAGRAM 199
FUNCTION OF MACHINE MONITOR SYSTEM 200
KomVision SYSTEM 201
LAYOUT DRAWING OF KOMVISION SYSTEM 201
KomVision SYSTEM DIAGRAM 203
FUNCTION OF KomVision SYSTEM 203
KOMTRAX SYSTEM 205
KOMTRAX SYSTEM DIAGRAM 205
FUNCTION OF KOMTRAX SYSTEM 205
COMPONENT PARTS OF CONTROL SYSTEM . 206
MACHINE MONITOR . 206
KomVision CONTROLLER 219
KomVision CAMERA 223
GATEWAY FUNCTION CONTROLLER . 224
COMMUNICATION TERMINAL 227
PUMP CONTROLLER . 229
RESISTOR FOR PC-EPC VALVE . 233
CAN TERMINATING RESISTOR 233
ENGINE CONTROLLER . 235
FUEL CONTROL DIAL . 241
HYDRAULIC SYSTEM 243
LAYOUT DRAWING OF HYDRAULIC SYSTEM 243
CLSS 249
STRUCTURE OF CLSS . 249
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 251
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 252
PRESSURE COMPENSATION CONTROL . 268
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 271
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 271
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 272
PUMP AND VALVE CONTROL SYSTEM . 277
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 277
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 278
COMPONENT PARTS OF HYDRAULIC SYSTEM . 280
HYDRAULIC TANK 280
MAIN PUMP . 282
CONTROL VALVE . 306
WORK EQUIPMENT SYSTEM . 369
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 369
STRUCTURE OF VALVE CONTROL 374
ONE-TOUCH POWER MAXIMIZING SYSTEM . 376
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 376
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 377
PPC LOCK SYSTEM . 378
PPC LOCK SYSTEM DIAGRAM . 378
FUNCTION OF PPC LOCK SYSTEM . 378
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 379
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 379
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 379
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 380
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 381
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 381
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 382
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 383
WORK EQUIPMENT AND SWING PPC VALVE 383
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 389
2ND-LINE ATTACHMENT PPC VALVE . 395
SOLENOID VALVE 397
ANTI-DROP VALVE FOR BOOM 400
ANTI-DROP VALVE FOR ARM . 404
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 408
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 410
PILOT CIRCUIT ACCUMULATOR . 413
ATTACHMENT CIRCUIT ACCUMULATOR 414
SWING SYSTEM 415
LAYOUT DRAWING OF SWING SYSTEM 415
SWING CONTROL SYSTEM DIAGRAM 419
FUNCTION OF SWING CONTROL SYSTEM 420
COMPONENT PARTS OF SWING SYSTEM . 423
SWING MOTOR . 423
SWING MACHINERY . 435
SWING CIRCLE 436
TRAVEL SYSTEM . 438
LAYOUT DRAWING OF TRAVEL SYSTEM . 438
TRAVEL CONTROL SYSTEM DIAGRAM . 442
FUNCTION OF TRAVEL CONTROL SYSTEM . 442
COMPONENT PARTS OF TRAVEL SYSTEM 444
TRAVEL MOTOR 444
FINAL DRIVE . 456
TRAVEL PPC VALVE 458
CENTER SWIVEL JOINT . 463
UNDERCARRIAGE AND FRAME . 465
LAYOUT DRAWING OF UNDERCARRIAGE . 465
SPECIFICATIONS OF UNDERCARRIAGE . 466
WORK EQUIPMENT 467
STRUCTURE OF WORK EQUIPMENT . 467
FUNCTION OF WORK EQUIPMENT 468
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 469
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 469
BUCKET CLEARANCE ADJUSTMENT SHIM 470
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 470
CAB AND ITS ATTACHMENTS . 471
ROPS CAB 471
STRUCTURE OF ROPS CAB . 471
FUNCTION OF ROPS CAB 471
CAB MOUNT . 472
STRUCTURE OF CAB MOUNT 472
FUNCTION OF CAB MOUNT . 472
CAB TIPPING STOPPER . 473
STRUCTURE OF CAB TIPPING STOPPER 473
FUNCTION OF CAB TIPPING STOPPER . 473
20 STANDARD VALUE TABLE . 475
CONTENTS 476
ABBREVIATION LIST . 477
STANDARD VALUE TABLE FOR ENGINE . 483
STANDARD VALUE TABLE FOR ENGINE: PC240LC-11 . 483
STANDARD VALUE TABLE FOR MACHINE 487
STANDARD VALUE TABLE FOR MACHINE: PC240LC-11 487
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 500
STANDARD VALUE TABLE FOR ELECTRICAL . 504
STANDARD VALUE TABLE FOR ELECTRICAL . 504
30 TESTING AND ADJUSTING 515
CONTENTS 516
ABBREVIATION LIST . 519
RELATED INFORMATION ON TESTING AND ADJUSTING 525
TOOLS FOR TESTING AND ADJUSTING . 525
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 532
ENGINE AND COOLING SYSTEM . 534
TEST ENGINE SPEED . 534
METHOD FOR TESTING ENGINE SPEED . 534
TEST BOOST PRESSURE . 537
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 537
METHOD FOR TESTING BOOST PRESSURE . 538
TEST EXHAUST GAS COLOR 539
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 539
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 540
TEST MASS AIR FLOW AND TEMPERATURE SENSOR . 542
TEST MASS AIR FLOW AND TEMPERATURE SENSOR . 542
TEST AND ADJUST VALVE CLEARANCE . 544
METHOD FOR TESTING VALVE CLEARANCE 544
METHOD FOR ADJUSTING VALVE CLEARANCE 545
TEST COMPRESSION PRESSURE . 547
METHOD FOR TESTING COMPRESSION PRESSURE . 547
TEST BLOWBY PRESSURE 552
METHOD FOR TESTING BLOWBY PRESSURE 552
TEST ENGINE OIL PRESSURE 554
METHOD FOR TESTING ENGINE OIL PRESSURE 554
TEST EGR VALVE AND VGT OIL PRESSURE . 555
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 555
TEST FUEL PRESSURE 557
METHOD FOR TESTING FUEL PRESSURE 558
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 563
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 564
BLEEDING AIR FROM FUEL SYSTEM . 570
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 570
TEST FUEL CIRCUIT FOR LEAKAGE . 571
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 571
HANDLE CYLINDER CUT-OUT MODE OPERATION 573
HANDLE NO-INJECTION CRANKING OPERATION 574
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 575
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 575
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 575
TEST FAN BELT AND ALTERNATOR BELT . 577
METHOD FOR TESTING FAN BELT AND ALTERNATOR BELT . 577
TEST AUTO-TENSIONER . 578
METHOD FOR TESTING AUTO-TENSIONER . 578
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 579
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 579
TEST SCR RELATED FUNCTIONS 580
TEST AdBlue/DEF PUMP RAISED PRESSURE 583
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 586
TEST AdBlue/DEF LINE HEATER RELAY 1 . 590
TEST AdBlue/DEF LINE HEATER RELAY 2 . 593
TEST AdBlue/DEF PUMP HEATER RELAY . 595
TEST AdBlue/DEF TANK HEATER VALVE . 598
TEST DENITRATION EFFICIENCY OF SCR 601
CLEAN AdBlue/DEF TANK . 605
METHOD FOR CLEANING AdBlue/DEF TANK . 605
CLEAN AdBlue/DEF PUMP . 609
METHOD FOR CLEAN AdBlue/DEF PUMP 609
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 616
