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

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Komatsu PC240LC-11,PC240NLC-11Hydraulic Excavator Shop Manual UENBM00330 – PDF DOWNLOAD

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Komatsu PC240LC-11,PC240NLC-11Hydraulic Excavator Shop Manual UENBM00330 – PDF DOWNLOAD

Language : English
Pages : 2668
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC240LC-11,PC240NLC-11Hydraulic Excavator Shop Manual UENBM00330 – PDF DOWNLOAD

SERIAL NUMBERS

• 95001 and up
• K70001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 21
FOREWORD, SAFETY, BASIC INFORMATION . 26
HOW TO READ THE SHOP MANUAL . 26
SAFETY NOTICE FOR OPERATION . 28
PRECAUTIONS TO PREVENT FIRE . 36
ACTIONS IF FIRE OCCURS 38
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 39
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 40
PRECAUTIONS FOR DEF . 41
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 41
PRECAUTIONS FOR ADDING 41
PRECAUTIONS FOR STORING . 41
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 41
THE OTHER PRECAUTIONS . 41
STORE AdBlue/DEF 42
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 43
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 45
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 51
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 53
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 54
PRACTICAL USE OF KOMTRAX 55
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 56
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 56
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 57
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 58
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 60
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 64
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 65
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 70
HOW TO READ ELECTRICAL WIRE CODE 71
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 75
STANDARD TIGHTENING TORQUE TABLE 78
CONVERSION TABLE 85
01 SPECIFICATIONS . 91
CONTENTS 92
ABBREVIATION LIST . 93
SPECIFICATIONS 98
SPECIFICATION DRAWING . 98
SPECIFICATION DRAWING: PC240LC-11, PC240NLC-11 98
WORKING RANGE DRAWINGS 99
WORKING RANGE: PC240LC-11, PC240NLC-11 99
SPECIFICATIONS 100
SPECIFICATIONS: PC240LC-11, PC240NLC-11 . 100
WEIGHT TABLE 103
WEIGHT TABLE: PC240LC-11, PC240NLC-11 . 103
TABLE OF FUEL, COOLANT, AND LUBRICANTS 105
10 STRUCTURE AND FUNCTION . 107
CONTENTS 108
ABBREVIATION LIST . 112
UREA SCR SYSTEM . 117
LAYOUT DRAWING OF UREA SCR SYSTEM . 118
UREA SCR SYSTEM DIAGRAM . 123
FUNCTION OF UREA SCR SYSTEM . 124
FUNCTION OF AdBlue/DEF SYSTEM . 124
INDUCEMENT STRATEGY . 126
COMPONENT PARTS OF UREA SCR SYSTEM 133
AdBlue/DEF MIXING TUBE 133
SCR ASSEMBLY 133
AdBlue/DEF TANK . 136
AdBlue/DEF PUMP . 138
AdBlue/DEF INJECTOR . 139
AdBlue/DEF HOSE . 140
AdBlue/DEF TANK HEATING VALVE . 141
BOOT-UP SYSTEM 142
LAYOUT DRAWING OF BOOT-UP SYSTEM 142
SYSTEM OPERATING LAMP SYSTEM 144
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 144
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 144
BATTERY DISCONNECT SWITCH . 145
FUNCTION OF BATTERY DISCONNECT SWITCH . 145
ENGINE SYSTEM . 146
LAYOUT DRAWING OF ENGINE SYSTEM . 146
SPECIFICATIONS OF ENGINE SYSTEM . 147
FUNCTION OF ENGINE SYSTEM . 147
ENGINE CONTROL SYSTEM . 148
ENGINE CONTROL SYSTEM DIAGRAM . 148
FUNCTION OF ENGINE CONTROL SYSTEM . 149
AUTO-DECELERATION SYSTEM 151
AUTO-DECELERATION SYSTEM DIAGRAM 151
FUNCTION OF AUTO-DECELERATION SYSTEM 151
OPERATION OF AUTO-DECELERATION SYSTEM . 152
ENGINE AUTOMATIC WARM-UP SYSTEM . 153
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 153
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 154
OVERHEAT PREVENTION SYSTEM 155
OVERHEAT PREVENTION SYSTEM DIAGRAM 155
FUNCTION OF OVERHEAT PREVENTION SYSTEM 156
TURBOCHARGER PROTECTION SYSTEM 158
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 158
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 159
AUTOMATIC IDLE STOP SYSTEM 160
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 160
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 160
COMPONENT PARTS OF ENGINE SYSTEM 163
KVGT 163
EGR SYSTEM 166
EGR VALVE . 168
EGR COOLER 170
KCCV SYSTEM . 171
KCCV VENTILATOR . 173
KDPF 175
COOLING SYSTEM 180
LAYOUT DRAWING OF COOLING SYSTEM 180
SPECIFICATIONS OF COOLING SYSTEM 181
CONTROL SYSTEM 182
LAYOUT DRAWING OF CONTROL SYSTEM 182
MACHINE MONITOR SYSTEM 185
MACHINE MONITOR SYSTEM DIAGRAM 185
KOMTRAX SYSTEM 186
KOMTRAX SYSTEM DIAGRAM 186
FUNCTION OF KOMTRAX SYSTEM 186
PPC LEVERS 187
LH PPC LEVER 187
RH PPC LEVER 188
AUTOMATIC GREASE SYSTEM . 189
OUTLINE OF AUTO GREASE SYSTEM . 189
COMPONENT PARTS OF CONTROL SYSTEM . 204
MACHINE MONITOR . 204
KOMTRAX TERMINAL 217
PUMP CONTROLLER . 219
RESISTOR FOR PC-EPC VALVE . 223
CAN TERMINATING RESISTOR 223
PPC OIL PRESSURE SWITCH . 224
ENGINE CONTROLLER . 225
FUEL CONTROL DIAL . 231
SENSOR 233
STRUCTURE OF AMBIENT PRESSURE SENSOR 233
FUNCTION OF AMBIENT PRESSURE SENSOR . 233
STRUCTURE OF ENGINE OIL PRESSURE SWITCH . 233
FUNCTION OF ENGINE OIL PRESSURE SWITCH 234
STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR . 234
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR 234
STRUCTURE OF COOLANT TEMPERATURE SENSOR . 235
FUNCTION OF COOLANT TEMPERATURE SENSOR 235
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR . 235
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR 236
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR . 236
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR 236
STRUCTURE OF COMMON RAIL PRESSURE SENSOR 237
FUNCTION OF COMMON RAIL PRESSURE SENSOR . 237
STRUCTURE OF EGR VALVE LIFT SENSOR 237
FUNCTION OF EGR VALVE LIFT SENSOR . 237
STRUCTURE OF KVGT SPEED SENSOR 238
FUNCTION OF KVGT SPEED SENSOR . 238
STRUCTURE OF KVGT POSITION SENSOR . 238
FUNCTION OF KVGT POSITION SENSOR 239
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR . 239
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR 240
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR . 240
STRUCTURE OF CRANKCASE PRESSURE SENSOR 240
FUNCTION OF CRANKCASE PRESSURE SENSOR . 241
STRUCTURE OF ENGINE OIL LEVEL SENSOR 241
STRUCTURE OF AIR CLEANER CLOGGING SENSOR 241
FUNCTION OF AIR CLEANER CLOGGING SENSOR . 242
STRUCTURE OF WATER-IN-FUEL SENSOR . 242
FUNCTION OF WATER-IN-FUEL SENSOR 242
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 242
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 243
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH . 243
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 243
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 244
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 244
STRUCTURE OF OVERLOAD CAUTION SENSOR 244
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 244
FUNCTION OF OVERLOAD CAUTION SENSOR . 244
HYDRAULIC SYSTEM 245
LAYOUT DRAWING OF HYDRAULIC SYSTEM 245
CLSS 251
STRUCTURE OF CLSS . 251
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 253
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 254
PRESSURE COMPENSATION CONTROL . 267
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 269
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 269
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 270
PUMP AND VALVE CONTROL SYSTEM . 275
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 275
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 276
COMPONENT PARTS OF HYDRAULIC SYSTEM . 278
HYDRAULIC TANK 278
MAIN PUMP . 279
PC-EPC VALVE 304
PILOT OIL FILTER 306
CONTROL VALVE . 306
WORK EQUIPMENT SYSTEM . 363
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 363
STRUCTURE OF VALVE CONTROL 368
ONE-TOUCH POWER MAXIMIZING SYSTEM . 370
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 370
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 371
PPC LOCK SYSTEM . 372
PPC LOCK SYSTEM DIAGRAM . 372
FUNCTION OF PPC LOCK SYSTEM . 372
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 373
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 373
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 373
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 374
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 375
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM . 375
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 377
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 378
WORK EQUIPMENT AND SWING PPC VALVE 378
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 383
SOLENOID VALVE 389
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) . 392
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 394
ATT EPC VALVE ASSEMBLY 397
RETURN OIL FILTER . 398
QUICK COUPLER CONTROL VALVE . 400
