Komatsu Hydraulic Excavator PC240LC Repair Service Manuals
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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC240LC, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC240LC-10 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CEAM025102 - Hydraulic Excavator PC240LC-10 Operation & Maintenance Manual.pdf
CEBM024902 - Hydraulic Excavator PC240LC-10 Shop Manual.pdf
CEBM028601 - Hydraulic Excavator PC240LC-11 Shop Manual.pdf
SEN05538-02 - Hydraulic Excavator PC240LC-10 Shop Manual.pdf
TEN00509-02 - Hydraulic Excavator PC240LC-10 Operation & Maintenance Manual.pdf
TEN00592-01 - Hydraulic Excavator PC240LC-10 Operation & Maintenance Manual.pdf
Total Pages: 7,273 pages
File Format: PDF
Language: English
CEAM025102 - Hydraulic Excavator PC240LC-10 Operation & Maintenance Manual...2
FORWARD...7
SAFETY INFORMATION...8
Safety Labels...9
INTRODUCTION...10
Directions of Machine...10
Visibility from Operator’s Seat...10
Structure to Protect the Operator...10
Breaking-in The New Machine...11
Product Information...12
Product Identification Number (Pin)/Machine Serial No. Plate...12
EPA* Regulations, Engine Number Plate...12
Service Meter Location...13
Your Machine Serial Numbers And Distributor...13
Engine Acronyms...13
TABLE OF CONTENTS...14
SAFETY LABELS...25
Location Of Safety Labels...25
Safety Labels...26
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE...35
Precautions Before Starting Operation...35
Ensuring Safe Operation...35
Understanding The Machine...35
Preparations For Safe Operation...35
Precautions Regarding Safety-related Equipment...35
Inspecting Machine...35
Clothing And Personal Protective Items...35
Keep Machine Clean...36
Keep Operator's Compartment Clean...36
Fire Extinguisher And First Aid Kit...36
Safety Equipment...36
If Problems Are Found...36
Fire Prevention And Explosion Prevention...37
Action If Fire Occurs...38
Handrails and Steps...39
Mounting And Dismounting...39
No Persons On Attachments...39
Leaving Operator's Seat With Lock...40
Emergency Exit From Operator's Cab...40
Do Not Get Caught In Work Equipment...41
Precautions Related To Protective Structures...41
Falling Objects, Flying Objects And Intruding Objects Prevention...41
Unauthorized Modification...42
Precautions Related To Attachments And Options...42
Precautions Related To Cab Glass...42
Precautions When Running Engine Inside Building...42
Safety At Jobsite...43
Working On Loose Ground...43
Distance To High Voltage Cables...43
Ensure Good Visibility...44
Signalman's Signal And Signs...44
Asbestos Dust Hazard Prevention...45
SAFETY MACHINE OPERATION...46
Starting Engine...46
Checks Before Starting Engine...46
Safety Rules For Starting Engine...47
Starting Engine In Cold Weather...47
Starting Engine With Booster Cables...47
Operation...48
Checks Before Operation...48
Safety Rules For Changing Machine Directions...48
Safety Rules For Traveling...49
Traveling On Slopes...50
Operations On Slopes...51
Prohibited Operations...52
Operations On Snow Or Frozen Surfaces...54
Parking Machine...54
TRANSPORTATION...55
Loading and Unloading...55
Shipping the Machine...55
TOWING...56
Safety Rules For Towing...56
LIFTING OBJECTS WITH BUCKET...57
Safety Rules For Lifting Objects...57
SAFETY MAINTENANCE INFORMATION...58
Warning Tag...58
Keep Work Place Clean And Tidy...58
Select Suitable Place For Inspection And Maintenance...58
Only Authorized Personnel...58
Appoint Leader When Working With Others...58
Stop Engine Before Carrying Out Maintenance...59
Precautions When Working At High Places...59
Two Workers For Maintenance When Engine Is Running...60
Attachments...60
Work On Machine...61
Work Under The Machine...61
Proper Tools...61
Battery Disconnect Switch...62
Removing Battery Terminals...62
Welding...62
Battery...62
Battery Hazard Prevention...62
When Using Hammer...63
Precautions With High-temperature Coolant...63
Precautions With High-temperature Oil...64
Safety Rules For High-pressure Oil...64
Precaution For High Fuel Pressure...64
Safety Handling High-pressure Hoses or Piping...64
Precaution For High Voltage...65
Noise...65
Safety First When Using High-pressure Grease To Adjust Track Tension...65
Do Not Disassemble Recoil Springs...66
Accumulator...66
Handling Gas Spring...66
Precautions when using...66
Precautions when discarding...67
Compressed Air...67
Air Conditioner Maintenance...67
Waste Materials...67
Select Window Washer Fluid...67
Personnel...67
Periodic Replacement Of Safety Critical Parts...68
MACHINE VIEW ILLUSTRATIONS...71
Overall Machine View...71
General View of Cab...73