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 616
POWER TRAIN . 618
TEST SWING CIRCLE BEARING CLEARANCE . 618
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 618
UNDERCARRIAGE AND FRAME . 619
TEST AND ADJUST TRACK TENSION . 619
METHOD FOR TESTING TRACK TENSION 619
METHOD FOR ADJUSTING TRACK TENSION 619
HYDRAULIC SYSTEM 621
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 621
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 621
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 622
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 623
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 629
TEST OIL PRESSURE OF CONTROL CIRCUIT 632
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 632
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 634
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 634
TEST PC-EPC VALVE OUTLET PRESSURE . 635
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 636
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 638
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 638
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 639
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 642
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 643
METHOD FOR ADJUSTING LS VALVE . 644
TEST OUTLET PRESSURE OF SOLENOID VALVE 645
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 645
OPERATING CONDITION OF SOLENOID VALVE . 646
TEST PPC VALVE OUTLET PRESSURE 649
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 649
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 651
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 651
TEST PUMP SWASH PLATE SENSOR 652
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 652
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 653
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 653
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 653
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 654
TEST OIL LEAKAGE 655
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 655
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 655
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 656
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 657
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 657
BLEED AIR FROM HYDRAULIC CIRCUIT 658
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 660
CAB AND ITS ATTACHMENTS . 662
TEST CAB TIPPING STOPPER 662
METHOD FOR TESTING CAB TIPPING STOPPER 662
METHOD FOR ADJUSTING MIRRORS 663
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 663
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 664
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 665
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 666
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 667
ELECTRICAL SYSTEM . 669
SET AND OPERATE MACHINE MONITOR . 669
OPERATOR MODE . 672
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 673
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 673
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 674
CHECKING FUNCTION OF SERVICE METER 674
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 674
SERVICE MODE 677
SERVICE MODE 677
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 679
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 685
ABNORMALITY RECORD MENU . 696
METHOD FOR CONFIRMING MAINTENANCE RECORD 700
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 701
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 705
DEFAULT MENU 706
DIAGNOSTIC TESTS MENU . 717
ADJUSTMENT MENU . 726
METHOD FOR PERFORMING NO-INJECTION CRANKING . 743
KOMTRAX SETTINGS MENU . 744
METHOD FOR DISPLAYING SERVICE MESSAGE . 747
METHOD FOR STARTING UP KOMTRAX SYSTEM . 749
ADJUST REARVIEW CAMERA ANGLE 754
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 754
ADJUST KomVision CAMERA ANGLE . 757
ADJUST KomVision RELATED ITEMS 759
SETTING OF KomVision (MAIN SETTING) . 759
SETTING OF KomVision (CAMERA SETTING) . 761
SETTING OF KomVision (CAMERA CALIBRATION) . 763
KomVision screen – Check 12 m visibility 776
SET REGION OF Bluetooth(R) COMPATIBLE RADIO . 779
SET REGION OF Bluetooth(R) COMPATIBLE RADIO . 779
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 781
HANDLE BATTERY DISCONNECT SWITCH 782
TEST DIODES . 783
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 783
METHOD FOR TESTING DIODE USING ANALOG TESTER 783
Pm CLINIC . 784
Pm CLINIC SERVICE . 784
Pm CLINIC CHECK SHEET . 785
40 TROUBLESHOOTING 797
CONTENTS 798
ABBREVIATION LIST . 809
RELATED INFORMATION ON TROUBLESHOOTING 815
GENERAL TROUBLESHOOTING POINTS 815
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 816
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 831
CHECKS BEFORE TROUBLESHOOTING . 833
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 835
WALK-AROUND CHECK . 835
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 837
CHECK FUEL LEVEL AND TYPE . 837
CHECK IMPURE INGREDIENT IN FUEL . 837
CHECK FUEL PREFILTER 838
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 838
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 839
CHECK MAIN FILTER . 840
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 842
CHECK COOLANT LEVEL (RESERVOIR TANK) 843
CHECK CLOGGING OF AIR CLEANER . 843
OUTER ELEMENT – CLEAN . 844
ELEMENTS – REPLACE 846
CHECK HYDRAULIC OIL LEVEL . 847
CHECK HYDRAULIC OIL STRAINER 848
CHECK HYDRAULIC FILTER 849
CHECK OIL LEVEL IN SWING MACHINERY CASE . 850
CHECK OIL LEVEL IN DAMPER CASE 851
CHECK OIL LEVEL IN FINAL DRIVE CASE . 851
BLEED AIR FROM FUEL SYSTEM 852
BLEED AIR FROM HYDRAULIC SYSTEM . 852
ELECTRICAL EQUIPMENT – CHECK METHOD . 852
PREPARATION TO TROUBLESHOOT ELECTRICAL SYSTEM . 860
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 870
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 873
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 877
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 879
CONNECTOR LIST AND LAYOUT . 882
CONNECTOR CONTACT IDENTIFICATION 895
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 935
FUSE LOCATION TABLE . 941
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 944
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 948
FAILURE CODE TABLE 950
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 969
FAILURE CODE [879AKA] . 969
FAILURE CODE [879AKB] . 970
FAILURE CODE [879BKA] . 971
FAILURE CODE [879BKB] . 973
FAILURE CODE [879CKA] . 975
FAILURE CODE [879CKB] . 976