PILOT CIRCUIT ACCUMULATOR . 402
ATTACHMENT CIRCUIT ACCUMULATOR 403
SWING SYSTEM 404
LAYOUT DRAWING OF SWING SYSTEM 404
SWING CONTROL SYSTEM DIAGRAM 408
FUNCTION OF SWING CONTROL SYSTEM 408
COMPONENT PARTS OF SWING SYSTEM . 412
SWING MOTOR . 412
SWING MACHINERY . 423
SWING CIRCLE 424
TRAVEL SYSTEM . 426
LAYOUT DRAWING OF TRAVEL SYSTEM . 426
TRAVEL CONTROL SYSTEM DIAGRAM . 430
FUNCTION OF TRAVEL CONTROL SYSTEM . 430
COMPONENT PARTS OF TRAVEL SYSTEM 432
TRAVEL MOTOR 432
FINAL DRIVE . 445
TRAVEL PPC VALVE 446
CENTER SWIVEL JOINT . 451
UNDERCARRIAGE AND FRAME . 453
LAYOUT DRAWING OF UNDERCARRIAGE . 453
SPECIFICATIONS OF UNDERCARRIAGE . 454
WORK EQUIPMENT 455
STRUCTURE OF WORK EQUIPMENT . 455
FUNCTION OF WORK EQUIPMENT 456
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 457
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 457
BUCKET CLEARANCE ADJUSTMENT SHIM 458
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 458
CAB AND ITS ATTACHMENTS . 459
ROPS CAB 459
STRUCTURE OF ROPS CAB . 459
FUNCTION OF ROPS CAB 459
CAB MOUNT . 460
STRUCTURE OF CAB MOUNT 460
FUNCTION OF CAB MOUNT . 460
CAB TIPPING STOPPER . 461
STRUCTURE OF CAB TIPPING STOPPER 461
FUNCTION OF CAB TIPPING STOPPER . 461
20 STANDARD VALUE TABLE . 463
CONTENTS 464
ABBREVIATION LIST . 465
STANDARD VALUE TABLE FOR ENGINE . 470
STANDARD VALUE TABLE FOR ENGINE: PC240LC-11, PC240NLC-11 470
STANDARD VALUE TABLE FOR MACHINE 474
STANDARD VALUE TABLE FOR MACHINE: PC240LC-11, PC240NLC-11 . 474
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 487
STANDARD VALUE TABLE FOR ELECTRICAL . 491
STANDARD VALUE TABLE FOR ELECTRICAL . 491
30 TESTING AND ADJUSTING 501
CONTENTS 502
ABBREVIATION LIST . 505
RELATED INFORMATION ON TESTING AND ADJUSTING 510
TOOLS FOR TESTING AND ADJUSTING . 510
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 516
ENGINE AND COOLING SYSTEM . 518
TEST ENGINE SPEED . 518
METHOD FOR TESTING ENGINE SPEED . 518
TEST BOOST PRESSURE . 521
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 521
METHOD FOR TESTING BOOST PRESSURE . 522
TEST EXHAUST GAS COLOR 523
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 523
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 524
TEST AND ADJUST VALVE CLEARANCE . 526
METHOD FOR TESTING VALVE CLEARANCE 526
METHOD FOR ADJUSTING VALVE CLEARANCE 527
TEST COMPRESSION PRESSURE . 528
METHOD FOR TESTING COMPRESSION PRESSURE . 528
TEST BLOWBY PRESSURE 533
METHOD FOR TESTING BLOWBY PRESSURE 533
TEST ENGINE OIL PRESSURE 535
METHOD FOR TESTING ENGINE OIL PRESSURE 535
TEST EGR VALVE AND KVGT OIL PRESSURE 536
METHOD FOR TESTING EGR VALVE AND KVGT OIL PRESSURE 536
TEST FUEL PRESSURE 538
METHOD FOR TESTING FUEL PRESSURE 539
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 544
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 545
BLEEDING AIR FROM FUEL SYSTEM . 550
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 550
TEST FUEL CIRCUIT FOR LEAKAGE . 551
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 551
HANDLE CYLINDER CUT-OUT MODE OPERATION 553
HANDLE NO-INJECTION CRANKING OPERATION 554
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 555
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 555
REPLACING FAN BELT 556
METHOD FOR REPLACING FAN BELT . 556
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 557
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 557
TEST SCR RELATED FUNCTIONS 558
TEST AdBlue/DEF PUMP RAISED PRESSURE 561
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 563
TEST AdBlue/DEF LINE HEATER RELAY 1 . 566
TEST AdBlue/DEF LINE HEATER RELAY 2 . 569
TEST AdBlue/DEF PUMP HEATER RELAY . 571
TEST AdBlue/DEF TANK HEATER VALVE . 574
TEST DENITRATION EFFICIENCY OF SCR 577
CLEAN AdBlue/DEF TANK . 580
METHOD FOR CLEANING AdBlue/DEF TANK . 580
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 584
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK . 584
POWER TRAIN . 586
TEST SWING CIRCLE BEARING CLEARANCE . 586
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 586
UNDERCARRIAGE AND FRAME . 587
TEST AND ADJUST TRACK TENSION . 587
METHOD FOR TESTING TRACK TENSION 587
METHOD FOR ADJUSTING TRACK TENSION 587
HYDRAULIC SYSTEM 589
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 589
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 589
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 590
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 591
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 597
TEST OIL PRESSURE OF CONTROL CIRCUIT 600
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 600
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 602
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 602
TEST PC-EPC VALVE OUTLET PRESSURE . 603
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 604
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 605
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR 605
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL . 606
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 609
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 610
METHOD FOR ADJUSTING LS VALVE . 611
TEST OUTLET PRESSURE OF SOLENOID VALVE 612
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 612
OPERATING CONDITION OF SOLENOID VALVE . 613
TEST PPC VALVE OUTLET PRESSURE 616
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 616
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 618
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 618
TEST PUMP SWASH PLATE SENSOR 619
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 619
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 620
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 620
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 620
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 621
TEST OIL LEAKAGE 622
TEST OIL LEAKAGE OF BOOM CYLINDER . 622
TEST OIL LEAKAGE OF ARM CYLINDER 622
TEST OIL LEAKAGE OF BUCKET CYLINDER . 623
METHOD FOR TESTING OIL LEAKAGE OF SWING MOTOR . 623
METHOD FOR TESTING OIL LEAKAGE OF TRAVEL MOTOR 623
BLEED AIR FROM HYDRAULIC CIRCUIT 625
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 626
CAB AND ITS ATTACHMENTS . 628
TEST CAB TIPPING STOPPER 628
METHOD FOR TESTING CAB TIPPING STOPPER 628
METHOD FOR ADJUSTING MIRRORS 629
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 629
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 630
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 631
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 632
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 633
ELECTRICAL SYSTEM . 635
ELECTRICAL SYSTEM . 636
SET AND OPERATE MACHINE MONITOR . 636
OPERATOR MODE . 639
SERVICE MODE 644
METHOD FOR STARTING UP KOMTRAX TERMINAL . 716
ADJUST REARVIEW CAMERA ANGLE 721
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE 721
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 724
HANDLE BATTERY DISCONNECT SWITCH 725
TEST DIODES . 726
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 726
METHOD FOR TESTING DIODE USING ANALOG TESTER 726
Pm CLINIC . 727
Pm CLINIC SERVICE . 727
Pm CLINIC SERVICE . 729
Pm CLINIC CHECK SHEET . 733
40 TROUBLESHOOTING 743
CONTENTS 744
ABBREVIATION LIST . 755
RELATED INFORMATION ON TROUBLESHOOTING 760
GENERAL TROUBLESHOOTING POINTS 760
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 761
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 773
CHECKS BEFORE TROUBLESHOOTING . 775
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 777
WALK-AROUND CHECK . 777
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 779
CHECK FUEL LEVEL AND TYPE . 779
CHECK IMPURE INGREDIENT IN FUEL . 779
CHECK FUEL PREFILTER 780
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 780
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 781
CHECK MAIN FILTER . 782
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 784
CHECK COOLANT LEVEL (RESERVOIR TANK) 785
CHECK CLOGGING OF AIR CLEANER . 785
OUTER ELEMENT – CLEAN . 786
ELEMENTS – REPLACE 788
CHECK HYDRAULIC OIL LEVEL . 789
CHECK HYDRAULIC OIL STRAINER 790
CHECK HYDRAULIC FILTER 791
CHECK OIL LEVEL IN SWING MACHINERY CASE . 792
CHECK OIL LEVEL IN DAMPER CASE 793
CHECK OIL LEVEL IN FINAL DRIVE CASE . 793
BLEED AIR FROM FUEL SYSTEM 794
BLEED AIR FROM HYDRAULIC SYSTEM . 794
ELECTRICAL EQUIPMENT – CHECK METHOD . 794
AUTOMATIC GREASE SYSTEM . 802
FINDING MALFUNCTIONS 802
MALFUNCTION FINDING PROCEDURES 804
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION . 806
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 816
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 819
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 823
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 825