FAILURE CODE [879DKZ] . 977
FAILURE CODE [879EMC] . 979
FAILURE CODE [879FMC] . 980
FAILURE CODE [879GKX] . 981
FAILURE CODE [989L00] . 983
FAILURE CODE [989M00] . 984
FAILURE CODE [989N00] . 985
FAILURE CODE [A1U0N3] . 986
FAILURE CODE [A1U0N4] . 988
FAILURE CODE [A900FR] . 990
FAILURE CODE [A900N6] . 991
FAILURE CODE [A900NY] . 992
FAILURE CODE [AA10NX] . 993
FAILURE CODE [AB00KE] . 995
FAILURE CODE [AQ10N3] . 998
FAILURE CODE [AS00N3] .1000
FAILURE CODE [AS00R2] .1002
FAILURE CODE [AS00R3] .1003
FAILURE CODE [AS00R4] .1004
FAILURE CODE [AS00R5] .1005
FAILURE CODE [AS00R6] .1006
FAILURE CODE [AS00ZK] .1007
FAILURE CODE [AS10KM] .1008
FAILURE CODE [AS10NR] .1009
FAILURE CODE [AS10NT] .1010
FAILURE CODE [B@BAZG] .1011
FAILURE CODE [B@BAZK] .1012
FAILURE CODE [B@BCNS] .1014
FAILURE CODE [B@BCQA] .1015
FAILURE CODE [B@BCZK] .1017
FAILURE CODE [B@HANS] .1019
FAILURE CODE [CA115] 1020
FAILURE CODE [CA122] 1021
FAILURE CODE [CA123] 1023
FAILURE CODE [CA131] 1025
FAILURE CODE [CA132] 1027
FAILURE CODE [CA144] 1029
FAILURE CODE [CA145] 1031
FAILURE CODE [CA153] 1033
FAILURE CODE [CA154] 1036
FAILURE CODE [CA187] 1038
FAILURE CODE [CA221] 1040
FAILURE CODE [CA222] 1042
FAILURE CODE [CA227] 1044
FAILURE CODE [CA234] 1045
FAILURE CODE [CA238] 1046
FAILURE CODE [CA239] 1048
FAILURE CODE [CA249] 1050
FAILURE CODE [CA256] 1052
FAILURE CODE [CA271] 1054
FAILURE CODE [CA272] 1056
FAILURE CODE [CA322] 1058
FAILURE CODE [CA323] 1060
FAILURE CODE [CA324] 1062
FAILURE CODE [CA325] 1064
FAILURE CODE [CA331] 1066
FAILURE CODE [CA332] 1068
FAILURE CODE [CA343] 1070
FAILURE CODE [CA351] 1071
FAILURE CODE [CA352] 1072
FAILURE CODE [CA356] 1075
FAILURE CODE [CA357] 1077
FAILURE CODE [CA386] 1079
FAILURE CODE [CA428] 1080
FAILURE CODE [CA429] 1082
FAILURE CODE [CA435] 1084
FAILURE CODE [CA441] 1086
FAILURE CODE [CA442] 1088
FAILURE CODE [CA449] 1089
FAILURE CODE [CA451] 1090
FAILURE CODE [CA452] 1092
FAILURE CODE [CA488] 1094
FAILURE CODE [CA515] 1095
FAILURE CODE [CA516] 1097
FAILURE CODE [CA553] 1099
FAILURE CODE [CA555] 1100
FAILURE CODE [CA556] 1101
FAILURE CODE [CA559] 1102
FAILURE CODE [CA595] 1105
FAILURE CODE [CA687] 1106
FAILURE CODE [CA689] 1108
FAILURE CODE [CA691] 1111
FAILURE CODE [CA692] 1113
FAILURE CODE [CA697] 1115
FAILURE CODE [CA698] 1116
FAILURE CODE [CA731] 1117
FAILURE CODE [CA778] 1119
FAILURE CODE [CA1117] .1124
FAILURE CODE [CA1664] .1125
FAILURE CODE [CA1669] .1127
FAILURE CODE [CA1673] .1128
FAILURE CODE [CA1677] .1129
FAILURE CODE [CA1678] .1130
FAILURE CODE [CA1682] .1131
FAILURE CODE [CA1683] .1134
FAILURE CODE [CA1684] .1136
FAILURE CODE [CA1686] .1138
FAILURE CODE [CA1691] .1139
FAILURE CODE [CA1694] .1142
FAILURE CODE [CA1695] .1145
FAILURE CODE [CA1696] .1146
FAILURE CODE [CA1712] .1148
FAILURE CODE [CA1713] .1151
FAILURE CODE [CA1714] .1153
FAILURE CODE [CA1715] .1154
FAILURE CODE [CA1776] .1155
FAILURE CODE [CA1777] .1158
FAILURE CODE [CA1843] .1161
FAILURE CODE [CA1844] .1163
FAILURE CODE [CA1879] .1166
FAILURE CODE [CA1881] .1168
FAILURE CODE [CA1883] .1170
FAILURE CODE [CA1885] .1173
FAILURE CODE [CA1887] .1175
FAILURE CODE [CA1921] .1177
FAILURE CODE [CA1922] .1180
FAILURE CODE [CA1942] .1185
FAILURE CODE [CA1993] .1186
FAILURE CODE [CA2185] .1189
FAILURE CODE [CA2186] .1190
FAILURE CODE [CA2249] .1192
FAILURE CODE [CA2271] .1193
FAILURE CODE [CA2272] .1196
FAILURE CODE [CA2288] .1199
FAILURE CODE [CA2311] .1200
FAILURE CODE [CA2349] .1201
FAILURE CODE [CA2353] .1204
FAILURE CODE [CA2357] .1206
FAILURE CODE [CA2381] .1207
FAILURE CODE [CA2382] .1210
FAILURE CODE [CA2383] .1213
FAILURE CODE [CA2386] .1216
FAILURE CODE [CA2387] .1218
TROUBLESHOOTING FLOWCHART .1222
FAILURE CODE [CA2555] .1223
FAILURE CODE [CA2556] .1226
FAILURE CODE [CA2637] .1229
FAILURE CODE [CA2639] .1231
FAILURE CODE [CA2771] .1234
FAILURE CODE [CA2777] .1240
FAILURE CODE [CA2976] .1243
FAILURE CODE [CA3133] .1245
FAILURE CODE [CA3134] .1248
FAILURE CODE [CA3135] .1250
FAILURE CODE [CA3142] .1253
FAILURE CODE [CA3143] .1254
FAILURE CODE [CA3144] .1255
FAILURE CODE [CA3146] .1257
FAILURE CODE [CA3147] .1258
FAILURE CODE [CA3148] .1259
FAILURE CODE [CA3151] .1261
FAILURE CODE [CA3165] .1267
FAILURE CODE [CA3229] .1269
FAILURE CODE [CA3231] .1271
FAILURE CODE [CA3232] .1273
FAILURE CODE [CA3235] .1277
FAILURE CODE [CA3239] .1279
FAILURE CODE [CA3241] .1282
FAILURE CODE [CA3242] .1285
FAILURE CODE [CA3251] .1288
FAILURE CODE [CA3253] .1290
FAILURE CODE [CA3254] .1293
FAILURE CODE [CA3255] .1296
FAILURE CODE [CA3256] .1300
FAILURE CODE [CA3311] .1302
FAILURE CODE [CA3312] .1304
FAILURE CODE [CA3313] .1307
FAILURE CODE [CA3314] .1308
FAILURE CODE [CA3315] .1309
FAILURE CODE [CA3316] .1311
FAILURE CODE [CA3317] .1312
FAILURE CODE [CA3318] .1313
FAILURE CODE [CA3319] .1315
FAILURE CODE [CA3321] .1316
FAILURE CODE [CA3322] .1318
FAILURE CODE [CA3419] .1320
FAILURE CODE [CA3421] .1322
FAILURE CODE [CA3497] .1324
FAILURE CODE [CA3498] .1325
FAILURE CODE [CA3543] .1326
FAILURE CODE [CA3545] .1333
FAILURE CODE [CA3547] .1335
FAILURE CODE [CA3558] .1336
FAILURE CODE [CA3559] .1338
FAILURE CODE [CA3562] .1340
FAILURE CODE [CA3563] .1342
FAILURE CODE [CA3567] .1345
FAILURE CODE [CA3568] .1348
FAILURE CODE [CA3571] .1352
FAILURE CODE [CA3572] .1354
FAILURE CODE [CA3574] .1356
FAILURE CODE [CA3575] .1358
FAILURE CODE [CA3577] .1360
FAILURE CODE [CA3578] .1362
FAILURE CODE [CA3582] .1364
FAILURE CODE [CA3583] .1370
FAILURE CODE [CA3596] .1372
FAILURE CODE [CA3649] .1374
FAILURE CODE [CA3681] .1376
FAILURE CODE [CA3682] .1381
FAILURE CODE [CA3713] .1387
FAILURE CODE [CA3717] .1390
FAILURE CODE [CA3718] .1391
FAILURE CODE [CA3725] .1392
FAILURE CODE [CA3741] .1395
FAILURE CODE [CA3748] .1396
FAILURE CODE [CA3751] .1398
FAILURE CODE [CA3755] .1400
FAILURE CODE [CA3866] .1402
FAILURE CODE [CA3867] .1406
FAILURE CODE [CA3868] .1409
FAILURE CODE [CA3899] .1413
FAILURE CODE [CA3911] .1415
FAILURE CODE [CA3912] .1419
FAILURE CODE [CA3932] .1421
FAILURE CODE [CA3933] .1423
FAILURE CODE [CA3934] .1425
FAILURE CODE [CA3935] .1428
FAILURE CODE [CA3936] .1430
FAILURE CODE [CA4151] .1432
FAILURE CODE [CA4152] .1436
FAILURE CODE [CA4155] .1440
FAILURE CODE [CA4156] .1442
FAILURE CODE [CA4157] .1445
FAILURE CODE [CA4158] .1447
FAILURE CODE [CA4159] .1448
FAILURE CODE [CA4161] .1449
FAILURE CODE [CA4162] .1452
FAILURE CODE [CA4163] .1455
FAILURE CODE [CA4164] .1456
FAILURE CODE [CA4165] .1458
FAILURE CODE [CA4166] .1460
FAILURE CODE [CA4168] .1461
FAILURE CODE [CA4169] .1464
FAILURE CODE [CA4171] .1466
FAILURE CODE [CA4249] .1469
FAILURE CODE [CA4251] .1471
FAILURE CODE [CA4259] .1473
FAILURE CODE [CA4261] .1476
FAILURE CODE [CA4277] .1479
FAILURE CODE [CA4281] .1483
FAILURE CODE [CA4459] .1486
FAILURE CODE [CA4461] .1489
FAILURE CODE [CA4658] .1492
FAILURE CODE [CA4731] .1496
FAILURE CODE [CA4732] .1497
FAILURE CODE [CA4739] .1498
FAILURE CODE [CA4768] .1499
FAILURE CODE [CA4769] .1501
FAILURE CODE [CA4842] .1504
FAILURE CODE [CA4952] .1508
FAILURE CODE [CA5115] .1510
FAILURE CODE [CA5179] .1513
FAILURE CODE [CA5181] .1515
FAILURE CODE [CA5383] .1517
FAILURE CODE [D110KB] .1519
FAILURE CODE [D19JKZ] .1521
FAILURE CODE [D811MC] .1524
FAILURE CODE [D862KA] .1525
FAILURE CODE [D8ALKA] .1527
FAILURE CODE [D8ALKB] .1530
FAILURE CODE [D8AQKR] .1532
FAILURE CODE [D8G1KT] .1539
FAILURE CODE [D8G6KT] .1540
FAILURE CODE [DA20MC] .1541
FAILURE CODE [DA22KK] .1542
FAILURE CODE [DA25KP] .1545
FAILURE CODE [DA26KP] .1548
FAILURE CODE [DA29KQ] .1551
FAILURE CODE [DA2LKA] .1553
FAILURE CODE [DA2LKB] .1556
FAILURE CODE [DA2QKR] .1558
FAILURE CODE [DA2RKR] .1567
FAILURE CODE [DAF0MB] .1568
FAILURE CODE [DAF0MC] .1569
FAILURE CODE [DAF8KB] .1570
FAILURE CODE [DAF9KQ] .1572
FAILURE CODE [DAFGMC] .1573
FAILURE CODE [DAFLKA] .1574
FAILURE CODE [DAFLKB] .1577
FAILURE CODE [DAFQKR] .1579
FAILURE CODE [DAZ9KQ] .1587
FAILURE CODE [DAZQKR] .1588
FAILURE CODE [DB2QKR] .1595
FAILURE CODE [DB2RKR] .1603
FAILURE CODE [DBP0KM] .1608
FAILURE CODE [DBP0KT] .1609
FAILURE CODE [DBP5KB] .1610
FAILURE CODE [DBP5KY] .1613
FAILURE CODE [DBPQKR] .1616
FAILURE CODE [DDNRKA] .1624
FAILURE CODE [DDNRKY] .1626
FAILURE CODE [DDNS00] .1628
FAILURE CODE [DGH2KA] .1630
FAILURE CODE [DGH2KB] .1632
FAILURE CODE [DHA4KA] .1634
FAILURE CODE [DHAAMA] .1636
FAILURE CODE [DHACMA] .1638
FAILURE CODE [DHPAMA] .1640
FAILURE CODE [DHPBMA] .1643
FAILURE CODE [DHS3MA] .1646
FAILURE CODE [DHS4MA] .1649
FAILURE CODE [DHS8MA] .1652
FAILURE CODE [DHS9MA] .1655
FAILURE CODE [DHSAMA] .1658
FAILURE CODE [DHSBMA] .1661
FAILURE CODE [DHSCMA] .1664
FAILURE CODE [DHSDMA] .1667
FAILURE CODE [DHSFMA] .1670
FAILURE CODE [DHSGMA] .1673
FAILURE CODE [DHSHMA] .1676
FAILURE CODE [DHSJMA] .1679
FAILURE CODE [DHZAMA] .1682
FAILURE CODE [DHZCL8] .1686
FAILURE CODE [DKR0MA] .1687
FAILURE CODE [DKR1MA] .1690
FAILURE CODE [DKULKA] .1693
FAILURE CODE [DKULKB] .1695
FAILURE CODE [DKULKY] .1697
FAILURE CODE [DR10KA] .1699
FAILURE CODE [DR12KA] .1702
FAILURE CODE [DR20KA] .1704
FAILURE CODE [DR21KX] .1706
FAILURE CODE [DR30KA] .1708
FAILURE CODE [DR31KX] .1710
FAILURE CODE [DR40KA] .1712
FAILURE CODE [DUMBKA] .1714
FAILURE CODE [DUMBKB] .1717
FAILURE CODE [DV20KB] .1719
FAILURE CODE [DW43KA] .1721
FAILURE CODE [DW43KB] .1723
FAILURE CODE [DW43KY] .1725
FAILURE CODE [DW45KA] .1727
FAILURE CODE [DW45KB] .1730
FAILURE CODE [DW45KY] .1733
FAILURE CODE [DW4CKY] .1735
FAILURE CODE [DW91KA] .1737
FAILURE CODE [DW91KB] .1739
FAILURE CODE [DW91KY] .1741
FAILURE CODE [DWA2KA] .1743
FAILURE CODE [DWA2KB] .1745
FAILURE CODE [DWA2KY] .1747
FAILURE CODE [DWK0KA] .1749
FAILURE CODE [DWK0KB] .1751
FAILURE CODE [DWK0KY] .1753
FAILURE CODE [DWK2KA] .1755
FAILURE CODE [DWK2KB] .1757
FAILURE CODE [DWK2KY] .1759
FAILURE CODE [DWK8KA] .1761
FAILURE CODE [DWK8KB] .1763
FAILURE CODE [DWK8KY] .1765
FAILURE CODE [DWPUKA] .1767
FAILURE CODE [DWPUKB] .1769
FAILURE CODE [DWPUKY] .1771
FAILURE CODE [DXA8KA] .1773
FAILURE CODE [DXA8KB] .1775
FAILURE CODE [DXA9KA] .1777
FAILURE CODE [DXA9KB] .1779
FAILURE CODE [DXE0KA] .1781
FAILURE CODE [DXE0KB] .1782
FAILURE CODE [DXE4KA] .1784
FAILURE CODE [DXE4KB] .1786
FAILURE CODE [DXE4KY] .1788
FAILURE CODE [DXE5KA] .1790
FAILURE CODE [DXE5KB] .1792
FAILURE CODE [DXE6KA] .1794
FAILURE CODE [DXE6KB] .1796
FAILURE CODE [DXE7KA] .1798
FAILURE CODE [DXE7KB] .1800
FAILURE CODE [DXE7KY] .1802
FAILURE CODE [DXE8KA] .1804
FAILURE CODE [DXE8KB] .1806
FAILURE CODE [DXE8KY] .1808
FAILURE CODE [DXE9KA] .1810
FAILURE CODE [DXE9KB] .1812
FAILURE CODE [DXE9KY] .1814
FAILURE CODE [DXEAKA] .1816
FAILURE CODE [DXEAKB] .1818
FAILURE CODE [DXEAKY] .1820
FAILURE CODE [DXEKKA] .1822
FAILURE CODE [DXEKKB] .1824
FAILURE CODE [DXEKKY] .1826
FAILURE CODE [DXELKA] .1828
FAILURE CODE [DXELKB] .1830
FAILURE CODE [DXELKY] .1832
FAILURE CODE [DY20KA] .1834
FAILURE CODE [DY20MA] .1836
FAILURE CODE [DY2CKB] .1838
FAILURE CODE [DY2DKB] .1841
FAILURE CODE [DY2EKB] .1843
FAILURE CODE [F311KA] .1845
FAILURE CODE [F311KB] .1847
FAILURE CODE [F312KA] .1849
FAILURE CODE [F312KB] .1851
FAILURE CODE [F313KA] .1853
FAILURE CODE [F313KB] .1855
FAILURE CODE [F314KA] .1858
FAILURE CODE [F314KB] .1860
FAILURE CODE [F315KB] .1862
FAILURE CODE [F315KY] .1864
FAILURE CODE [F316KB] .1866
FAILURE CODE [F316KY] .1868
FAILURE CODE [F318KB] .1870
FAILURE CODE [F318KY] .1873
FAILURE CODE [F31AKB] .1875
FAILURE CODE [F31AKY] .1877
FAILURE CODE [F31BKB] .1879
FAILURE CODE [F31BKY] .1881
FAILURE CODE [F31CKB] .1883
FAILURE CODE [F31CKY] .1885
FAILURE CODE [F31DKB] .1887
FAILURE CODE [F31DKY] .1889
FAILURE CODE [F31EKB] .1891
FAILURE CODE [F31EKY] .1893
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1895
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1895
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1901
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1904
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1906
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1908
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1911
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1912
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1913
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1914
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1915
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1916
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1917
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1918
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1919
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1920
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1921
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1922
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1924
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1925
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1926
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1927
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1929
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1930
E-24 FUNCTION SWITCH DOES NOT OPERATE .1931