CONNECTOR LIST AND LAYOUT . 828
CONNECTOR CONTACT IDENTIFICATION 841
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 881
FUSE LOCATION TABLE . 887
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) . 889
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) . 893
FAILURE CODES TABLE . 895
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) . 912
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit . 912
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit 913
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit . 914
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit 916
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit . 918
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit 919
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit . 920
FAILURE CODE [879EMC] Ventilation Damper Malfunction 922
FAILURE CODE [879FMC] Air Mix Damper Malfunction 923
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range 924
FAILURE CODE [989L00] Engine Controller Lock Caution 1 926
FAILURE CODE [989M00] Engine Controller Lock Caution 2 927
FAILURE CODE [989N00] Engine Controller Lock Caution 3 928
FAILURE CODE [A1U0N3] HC Desorb Request 1 . 929
FAILURE CODE [A1U0N4] HC Desorb Request 2 . 931
FAILURE CODE [A900FR] Abrupt Engine Stop by Auto Idling Stop 3 933
FAILURE CODE [A900N6] Abrupt Engine Stop by Auto Idling Stop 1 934
FAILURE CODE [A900NY] Abrupt Engine Stop by Auto Idling Stop 2 935
FAILURE CODE [AA10NX] Air Cleaner Clogging 936
FAILURE CODE [AB00KE] Charge Voltage Low 938
FAILURE CODE [AQ10N3] Manual Stationary Regeneration Request (KDOC Face Plugging) . 941
FAILURE CODE [AS00N3] Manual Stationary Regeneration Request (SCR) 943
FAILURE CODE [AS00R2] Warning 2 (SCR Device Abnormality) 945
FAILURE CODE [AS00R3] Inducement 1 (SCR Device Abnormality) . 946
FAILURE CODE [AS00R4] Inducement 2 (SCR Device Abnormality) . 947
FAILURE CODE [AS00R5] Inducement 3 (SCR Device Abnormality) . 948
FAILURE CODE [AS00R6] Temporary Recovery of Inducement 949
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Error 5 950
FAILURE CODE [AS10KM] AdBlue/DEF Injector Overheat Warning 951
FAILURE CODE [AS10NR] AdBlue/DEF Injector High Temperature Warning 952
FAILURE CODE [AS10NT] AdBlue/DEF Injector Overheat Caution 953
FAILURE CODE [B@BAZG] Engine Oil Pressure Low . 954
FAILURE CODE [B@BAZK] Eng Oil Level Low . 955
FAILURE CODE [B@BCNS] Eng Water Overheat 957
FAILURE CODE [B@BCZK] Eng Water Level Low . 958
FAILURE CODE [B@HANS] Hyd Oil Overheat 960
FAILURE CODE [CA115] Engine NE and Backup Speed Sensor Error 961
FAILURE CODE [CA122] Charge Air Pressure Sensor High Error 962
FAILURE CODE [CA123] Charge Air Pressure Sensor Low Error . 964
FAILURE CODE [CA131] Throttle Sensor High Error . 966
FAILURE CODE [CA132] Throttle Sensor Low Error 968
FAILURE CODE [CA144] Coolant Temperature Sensor High Error 970
FAILURE CODE [CA145] Coolant Temperature Sensor Low Error . 972
FAILURE CODE [CA153] Charge Air Temperature Sensor High Error . 974
FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error 977
FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error 979
FAILURE CODE [CA221] Ambient Pressure Sensor High Error . 981
FAILURE CODE [CA222] Ambient Pressure Sensor Low Error 983
FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error . 985
FAILURE CODE [CA234] Engine Overspeed . 986
FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error . 987
FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Error 989
FAILURE CODE [CA249] Ambient Air Temp Sensor High Error . 991
FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error 993
FAILURE CODE [CA271] IMV or PCV 1 Short Circuit Error . 995
FAILURE CODE [CA272] IMV or PCV 1 Open Circuit Error 997
FAILURE CODE [CA322] Injector #1 (L#1) Open Circuit Error or Short Circuit Error 999
FAILURE CODE [CA323] Injector #5 (L#5) Open Circuit Error or Short Circuit Error 1001
FAILURE CODE [CA324] Injector #3 (L#3) Open Circuit Error or Short Circuit Error 1003
FAILURE CODE [CA325] Injector #6 (L#6) Open Circuit Error or Short Circuit Error 1005
FAILURE CODE [CA331] Injector #2 (L#2) Open Circuit Error or Short Circuit Error 1007
FAILURE CODE [CA332] Injector #4 (L#4) Open Circuit Error or Short Circuit Error 1009
FAILURE CODE [CA343] Engine Controller Internal Failure .1011
FAILURE CODE [CA351] Injectors Drive Circuit Error 1012
FAILURE CODE [CA352] Sensor 1 Supply Voltage Low Error 1013
FAILURE CODE [CA356] MAF Sensor High Error 1016
FAILURE CODE [CA357] MAF Sensor Low Error .1018
FAILURE CODE [CA386] Sensor 1 Supply Voltage High Error .1020
FAILURE CODE [CA428] Water in Fuel Sensor High Error 1021
FAILURE CODE [CA429] Water in Fuel Sensor Low Error .1023
FAILURE CODE [CA435] Engine Oil Pressure SW Error .1025
FAILURE CODE [CA441] Battery Voltage Low Error 1027
FAILURE CODE [CA442] Battery Voltage High Error .1029
FAILURE CODE [CA449] Common Rail Pressure High Error 2 1030
FAILURE CODE [CA451] Common Rail Pressure Sensor High Error .1031
FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error 1033
FAILURE CODE [CA488] Charge Air Temperature High Torque Derate 1035
FAILURE CODE [CA515] Common Rail Pressure Sensor Supply Voltage High Error 1036
FAILURE CODE [CA516] Common Rail Pressure Sensor Supply Voltage Low Error .1038
FAILURE CODE [CA553] Common Rail Pressure High Error 1 1040
FAILURE CODE [CA555] Crankcase Pressure High Error 1 1041
FAILURE CODE [CA556] Crankcase Pressure High Error 2 1042
FAILURE CODE [CA559] Common Rail Pressure Low Error 1 .1043
FAILURE CODE [CA595] Turbocharger Speed High Error 2 1046
FAILURE CODE [CA687] Turbocharger Speed Low Error .1047
FAILURE CODE [CA689] Engine NE Speed Sensor Error .1049
FAILURE CODE [CA691] Intake Air Temperature Sensor High Error .1052
FAILURE CODE [CA692] Intake Air Temperature Sensor Low Error 1054
FAILURE CODE [CA697] Engine Controller Internal Temperature Sensor High Error .1056
FAILURE CODE [CA698] Engine Controller Internal Temperature Sensor Low Error 1057
FAILURE CODE [CA731] Engine Backup Speed Sensor Phase Error .1058
FAILURE CODE [CA778] Engine Backup Speed Sensor Error .1060
FAILURE CODE [CA1117] Engine Controller Partial Data Lost Error .1065
FAILURE CODE [CA1664] KDOC Abnormality 1066
FAILURE CODE [CA1669] AdBlue/DEF Level Sensor Voltage High Error 1068
FAILURE CODE [CA1673] AdBlue/DEF Level Low Error 3 1069
FAILURE CODE [CA1677] AdBlue/DEF Temperature Sensor Low Error .1070
FAILURE CODE [CA1678] AdBlue/DEF Temperature Sensor High Error 1071
FAILURE CODE [CA1682] AdBlue/DEF Pump Priming Error .1072
FAILURE CODE [CA1683] AdBlue/DEF Tank Heating Valve Voltage High Error 1074
FAILURE CODE [CA1684] AdBlue/DEF Tank Heating Valve Voltage Low Error .1076
FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High Error 1078
FAILURE CODE [CA1691] Defective Regeneration 1079
FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error 1082
FAILURE CODE [CA1695] Sensor 5 Supply Voltage High Error 1085
FAILURE CODE [CA1696] Sensor 5 Supply Voltage Low Error .1086
FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error .1088
FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Error .1091
FAILURE CODE [CA1714] AdBlue/DEF Quality Sensor Out of Calibration Error 1093
FAILURE CODE [CA1715] AdBlue/DEF Quality Sensor Internal Circuit Error 1094
FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error 1095
FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error .1098
FAILURE CODE [CA1843] Crankcase Pressure Sensor High Error 1101
FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error .1103
FAILURE CODE [CA1879] KDPF Differential Pressure Sensor High Error 1106
FAILURE CODE [CA1881] KDPF Differential Pressure Sensor Low Error .1108
FAILURE CODE [CA1883] KDPF Differential Pressure Sensor In Range Error 1110
FAILURE CODE [CA1885] Turbo Outlet NOx Sensor Circuit Error .1113
FAILURE CODE [CA1887] SCR Outlet NOx Sensor Circuit Error .1115
FAILURE CODE [CA1921] KDPF Soot Accumulation High Error 1 .1117
FAILURE CODE [CA1922] KDPF Soot Accumulation High Error 2 .1120
FAILURE CODE [CA1942] Crankcase Pressure Sensor In Range Error 1125
FAILURE CODE [CA1993] KDPF Differential Pressure Low Error 1126
FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error .1129
FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error 1130
FAILURE CODE [CA2249] Common Rail Pressure Low Error 2 1132
FAILURE CODE [CA2271] EGR Valve Position Sensor High Error 1133
FAILURE CODE [CA2272] EGR Valve Position Sensor Low Error .1136
FAILURE CODE [CA2288] Turbocharger Speed High Error 1 .1139
FAILURE CODE [CA2311] lMV Solenoid Error 1140
FAILURE CODE [CA2349] EGR Valve Solenoid Open Circuit Error .1141
FAILURE CODE [CA2353] EGR Valve Solenoid Short Circuit Error 1144
FAILURE CODE [CA2357] EGR Valve Servo Error .1146
FAILURE CODE [CA2381] KVGT Position Sensor High Error .1147
FAILURE CODE [CA2382] KVGT Position Sensor Low Error 1150
FAILURE CODE [CA2383] KVGT Solenoid Open Circuit Error 1153
FAILURE CODE [CA2386] KVGT Solenoid Short Circuit Error .1156
FAILURE CODE [CA2387] KVGT Servo Error 1158
FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error 1159
FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error .1162
FAILURE CODE [CA2637] KDOC Face Plugging 1165
FAILURE CODE [CA2639] Manual Stationary Regeneration Request 1167
FAILURE CODE [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error 1170
FAILURE CODE [CA2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable 1176
FAILURE CODE [CA2976] AdBlue/DEF Pump Temperature Sensor Signal Error .1179
FAILURE CODE [CA3133] KDPF Outlet Pressure Sensor High Error 1181
FAILURE CODE [CA3134] KDPF Outlet Pressure Sensor Low Error .1184
FAILURE CODE [CA3135] KDPF Outlet Pressure Sensor In Range Error 1186
FAILURE CODE [CA3142] SCR Temperature Sensor High Error .1189
FAILURE CODE [CA3143] SCR Temperature Sensor Low Error 1190
FAILURE CODE [CA3144] SCR Temperature Sensor In Range Error .1191
FAILURE CODE [CA3146] SCR Outlet Temperature Sensor High Error 1193
FAILURE CODE [CA3147] SCR Outlet Temperature Sensor Low Error .1194
FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range Error 1195
FAILURE CODE [CA3151] SCR Catalyst Efficiency Low Error 2 .1197
FAILURE CODE [CA3165] SCR Outlet Temperature High Error .1203
FAILURE CODE [CA3229] SCR Temperature High Error 1205
FAILURE CODE [CA3231] SCR Temperature High Error – Non Regeneration .1207
FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error 1209
FAILURE CODE [CA3235] SCR Outlet Temperature High Error – Non Regeneration 1213
FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error .1215
FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error 1218
FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error .1221
FAILURE CODE [CA3251] KDOC Inlet Temperature High Error .1224
FAILURE CODE [CA3253] KDOC Temperature Error – Non Regeneration .1226
FAILURE CODE [CA3254] KDOC Outlet Temperature High Error 1 1229
FAILURE CODE [CA3255] KDPF Temperature Error – Non Regeneration .1232
FAILURE CODE [CA3256] KDPF Outlet Temperature High Error 1 1236
FAILURE CODE [CA3311] KDOC Outlet Temperature High Error 2 1238
FAILURE CODE [CA3312] KDPF Outlet Temperature High Error 2 1240
FAILURE CODE [CA3313] KDOC Inlet Temperature Sensor Low Error .1243
FAILURE CODE [CA3314] KDOC Inlet Temperature Sensor High Error 1245
FAILURE CODE [CA3315] KDOC Inlet Temperature Sensor In Range Error 1246
FAILURE CODE [CA3316] KDOC Outlet Temperature Sensor Low Error 1248
FAILURE CODE [CA3317] KDOC Outlet Temperature Sensor High Error .1250
FAILURE CODE [CA3318] KDOC Outlet Temperature Sensor In Range Error .1251
FAILURE CODE [CA3319] KDPF Outlet Temperature Sensor High Error .1253
FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Error 1254
FAILURE CODE [CA3322] KDPF Outlet Temperature Sensor In Range Error .1256
FAILURE CODE [CA3419] MAF Sensor Supply Voltage High Error 1258
FAILURE CODE [CA3421] MAF Sensor Supply Voltage Low Error .1260
FAILURE CODE [CA3497] AdBlue/DEF Level Low Error 1 1262
FAILURE CODE [CA3498] AdBlue/DEF Level Low Error 2 1263
FAILURE CODE [CA3543] AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low) 1264
FAILURE CODE [CA3545] SCR Outlet NOx Sensor Unstable Error 1270
FAILURE CODE [CA3547] AdBlue/DEF Level Low Error 4 1272
FAILURE CODE [CA3558] AdBlue/DEF Pump Voltage High Error 1273
FAILURE CODE [CA3559] AdBlue/DEF Pump Voltage Low Error .1275
FAILURE CODE [CA3562] AdBlue/DEF LineHeater Relay 1 Voltage High Error 1277
FAILURE CODE [CA3563] AdBlue/DEF LineHeater Relay 1 Voltage Low Error .1279
FAILURE CODE [CA3567] AdBlue/DEF Injector Open Circuit Error or Short Circuit Error .1282
FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction .1285
FAILURE CODE [CA3571] AdBlue/DEF Pump Pressure Sensor High Error 1289
FAILURE CODE [CA3572] AdBlue/DEF Pump Pressure Sensor Low Error .1291
FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Error 1293
FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Error .1295
FAILURE CODE [CA3577] AdBlue/DEF FCV Voltage High Error .1297
FAILURE CODE [CA3578] AdBlue/DEF FCV Voltage Low Error 1299
FAILURE CODE [CA3582] SCR Catalyst Efficiency Low Error 1 .1301
FAILURE CODE [CA3583] SCR Outlet NOx Sensor Heater Warming up Error .1307
FAILURE CODE [CA3596] AdBlue/DEF Pump Pressure Unstable Error .1309
FAILURE CODE [CA3649] Turbo Outlet NOx Sensor Heater Warming up Error .1311
FAILURE CODE [CA3681] SCR Outlet NOx Sensor Power Voltage Error .1313
FAILURE CODE [CA3682] Turbo Outlet NOx Sensor Power Voltage Error .1318
FAILURE CODE [CA3713] AdBlue/DEF Line Heater 1 Voltage High Error .1324
FAILURE CODE [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error 1327
FAILURE CODE [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Error 1328
FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error 1329
FAILURE CODE [CA3741] Rail Press Valve Trip Error .1332
FAILURE CODE [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error 1333
FAILURE CODE [CA3751] SCR Catalyst Degradation Error 1335
FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degradation Error .1337
FAILURE CODE [CA3866] AdBlue/DEF Low Concentration Error 2 1339
FAILURE CODE [CA3867] AdBlue/DEF Low Concentration Error 1 1342
FAILURE CODE [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout Error .1345
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error 1349
FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error .1351
FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error 1355
FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Error 1357
FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error .1359
FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error 1361
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error 1364
FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error .1366
FAILURE CODE [CA4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error .1368
FAILURE CODE [CA4152] SCR Temperature Sensor Datalink Timeout Error .1372
FAILURE CODE [CA4155] AdBlue/DEF Pump Heater Relay Voltage High Error .1376
FAILURE CODE [CA4156] AdBlue/DEF Pump Heater Relay Voltage Low Error 1379
FAILURE CODE [CA4157] AdBlue/DEF FCV Malfunction 1382
FAILURE CODE [CA4158] KDOC and KDPF Temperature Sensor Internal Circuit Error .1384
FAILURE CODE [CA4159] SCR Temperature Sensor Internal Circuit Error .1385
FAILURE CODE [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error .1386
FAILURE CODE [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error 1389
FAILURE CODE [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error .1392
FAILURE CODE [CA4164] SCR Temperature Sensor ECU Voltage High Error .1394
FAILURE CODE [CA4165] SCR Temperature Sensor ECU Voltage Low Error 1396
FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Temperature Error .1398
FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error .1400
FAILURE CODE [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error 1403
FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error .1405
FAILURE CODE [CA4249] AdBlue/DEF Pump Temperature Sensor 1 In Range Error .1408
FAILURE CODE [CA4251] AdBlue/DEF Pump Temperature Sensor 2 In Range Error .1410
FAILURE CODE [CA4259] KDOC and KDPF Temperature Sensor Power Interrupt Error 1412
FAILURE CODE [CA4261] SCR Temperature Sensor Power Interrupt Error 1415
FAILURE CODE [CA4277] AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error .1418
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error .1421
FAILURE CODE [CA4459] AdBlue/DEF LineHeater Relay 2 Voltage High Error 1424
FAILURE CODE [CA4461] AdBlue/DEF LineHeater Relay 2 Voltage Low Error .1427
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error .1430
FAILURE CODE [CA4731] AdBlue/DEF Temperature Sensor Transmission Data Error .1434
FAILURE CODE [CA4732] AdBlue/DEF Level Sensor Transmission Data Error .1435
FAILURE CODE [CA4739] AdBlue/DEF Level Sensor Internal Circuit Error 1436
FAILURE CODE [CA4768] Fuel in AdBlue/DEF Tank Error .1437
FAILURE CODE [CA4769] AdBlue/DEF Level Measurement Impossible .1439
FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error .1442
FAILURE CODE [CA4952] System Operating Lamp Short Circuit (Engine Controller) .1445
FAILURE CODE [CA5115] AdBlue/DEF Line Heater 1 Voltage Low Error 1447
FAILURE CODE [CA5179] Engine Room Temperature Sensor High Error .1450