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1932
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1933
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1934
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1935
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1936
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1937
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1938
E-32 ALARM BUZZER CANNOT BE CANCELED 1940
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1941
E-34 SERVICE MODE CANNOT BE SELECTED 1942
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1943
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1946
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1948
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1951
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1953
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1956
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1957
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1959
E-43 HORN DOES NOT SOUND 1960
E-44 HORN DOES NOT STOP SOUNDING 1963
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1965
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1966
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1968
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1969
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1970
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1971
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1972
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1973
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1974
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1975
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1976
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1977
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1979
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1980
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1981
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1981
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1982
FAILURE MODE AND CAUSE TABLE 1984
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1993
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1994
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1997
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1998
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1999
H-6 SPEED OR POWER OF BOOM IS LOW .2001
H-7 ARM SPEED OR POWER IS LOW .2005
H-8 BUCKET SPEED OR POWER IS LOW 2010
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 2013
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .2014
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 2016
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .2018
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .2019
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 2020
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .2021
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .2022
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .2023
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 2024
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 2025
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 2026
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .2027
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .2029
H-23 TRAVEL SPEED IS LOW 2032
H-24 ONE OF TRACKS DOES NOT RUN .2034
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2035
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 2036
H-27 SWINGS ONLY IN ONE DIRECTION .2037
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .2038
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 2039
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 2040
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 2041
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .2042
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .2043
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .2044
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2045
TROUBLESHOOTING OF ENGINE (S-MODE) 2046
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .2046
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2047
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2048
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2049
S-4 ENGINE STARTABILITY IS POOR .2051
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2053
S-6 ENGINE STOPS DURING OPERATION .2055
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2057
S-8 ENGINE LACKS POWER 2058
S-9 KDPF GETS CLOGGED IN A SHORT TIME .2060
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2062
S-11 OIL BECOMES CONTAMINATED QUICKLY .2063
S-12 FUEL CONSUMPTION IS EXCESSIVE 2064
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2065
S-14 OIL PRESSURE DROPS .2066
S-15 FUEL MIXES INTO ENGINE OIL .2068
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2069
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2070
S-18 UNUSUAL NOISE IS HEARD .2071
S-19 VIBRATION IS EXCESSIVE .2072
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .2073
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2074
S-22 ACTIVE REGENERATION TAKES TIME .2076
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2077
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2078
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2080
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2081
50 DISASSEMBLY AND ASSEMBLY .2083
CONTENTS 2084
ABBREVIATION LIST .2089
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2095
HOW TO READ THIS MANUAL .2095
COATING MATERIALS LIST 2097
SPECIAL TOOLS LIST 2102
SKETCHES OF SPECIAL TOOLS .2114
ENGINE AND COOLING SYSTEM .2120
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2120
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2120
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2123
REMOVE AND INSTALL INJECTOR ASSEMBLY 2127
METHOD FOR REMOVING INJECTOR ASSEMBLY .2127
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2132
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2140
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2141
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2150
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2166
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2166
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2167
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2170
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2170
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2173
REMOVE AND INSTALL STARTER ASSEMBLY .2178
METHOD FOR REMOVING STARTER ASSEMBLY 2178
METHOD FOR INSTALLING STARTER ASSEMBLY 2180
REMOVE AND INSTALL ALTERNATOR BELT 2182
METHOD FOR REMOVING ALTERNATOR BELT .2182
METHOD FOR INSTALLING ALTERNATOR BELT .2184
REMOVE AND INSTALL RADIATOR ASSEMBLY 2186
METHOD FOR REMOVING RADIATOR ASSEMBLY .2186
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2188
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2190
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2190
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2193
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2196
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2196
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2197
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2199
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2200
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2208
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2219
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2219
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2222
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2226
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2226
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2227
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2230
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2230
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2231
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2232
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2232
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2234
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2240
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2240
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2244
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2250
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2250
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2255
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2261
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2261
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2266
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2272
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2272
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2272
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2279
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2279
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2279
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2281
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2281
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2283
REMOVE AND INSTALL KDPF ASSEMBLY 2286
METHOD FOR REMOVING KDPF ASSEMBLY .2286
METHOD FOR INSTALLING KDPF ASSEMBLY .2288
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2290
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2291
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2294
REMOVE AND INSTALL SCR ASSEMBLY .2299
METHOD FOR REMOVING SCR ASSEMBLY 2299
METHOD FOR INSTALLING SCR ASSEMBLY 2301
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2303
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2303
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2309
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2315
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2315
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2321
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 2328
REMOVE BELLOWS PIPE ASSEMBLY 2328
INSTALL BELLOWS PIPE ASSEMBLY .2330
REMOVE AND INSTALL KCCV ASSEMBLY 2334
METHOD FOR REMOVING KCCV ASSEMBLY .2334
METHOD FOR INSTALLING KCCV ASSEMBLY .2337
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2341
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2341
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2346
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2351
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2351
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2353
REMOVE AND INSTALL AdBlue/DEF PUMP 2355
METHOD FOR REMOVING AdBlue/DEF PUMP .2355
METHOD FOR INSTALLING AdBlue/DEF PUMP .2357
REMOVE AND INSTALL AdBlue/DEF HOSE 2360
METHOD FOR REMOVING AdBlue/DEF HOSE .2360
METHOD FOR INSTALLING AdBlue/DEF HOSE .2368
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2374
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2374
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2375
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2377
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2377
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2379
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2382
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2382
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2383
POWER TRAIN .2384
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2384
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2384
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2385
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2387
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2387
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2391
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2400
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2400
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2403
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2406
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2406
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2410
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2417
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2417
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2417
UNDERCARRIAGE AND FRAME .2419
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2419
METHOD FOR SEPARATING TRACK ASSEMBLY 2419
METHOD FOR INSTALLING TRACK ASSEMBLY 2421
REMOVE AND INSTALL SPROCKET .2424
METHOD FOR REMOVING SPROCKET 2424
METHOD FOR INSTALLING SPROCKET 2424
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2426
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2426
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2427
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2428
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2428
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2429
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2433