FAILURE CODE [CA5181] Engine Room Temperature Sensor Low Error 1452
FAILURE CODE [CA5383] Ash Accumulation High Error .1454
FAILURE CODE [D110KB] Battery Relay Output Short Circuit 1456
FAILURE CODE [D19JKZ] Personal Code Relay Open Circuit or Short Circuit .1458
FAILURE CODE [D811MC] KOMTRAX Malfunction .1461
FAILURE CODE [D862KA] GPS Antenna Open Circuit 1462
FAILURE CODE [D8ALKA] System Operating Lamp Open Circuit (KOMTRAX) 1463
FAILURE CODE [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) .1465
FAILURE CODE [D8AQKR] CAN 2 Defective Communication (KOMTRAX) .1467
FAILURE CODE [DA20MC] Pump Controller Malfunction .1469
FAILURE CODE [DA22KK] Pump Controller Solenoid Power Voltage Low Error 1470
FAILURE CODE [DA25KP] 5V Sensor 1 Power Voltage Low Error .1473
FAILURE CODE [DA29KQ] Model Selection Signal Mismatch (Pump Controller) .1476
FAILURE CODE [DA2LKA] System Operating Lamp Open Circuit (Pump Controller) 1478
FAILURE CODE [DA2LKB] System Operating Lamp Short Circuit (Pump Controller) .1480
FAILURE CODE [DA2QKR] Controller Area Network 2 Defective Communication (Pump Controller) .1482
FAILURE CODE [DA2RKR] Controller Area Network 1 Defective Communication (Pump Controller) .1485
FAILURE CODE [DAF0MB] Monitor ROM Abnormality .1486
FAILURE CODE [DAF0MC] Monitor Malfunction .1487
FAILURE CODE [DAF8KB] Camera Power Supply Short Circuit .1488
FAILURE CODE [DAF9KQ] Model Selection Signal Mismatch (Monitor) .1490
FAILURE CODE [DAFGMC] GPS Module Malfunction 1491
FAILURE CODE [DAFLKA] System Operating Lamp Open Circuit (Monitor) 1492
FAILURE CODE [DAFLKB] System Operating Lamp Short Circuit (Monitor) .1494
FAILURE CODE [DAFQKR] CAN 2 Defective Communication (Monitor) .1496
FAILURE CODE [DAZ9KQ] Model Selection Signal Mismatch (A/C) .1497
FAILURE CODE [DAZQKR] CAN 2 Defective Communication (A/C ECU) .1498
FAILURE CODE [DB2QKR] CAN 2 Defective Communication (Engine Controller) .1503
FAILURE CODE [DB2RKR] CAN 1 Defective Communication (Engine Controller) .1508
FAILURE CODE [DDNRKA] W/E Lever Lock SW Open Circuit 1513
FAILURE CODE [DDNRKY] W/E Lever Lock SW Short Circuit .1515
FAILURE CODE [DDNS00] Lock Lever Auto Lock Release SW On 1517
FAILURE CODE [DFB1KZ] Service Lever Potentio 1 Open or Short Circuit 1519
FAILURE CODE [DFB2KZ] Service Lever Potentio 2 Open or Short Circuit 1522
FAILURE CODE [DFB3L8] Service Lever 1 Potentiometer Error .1525
FAILURE CODE [DFB4L8] Service Lever 2 Potentiometer Error .1527
FAILURE CODE [DFB5KZ] Service Lever Sub Potentio 1 Open or Short Circuit 1529
FAILURE CODE [DFB6KZ] Service Lever Sub Potentio 2 Open or Short Circuit 1532
FAILURE CODE [DGH2KA] Hydraulic Oil Temperature Sensor Open Circuit .1535
FAILURE CODE [DGH2KB] Hydraulic Oil Temperature Sensor Ground Fault .1537
FAILURE CODE [DHA4KA] Air Cleaner Clog Sensor Open Circuit 1539
FAILURE CODE [DHAAMA] KDPF Differential Pressure Sensor Frozen 1541
FAILURE CODE [DHACMA] KDPF Outlet Pressure Sensor Frozen 1543
FAILURE CODE [DHPAMA] Front Pump Pressure Sensor Defective Function .1545
FAILURE CODE [DHPBMA] Rear Pump Pressure Sensor Defective Function 1548
FAILURE CODE [DHS3MA] Arm IN PPC Pressure Sensor Defective Function .1551
FAILURE CODE [DHS4MA] Bucket CURL PPC Pressure Sensor Defective Function 1554
FAILURE CODE [DHS8MA] Boom RAISE PPC Pressure Sensor Defective Function .1557
FAILURE CODE [DHS9MA] Boom LOWER PPC Pressure Sensor Defective Function .1560
FAILURE CODE [DHSAMA] Swing Right PPC Pressure Sensor Defective Function 1563
FAILURE CODE [DHSBMA] Swing Left PPC Pressure Sensor Defective Function .1566
FAILURE CODE [DHSCMA] Arm OUT PPC Pressure Sensor Defective Function 1569
FAILURE CODE [DHSDMA] Bucket DUMP PPC Pressure Sensor Defective Function 1572
FAILURE CODE [DHSFMA] Travel Forward Left PPC Pressure Sensor Defective Function 1575
FAILURE CODE [DHSGMA] Travel Forward Right PPC Pressure Sensor Defective Function .1578
FAILURE CODE [DHSHMA] Travel Reverse Left PPC Pressure Sensor Defective Function 1581
FAILURE CODE [DHSJMA] Travel Reverse Right PPC Pressure Sensor Defective Function .1584
FAILURE CODE [DHX1MA] Overload Sensor Abnormality (Analog) 1587
FAILURE CODE [DKR0MA] Front Pump Swash Plate Sensor Defective Function 1590
FAILURE CODE [DKR1MA] Rear Pump Swash Plate Sensor Defective Function .1593
FAILURE CODE [DKULKA] PPC Lock Relay Open Circuit .1596
FAILURE CODE [DKULKB] PPC Lock Relay Short Circuit 1598
FAILURE CODE [DKULKY] PPC Lock Relay Hot Short Circuit 1600
FAILURE CODE [DR21KX] Camera 2 Picture Reverse Drive Input Out of Range .1602
FAILURE CODE [DR31KX] Camera 3 Picture Reverse Drive Input Out of Range .1604
FAILURE CODE [DV20KB] Travel Alarm Short Circuit 1606
FAILURE CODE [DW43KA] Travel Speed Solenoid Open Circuit 1608
FAILURE CODE [DW43KB] Travel Speed Solenoid Short Circuit .1610
FAILURE CODE [DW43KY] Travel Speed Solenoid Hot Short Circuit .1612
FAILURE CODE [DW45KA]Swing Parking Brake Solenoid Open Circuit 1614
FAILURE CODE [DW45KB] Swing Parking Brake Solenoid Short Circuit 1617
FAILURE CODE [DW45KY] Swing Parking Brake Solenoid Hot Short Circuit 1620
FAILURE CODE [DW4CKY] PPC Lock Solenoid Hot Short Circuit .1622
FAILURE CODE [DW91KA] Travel Junction Solenoid Open Circuit .1624
FAILURE CODE [DW91KB] Travel Junction Solenoid Short Circuit 1626
FAILURE CODE [DW91KY] Travel Junction Solenoid Hot Short Circuit 1628
FAILURE CODE [DWA2KA] Attachment Single or 2-Way Change Solenoid Open Circuit .1630
FAILURE CODE [DWA2KB] Attachment Single or 2-Way Change Solenoid Short Circuit 1632
FAILURE CODE [DWA2KY] Attachment Single or 2-Way Change Solenoid Hot Short Circuit 1634
FAILURE CODE [DWK0KA] 2-Stage Relief Solenoid Open Circuit 1636
FAILURE CODE [DWK0KB] 2-Stage Relief Solenoid Open Circuit 1638
FAILURE CODE [DWK0KY] 2-Stage Relief Solenoid Hot Short Circuit .1640
FAILURE CODE [DWK2KA] Variable Back Pressure Solenoid Open Circuit 1642
FAILURE CODE [DWK2KB] Variable Back Pressure Solenoid Short Circuit .1644
FAILURE CODE [DWK2KY] Variable Back Pressure Solenoid Hot Short Circuit .1646
FAILURE CODE [DWK8KA] Swing Pressure Cutoff Solenoid Open Circuit .1648
FAILURE CODE [DWK8KB] Swing Pressure Cutoff Solenoid Short Circuit 1650
FAILURE CODE [DWK8KY] Swing Pressure Cutoff Solenoid Hot Short Circuit 1652
FAILURE CODE [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit .1654
FAILURE CODE [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit 1656
FAILURE CODE [DXA9KA] Rear Pump PC-EPC Solenoid Open Circuit 1658
FAILURE CODE [DXA9KB] Rear Pump PC-EPC Solenoid Short Circuit .1660
FAILURE CODE [DXE0KA] LS-EPC Solenoid Open Circuit 1662
FAILURE CODE [DXE0KB] LS-EPC Solenoid Short Circuit .1663
FAILURE CODE [DXE4KA] Attachment Flow Regulating EPC Solenoid Open Circuit 1665
FAILURE CODE [DXE4KB] Attachment Flow Regulating EPC Solenoid Short Circuit .1667
FAILURE CODE [DXE4KY] Attachment Flow EPC Hot Short Circuit .1669
FAILURE CODE [DXE5KA] Merge-divider Main Solenoid Open Circuit 1671
FAILURE CODE [DXE5KB] Merge-divider Main Solenoid Short Circuit .1673
FAILURE CODE [DXE6KA] Merge-divider LS Solenoid Open Circuit 1675
FAILURE CODE [DXE6KB] Merge-divider LS Solenoid Short Circuit .1677
FAILURE CODE [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid Open Circuit 1679
FAILURE CODE [DXE7KB] Attachment Flow Regulating EPC 2 Solenoid Short Circuit .1681
FAILURE CODE [DXE7KY] Attachment Flow Regulating EPC 2 Hot Short Circuit 1683
FAILURE CODE [DXE8KA] Attachment Flow Regulating EPC 3 Solenoid Open Circuit 1685
FAILURE CODE [DXE8KB] Attachment Flow Regulating EPC 3 Solenoid Short Circuit .1687
FAILURE CODE [DXE8KY] Attachment Flow Regulating EPC 3 Hot Short Circuit 1689
FAILURE CODE [DXE9KA] Attachment Flow Regulating EPC 4 Solenoid Open Circuit 1691
FAILURE CODE [DXE9KB] Attachment Flow Regulating EPC 4 Solenoid Short Circuit .1693
FAILURE CODE [DXE9KY] Attachment Flow Regulating EPC 4 Hot Short Circuit 1695
FAILURE CODE [DXEAKA] Attachment Flow Regulating EPC 5 Solenoid Open Circuit 1697
FAILURE CODE [DXEAKB] Attachment Flow Regulating EPC 5 Solenoid Short Circuit .1699
FAILURE CODE [DXEAKY] Attachment Flow Regulating EPC 5 Hot Short Circuit 1701
FAILURE CODE [DY20KA]Wiper Motor Open Circuit .1703
FAILURE CODE [DY20MA] Wiper Motor Defective Function 1705
FAILURE CODE [DY2CKB] Washer Motor Short Circuit 1707
FAILURE CODE [DY2DKB] Wiper Motor (Normal Rotation) Short Circuit .1710
FAILURE CODE [DY2EKB] Wiper Motor (Reverse Rotation) Short Circuit 1712
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1714
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1714
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1720
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1723
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1725