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2434
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2435
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2436
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2437
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2438
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2440
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2440
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2442
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2444
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2444
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2446
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2449
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2449
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2452
HYDRAULIC SYSTEM 2456
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2456
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2456
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2458
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2461
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2462
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2463
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2464
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2464
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2467
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2471
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2471
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2474
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2478
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2478
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2485
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2493
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2493
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2495
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2499
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2499
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2499
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2501
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2501
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2502
WORK EQUIPMENT 2504
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2504
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2504
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2508
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM 2514
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR BOOM .2514
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR BOOM .2516
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM .2517
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR ARM 2517
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR ARM 2519
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY .2520
METHOD FOR DISASSEMBLING ANTI-DROP VALVE ASSEMBLY .2520
METHOD FOR ASSEMBLING ANTI-DROP VALVE ASSEMBLY 2520
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2521
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2521
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2524
CAB AND ITS ATTACHMENTS .2530
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2530
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2530
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2536
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2543
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2545
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2545
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2555
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2555
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2558
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2564
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2564
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2571
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2578
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2578
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2584
REMOVE AND INSTALL OPERATOR’S SEAT 2591
METHOD FOR REMOVING OPERATOR’S SEAT .2591
METHOD FOR INSTALLING OPERATOR’S SEAT .2593
REMOVE AND INSTALL SEAT BELT 2596
METHOD FOR REMOVING SEAT BELT .2596
METHOD FOR INSTALLING SEAT BELT .2597
REMOVE AND INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY 2598
REMOVE WORK EQUIPMENT CONTROL LEVER ASSEMBLY 2598
INSTALL WORK EQUIPMENT CONTROL LEVER ASSEMBLY .2604
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2613
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2613
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2618
ELECTRICAL SYSTEM .2627
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2627
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2627
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2629
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2630
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2630
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2634
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2639
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2639
METHOD FOR INSTALLING KomVision CONTROLLER 2640
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2641
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2641
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2644
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2647
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2647
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2648
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2649
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2649
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2650
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2651
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2651
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2652
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2654
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2654
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2656
REMOVE AND INSTALL KomVision CAMERA .2659
METHOD FOR REMOVING KomVision CAMERA 2659
METHOD FOR INSTALLING KomVision CAMERA 2660
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY .2662
METHOD FOR REMOVING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2662
METHOD FOR INSTALLING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2667
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 2672
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS .2672