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1727
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1730
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1731
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1732
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1733
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1734
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1735
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1736
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1737
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1738
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1739
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1740
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1741
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1743
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1744
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1745
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1746
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1748
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1749
E-24 FUNCTION SWITCH DOES NOT OPERATE .1750
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1751
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1752
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1753
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1754
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1755
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1756
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1757
E-32 ALARM BUZZER CANNOT BE CANCELED 1759
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1760
E-34 SERVICE MODE CANNOT BE SELECTED 1761
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1762
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1765
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1767
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1770
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1772
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1775
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1776
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1778
E-43 HORN DOES NOT SOUND 1779
E-44 HORN DOES NOT STOP SOUNDING 1782
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1784
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1785
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1787
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1788
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1789
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1790
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1791
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1792
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1793
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1794
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1795
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1796
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1798
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1799
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1800
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1800
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1801
FAILURE MODE AND CAUSE TABLE 1803
H-1 ANY OF WORK EQUIPMENT, SWING AND TRAVEL DOES NOT WORK .1812
H-2 ALL OF WORK EQUIPMENTS, SWING AND TRAVEL OPERATION LACK SPEED OR POWER 1813
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1816
H-4 UNUSUAL SOUND IS HEARD FROM AROUND HYDRAULIC PUMP .1817
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1818
H-6 SPEED OR POWER OF BOOM IS LOW .1820
H-7 SPEED OR POWER OF ARM IS LOW 1824
H-8 SPEED OR POWER OF BUCKET IS LOW .1829
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1832
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1833
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1835
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .1837
H-13 OTHER WORK EQUIPMENT MOVES WHEN ONE OF WORK EQUIPMENT IS RELIEVED 1838
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1839
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT WORK 1840
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1841
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CONTROLLED 1842
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT , EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER .1843
H-19 TRAVEL SPEED DROPS LARGELY IN COMBINED OPERATION OF SWING AND TRAVE 1844
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1845
H-21 MACHINE DOES NOT TRAVEL STRAIGHT .1846
H-22 MACHINE IS HARD TO STEER OR TRAVEL POWER IS LOW 1848
H-23 TRAVEL SPEED IS LOW 1851
H-24 ONE OF TRACKS DOES NOT RUN .1853
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO LOW OR HIGH .1854
H-26 UPPER STRUCTURE DOES NOT SWING IN BOTH RIGHT AND LEFT DIRECTIONS .1855
H-27 UPPER STRUCTURE SWING IN ONLY ONE DIRECTION 1856
H-28 SWING ACCELERATION OR SWING SPEED OF UPPER STRUCTURE IS LOW IN BOTH RIGHT AND LEFT DIRECTIONS 1857
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION .1858
H-30 OVERRUN OF UPPER STRUCTURE IS LARGE IN BOTH RIGHT AND LEFT DIRECTIONS 1859
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING IN ONLY ONE DIRECTION .1860
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .1861
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .1862
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .1863
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1864
H-36 Quick coupler cylinder will not extend .1865
H-37 Quick coupler cylinder will not retract (but buzzer does not sound) 1867
H-38 Buzzer does not sound (but quick coupler cylinder does retract) 1869
H-39 Quick coupler cylinder extends and retracts slowly .1871
TROUBLESHOOTING OF ENGINE (S-MODE) 1872
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .1872
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1873
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1874
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1875
S-4 ENGINE STARTABILITY IS POOR .1877
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1879
S-6 ENGINE STOPS DURING OPERATION .1881
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1883
S-8 ENGINE LACKS POWER 1884
S-9 KDPF GETS CLOGGED IN A SHORT TIME .1886
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1888
S-11 OIL BECOMES CONTAMINATED QUICKLY .1889
S-12 FUEL CONSUMPTION IS EXCESSIVE 1890
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1891
S-14 OIL PRESSURE DROPS .1892
S-15 FUEL MIXES INTO ENGINE OIL .1894
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1895
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .1896
S-18 UNUSUAL NOISE IS HEARD .1897
S-19 VIBRATION IS EXCESSIVE .1898
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .1899
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .1900
S-22 ACTIVE REGENERATION TAKES TIME .1902
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1903
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1904
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .1906
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1907
50 DISASSEMBLY AND ASSEMBLY .1909
CONTENTS 1910
ABBREVIATION LIST .1915
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .1920
HOW TO READ THIS MANUAL .1920
COATING MATERIALS LIST 1922
SPECIAL TOOLS LIST 1927
SKETCHES OF SPECIAL TOOLS .1939
ENGINE AND COOLING SYSTEM .1945
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .1945
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1945
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1948
REMOVE AND INSTALL INJECTOR ASSEMBLY 1952
METHOD FOR REMOVING INJECTOR ASSEMBLY .1952
METHOD FOR INSTALLING INJECTOR ASSEMBLY .1957
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .1965
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 1966
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 1975
REMOVE AND INSTALL EGR VALVE ASSEMBLY .1991
METHOD FOR REMOVING EGR VALVE ASSEMBLY 1991
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 1992
REMOVE AND INSTALL EGR COOLER ASSEMBLY 1995
METHOD FOR REMOVING EGR COOLER ASSEMBLY .1995
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .1998
REMOVE AND INSTALL STARTER ASSEMBLY .2003
METHOD FOR REMOVING STARTER ASSEMBLY 2003
METHOD FOR INSTALLING STARTER ASSEMBLY 2005
REMOVE AND INSTALL ALTERNATOR BELT 2007
METHOD FOR REMOVING ALTERNATOR BELT .2007
METHOD FOR INSTALLING ALTERNATOR BELT .2009
REMOVE AND INSTALL RADIATOR ASSEMBLY 2011
METHOD FOR REMOVING RADIATOR ASSEMBLY .2011
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2013
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2015
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2015