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS .2680
REMOVE AND INSTALL COMMUNICATION TERMINAL .2689
METHOD FOR REMOVING COMMUNICATION TERMINAL 2689
METHOD FOR INSTALLING COMMUNICATION TERMINAL 2691
60 MAINTENANCE STANDARD .2695
CONTENTS 2696
ABBREVIATION LIST .2697
ENGINE AND COOLING SYSTEM .2703
MAINTENANCE STANDARD OF ENGINE MOUNT 2703
MAINTENANCE STANDARD OF COOLING SYSTEM 2704
POWER TRAIN .2705
MAINTENANCE STANDARD OF SWING CIRCLE 2705
MAINTENANCE STANDARD OF SWING MACHINERY .2706
MAINTENANCE STANDARD OF FINAL DRIVE .2708
MAINTENANCE STANDARD OF SPROCKET 2710
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2711
UNDERCARRIAGE AND FRAME .2713
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2713
MAINTENANCE STANDARD OF IDLER .2715
MAINTENANCE STANDARD OF TRACK ROLLER 2717
MAINTENANCE STANDARD OF CARRIER ROLLER 2718
MAINTENANCE STANDARD OF TRACK SHOE 2719
MAINTENANCE STANDARD OF TRIPLE SHOE .2722
MAINTENANCE STANDARD OF SWAMP SHOE 2723
MAINTENANCE STANDARD OF ROAD LINER 2724
HYDRAULIC SYSTEM 2725
MAINTENANCE STANDARD OF HYDRAULIC TANK 2725
MAINTENANCE STANDARD OF MAIN PUMP .2726
MAINTENANCE STANDARD OF LS-EPC VALVE 2727
MAINTENANCE STANDARD OF PC-EPC VALVE 2728
MAINTENANCE STANDARD OF SWING MOTOR .2729
MAINTENANCE STANDARD OF TRAVEL MOTOR 2732
MAINTENANCE STANDARD OF CONTROL VALVE .2735
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 2745
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM .2747
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2749
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2752
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2755
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2757
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE .2758
MAINTENANCE STANDARD OF SOLENOID VALVE 2760
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2761
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2762
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2763
WORK EQUIPMENT 2764
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2764
DIMENSION OF ARM 2769
DIMENSIONS OF BUCKET 2771
MAINTENANCE STANDARD OF BOOM CYLINDER .2773
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2774
MAINTENANCE STANDARD OF ARM CYLINDER 2775
MAINTENANCE STANDARD OF BUCKET CYLINDER .2776
80 APPENDIX .2777
CONTENTS 2778
ABBREVIATION LIST .2780
AIR CONDITIONER SYSTEM 2786
PRECAUTIONS FOR REFRIGERANT .2786
AIR CONDITIONER COMPONENT .2787
SPECIFICATIONS OF AIR CONDITIONER .2789
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2790
OUTLINE OF REFRIGERATION CYCLE 2791
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2793
AIR CONDITIONER UNIT 2793
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2793
FUNCTION OF AIR CONDITIONER UNIT 2795
COMPONENT PARTS OF AIR CONDITIONER UNIT .2797
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2798
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2798
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2798
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2798
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2799
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2799
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2799
FUNCTION OF DUAL PRESSURE SWITCH 2800
AIR CONDITIONER CONTROLLER 2801
STRUCTURE OF AIR CONDITIONER CONTROLLER .2801
COMPRESSOR 2802
STRUCTURE OF COMPRESSOR .2802
SPECIFICATIONS OF COMPRESSOR 2802
FUNCTION OF COMPRESSOR 2802
CONDENSER .2803
STRUCTURE OF CONDENSER 2803
SPECIFICATIONS OF CONDENSER .2803
FUNCTION OF CONDENSER .2803
SENSORS FOR AIR CONDITIONER SYSTEM 2805
STRUCTURE OF SUNLIGHT SENSOR 2805
FUNCTION OF SUNLIGHT SENSOR .2805
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2805
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2805
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2807
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2809
AIR CONDITIONER SYSTEM DIAGRAM 2811
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2812
FUNCTION OF AIR CONDITIONER CONTROLLER 2813
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2814
TESTING AIR LEAKAGE (DUCT) 2818
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2818
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2820
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2821
TEST VENT (MODE) CHANGEOVER .2822
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2822
TESTING FRESH/RECIRC AIR CHANGEOVER .2824
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2824
TEST SUNLIGHT SENSOR 2825
METHOD FOR TESTING SUNLIGHT SENSOR 2825
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2826
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2826
TEST RELAYS .2827
METHOD FOR TESTING RELAYS .2827
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2828
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2829
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2832
FAILURE CODE [879AKA] .2834
FAILURE CODE [879AKB] .2835
FAILURE CODE [879BKA] .2836
FAILURE CODE [879BKB] .2838
FAILURE CODE [879CKA] .2840
FAILURE CODE [879CKB] .2841
FAILURE CODE [879DKZ] .2842
FAILURE CODE [879EMC] .2844
FAILURE CODE [879FMC] .2845
FAILURE CODE [879GKX] .2846
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2848
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2850
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2853
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2855
TROUBLESHOOTING USING GAUGE PRESSURE 2857
CONNECTION OF SERVICE TOOL 2860
METHOD FOR CONNECTING SERVICE TOOL 2860
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2862
HANDLE COMPRESSOR OIL .2864
METHOD FOR REPLACING DESICCANT 2866
90 CIRCUIT DIAGRAMS .2869
CONTENTS 2870
ABBREVIATION LIST .2871
HYDRAULIC CIRCUIT DIAGRAM .2877
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2877
HYDRAULIC CIRCUIT DIAGRAM .2881
ELECTRICAL CIRCUIT DIAGRAM 2883
ELECTRICAL CIRCUIT DIAGRAM (1/10) .2885
ELECTRICAL CIRCUIT DIAGRAM (2/10) .2887
ELECTRICAL CIRCUIT DIAGRAM (3/10) .2889
ELECTRICAL CIRCUIT DIAGRAM (4/10) .2891
ELECTRICAL CIRCUIT DIAGRAM (5/10) .2893
ELECTRICAL CIRCUIT DIAGRAM (6/10) .2895
ELECTRICAL CIRCUIT DIAGRAM (7/10) .2897
ELECTRICAL CIRCUIT DIAGRAM (8/10) .2899
ELECTRICAL CIRCUIT DIAGRAM (9/10) .2901
ELECTRICAL CIRCUIT DIAGRAM (10/10) 2903
INDEX 2905

DESCRIPTION:

Komatsu PC240LC-11 Hydraulic Excavator Shop Manual SEN06737-C8  – PDF DOWNLOAD

• SERIAL NUMBERS C70001 and up

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

G.B 29/12/24