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2018
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2021
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2021
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2022
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2024
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2025
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2033
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2044
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2044
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2047
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2051
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2051
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2052
REMOVE AND INSTALL FUEL COOLER ASSEMBLY .2055
METHOD FOR REMOVING FUEL COOLER ASSEMBLY 2055
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY 2056
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2057
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2057
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2059
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2065
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2065
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2069
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2073
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2073
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2078
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2084
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2084
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2089
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2095
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2095
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2095
REMOVE AND INSTALL AdBlue/DEF STRAINER 2097
METHOD FOR REMOVING AdBlue/DEF STRAINER .2097
METHOD FOR INSTALLING AdBlue/DEF STRAINER .2097
REMOVE AND INSTALL KDPF ASSEMBLY 2099
METHOD FOR REMOVING KDPF ASSEMBLY .2099
METHOD FOR INSTALLING KDPF ASSEMBLY .2101
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2103
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2104
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2107
REMOVE AND INSTALL SCR ASSEMBLY .2112
METHOD FOR REMOVING SCR ASSEMBLY 2112
METHOD FOR INSTALLING SCR ASSEMBLY 2114
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2116
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2116
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2122
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2128
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2128
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2135
REMOVE AND INSTALL KCCV ASSEMBLY 2143
METHOD FOR REMOVING KCCV ASSEMBLY .2143
METHOD FOR INSTALLING KCCV ASSEMBLY .2145
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2150
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2150
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2155
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2160
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2160
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2162
REMOVE AND INSTALL AdBlue/DEF PUMP 2164
METHOD FOR REMOVING AdBlue/DEF PUMP .2164
METHOD FOR INSTALLING AdBlue/DEF PUMP .2166
REMOVE AND INSTALL AdBlue/DEF HOSE 2169
METHOD FOR REMOVING AdBlue/DEF HOSE .2169
METHOD FOR INSTALLING AdBlue/DEF HOSE .2176
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2182
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2182
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2183
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2185
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2185
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2187
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2190
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2190
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2191
POWER TRAIN .2192
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2192
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2192
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2193
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2195
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2195
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2199
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2208
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2208
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2211
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2214
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2214
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2218
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2225
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2225
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2225
UNDERCARRIAGE AND FRAME .2227
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2227
METHOD FOR SEPARATING TRACK ASSEMBLY 2227
METHOD FOR INSTALLING TRACK ASSEMBLY 2229
REMOVE AND INSTALL SPROCKET .2232
METHOD FOR REMOVING SPROCKET 2232
METHOD FOR INSTALLING SPROCKET 2232
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2234
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2234
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2235
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2236
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2236
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2237
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2241
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2242
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2243
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2244
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2245
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2246
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2248
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2248
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2250
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2252
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2252
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2254
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2257
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2257
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2260
HYDRAULIC SYSTEM 2264
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2264
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2264
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2266
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2269
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2270
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2271
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2272
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2272
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2274
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2277
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2277
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2280
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2283
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2283
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2290
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2298
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2298
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2300
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2304
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2304
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2304
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2306
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2306
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2307
REMOVE AND INSTALL QUICK COUPLER VALVE 2309
WORK EQUIPMENT 2311
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2311
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2311
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2315
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2321
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2321
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2324
CAB AND ITS ATTACHMENTS .2330
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2330
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY .2330
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY .2335
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2342
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY .2344
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY .2344
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2354
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2354
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2357
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2363
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2363
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2370
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2377
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2377
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2382
REMOVE AND INSTALL OPERATOR’S SEAT 2388
METHOD FOR REMOVING OPERATOR’S SEAT .2388
METHOD FOR INSTALLING OPERATOR’S SEAT .2390
REMOVE AND INSTALL SEAT BELT 2393
METHOD FOR REMOVING SEAT BELT .2393
METHOD FOR INSTALLING SEAT BELT .2394
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2395
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2395
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2400
ELECTRICAL SYSTEM .2408
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2408
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2408
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2410
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2411
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2411
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2415
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2420
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2420
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2423
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2426
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2426
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2427
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2428
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2428
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2429
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2430
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2430
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2431
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2432
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2432
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2434
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2436
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2436
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2439
60 MAINTENANCE STANDARD .2443
CONTENTS 2444
ABBREVIATION LIST .2445
ENGINE AND COOLING SYSTEM .2450
MAINTENANCE STANDARD OF ENGINE MOUNT 2450
MAINTENANCE STANDARD OF COOLING SYSTEM 2451
POWER TRAIN .2452
MAINTENANCE STANDARD OF SWING CIRCLE 2452
MAINTENANCE STANDARD OF SWING MACHINERY .2453
MAINTENANCE STANDARD OF FINAL DRIVE .2455
MAINTENANCE STANDARD OF SPROCKET 2457
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2458
UNDERCARRIAGE AND FRAME .2460
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2460
MAINTENANCE STANDARD OF IDLER .2462
MAINTENANCE STANDARD OF TRACK ROLLER 2464
MAINTENANCE STANDARD OF CARRIER ROLLER 2465
MAINTENANCE STANDARD OF TRACK SHOE 2466
MAINTENANCE STANDARD OF TRIPLE SHOE .2469
MAINTENANCE STANDARD OF SWAMP SHOE 2470
MAINTENANCE STANDARD OF ROAD LINER 2471
HYDRAULIC SYSTEM 2472
MAINTENANCE STANDARD OF HYDRAULIC TANK 2472
MAINTENANCE STANDARD OF MAIN PUMP .2473
MAINTENANCE STANDARD OF LS-EPC VALVE 2474
MAINTENANCE STANDARD OF PC-EPC VALVE 2475
MAINTENANCE STANDARD OF SWING MOTOR .2476
MAINTENANCE STANDARD OF TRAVEL MOTOR 2479
MAINTENANCE STANDARD OF CONTROL VALVE .2482
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2492
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2495
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2498
MAINTENANCE STANDARD OF EPC VALVE .2499
MAINTENANCE STANDARD OF SOLENOID VALVE 2501
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 2502
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) .2504
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2505
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2506
WORK EQUIPMENT 2507
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2507
DIMENSION OF ARM 2512
DIMENSIONS OF BUCKET 2514
MAINTENANCE STANDARD OF BOOM CYLINDER .2516
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) .2517
MAINTENANCE STANDARD OF ARM CYLINDER 2518
MAINTENANCE STANDARD OF BUCKET CYLINDER .2519
80 APPENDIX .2521
CONTENTS 2522
ABBREVIATION LIST .2524
AIR CONDITIONER SYSTEM 2529
PRECAUTIONS FOR REFRIGERANT .2529
AIR CONDITIONER COMPONENT .2530
SPECIFICATIONS OF AIR CONDITIONER .2532
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2533
OUTLINE OF REFRIGERATION CYCLE 2534
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2536
AIR CONDITIONER UNIT 2536
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2536
FUNCTION OF AIR CONDITIONER UNIT 2538
COMPONENT PARTS OF AIR CONDITIONER UNIT .2540
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2541
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2541
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2541
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2541
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2542
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2542
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2542
FUNCTION OF DUAL PRESSURE SWITCH 2543
AIR CONDITIONER CONTROLLER 2544
STRUCTURE OF AIR CONDITIONER CONTROLLER .2544
COMPRESSOR 2545
STRUCTURE OF COMPRESSOR .2545
SPECIFICATIONS OF COMPRESSOR 2545
FUNCTION OF COMPRESSOR 2545
CONDENSER .2546
STRUCTURE OF CONDENSER 2546
SPECIFICATIONS OF CONDENSER .2546
FUNCTION OF CONDENSER .2546
SENSORS FOR AIR CONDITIONER SYSTEM 2548
STRUCTURE OF SUNLIGHT SENSOR 2548
FUNCTION OF SUNLIGHT SENSOR .2548
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2548
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2548
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2550
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2552
AIR CONDITIONER SYSTEM DIAGRAM 2554
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2555
FUNCTION OF AIR CONDITIONER CONTROLLER 2556
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2557
TESTING AIR LEAKAGE (DUCT) 2561
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2561
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2563
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2564
TEST VENT (MODE) CHANGEOVER .2565
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2565
TESTING FRESH/RECIRC AIR CHANGEOVER .2567
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2567
TEST SUNLIGHT SENSOR 2568
METHOD FOR TESTING SUNLIGHT SENSOR 2568
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2569
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2569
TEST RELAYS .2570
METHOD FOR TESTING RELAYS .2570
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2571
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2572
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2575
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit .2577
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit 2578
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit .2579
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit 2581
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit .2583
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit 2584
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit .2585
FAILURE CODE [879EMC] Ventilation Damper Malfunction 2587
FAILURE CODE [879FMC] Air Mix Damper Malfunction 2588
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range 2589
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2591
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2593
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2596
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2598
TROUBLESHOOTING USING GAUGE PRESSURE 2600
CONNECTION OF SERVICE TOOL 2603
METHOD FOR CONNECTING SERVICE TOOL 2603
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2605
HANDLE COMPRESSOR OIL .2607
METHOD FOR REPLACING DESICCANT 2609
90 CIRCUIT DIAGRAMS .2611
CONTENTS 2612
ABBREVIATION LIST .2613
HYDRAULIC CIRCUIT DIAGRAM .2618
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2618
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2623
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2625
ELECTRICAL CIRCUIT DIAGRAM 2627
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2627
ELECTRICAL CIRCUIT DIAGRAM (1/8) 2631
ELECTRICAL CIRCUIT DIAGRAM (2/8) 2633
ELECTRICAL CIRCUIT DIAGRAM (3/8) 2635
ELECTRICAL CIRCUIT DIAGRAM (4/8) 2637
ELECTRICAL CIRCUIT DIAGRAM (5/8) 2639
ELECTRICAL CIRCUIT DIAGRAM (6/8) 2641
ELECTRICAL CIRCUIT DIAGRAM (7/8) 2643
ELECTRICAL CIRCUIT DIAGRAM (8/8) 2645
INDEX .2647

DESCRIPTION:

Komatsu PC240LC-11,PC240NLC-11Hydraulic Excavator Shop Manual UENBM00330 – PDF DOWNLOAD

SERIAL NUMBERS

• 95001 and up
• K70001 and up

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

G.B 30/12/24