CONTROLS AND GAUGES...74
Machine Monitor...75
EXPLANATION OF COMPONENTS...76
Machine Monitor...76
Basic Operation of Machine Monitor...77
Warning Display...82
Meter Display...92
Gauges and Meter...99
Monitor Switches Portion...102
Handling Function Switches...112
User Menu Selector Switch...116
User Menu...117
Machine Settings...128
Maintenance Screen Setting...133
Monitor Setting...135
Screen Adjustment...135
Screen Adjustment (Camera)...136
Clock Adjustment...136
Time...138
SWITCHES...143
Starting Switch...143
Fuel Control Dial...144
Cigarette Lighter...144
Swing Lock Switch...144
Lamp Switch...145
Horn Switch...145
One Touch Power Max. Switch...145
Room Lamp Switch...145
Emergency Pump Drive Switch...146
Swing Brake Cancel Switch...146
Ceiling Window Wiper Switch...147
Seat Heater Switch...147
Engine Shutdown Secondary Switch...148
CONTROL LEVERS AND PEDALS...149
Lock Lever...149
Travel Levers...150
Work Equipment Control Lever...151
ROOF WINDOW...153
WINDSHIELD...153
EMERGENCY ESCAPE HAMMER...159
DOOR LOCK...160
CAB DOOR HINGE...160
ENGINE HOOD...161
When Opening (Normal Case: Intermediate Lock Position)...161
When Closing (Normal Case: Intermediate Lock Position)...163
CAPS AND COVERS WITH LOCK...165
Open and Close Caps with Lock...165
Opening the Cap...165
Locking the Cap...165
Open and Close Covers with Lock...166
Opening the Cover (Locked Cover)...166
Locking the Cover...166
Lock and Unlock Engine Hood...166
Opening the Hood (Locked Hood)...166
Locking the Hood...166
Lock and Unlock Cab Door...167
Opening the Door (Locked Door)...167
Locking the Door...167
DRINK BOX...168
MAGAZINE BOX...168
CUP HOLDER...168
ASHTRAY...169
AIR CONDITIONER CONTROLS...170
Air Conditioner Control Panel...170
Method of Operation...175
Automatic Operation...175
Stopping Automatic Operation...176
Manual Operation...176
Stop Manual Operation...178
Operation with Cold Air to Face and Warm Air to Feet...178
Defroster Operation...180
Rules for Using Air Conditioner...182
Air Conditioner Maintenance...182
RADIO...183
Control Panel...183
Operation Method...185
Frequency Adjustment...185
Frequency Adjustment (Auto Presetting)...185
Preset Call...185
Preset Memory...185
Sound Adjustment (Balance)...185
Sound Adjustment (Treble)...186
Sound Adjustment (Bass)...186
Time Adjustment...186
Stowing Radio Antenna...186
AUXILIARY ELECTRIC POWER...187
24 V Power Source...187
12 V Power Source...187
FUSE...188
FUSIBLE LINK...189
TOOL BOX...189
GREASE GUN HOLDER...189
FIRE EXTINGUISHER...189
BATTERY DISCONNECT SWITCH...190
SYSTEM OPERATING LAMP...191
HANDLING KOMATSU DIESEL PARTICULATE FILTER (KDPF)...192
Operation Procedure of Manual Stationary Regeneration...195
Komatsu Diesel Particulate Filter (KDPF) Regeneration Disable Procedure...197
While Regeneration is not being Performed: Setting for Regeneration Disable...198
While Regeneration is being Performed: Stopping Regeneration...200
Komatsu Diesel Particulate Filter (KDPF) Regeneration Disable Cancel Procedure...201
Handling Komatsu Closed Crankcase Ventilation (KCCV)...201
HANDLING MACHINES EQUIPPED WITH KOMTRAX...202
Basic Precautions...203
MACHINE OPERATIONS AND CONTROLS...204
Before Starting Engine...204
Walk-around Checks...204
Checks Before Starting...206
Adjustment...215
Seat Belt Inspection...224
Seat Belt...225
Operations Before Starting Engine...226
STARTING ENGINE...228
Turbo Protect Function...231
AFTER STARTING ENGINE...232
Engine Warm Up...234
Hydraulic System Warm-Up...236
Operation After Completion Of Warming-Up Operation...242
STOPPING THE ENGINE...244
MACHINE OPERATION...245
Preparations for Moving the Machine...245
Moving Machine Forward...246
Moving Machine Backward...247
Stopping Machine...248
STEERING THE MACHINE...249
Steering...249
Steering the Machine when Stopped...249
Changing Direction of the Machine...250
Counter-rotation Turn (Spin Turn)...250
SWINGING...251
WORK EQUIPMENT CONTROLS AND OPERATIONS...252
WORKING MODE...254
Working Mode Switch...254
One-Touch Power Max. Switch...256
PROHIBITED OPERATIONS...257
GENERAL OPERATION INFORMATION...260
Traveling...260
High Speed Travel...260
Permissible Water Depth...261
TRAVELING ON SLOPES...262
ESCAPE FROM MUD...264
Track on One Side Stuck...264
Tracks on Both Sides Stuck...264
RECOMMENDED APPLICATIONS...265
Backhoe Work...265
Shovel Work...265
Ditching Work...265
Loading Work...266
BUCKET REPLACEMENT AND INVERSION...267
Replacement...267
Inversion...269
PARKING MACHINE...271
MACHINE INSPECTION AFTER DAILY WORK...273
LOCKING...273
TRANSPORTATION...273
Transportation Procedure...273
Loading And Unloading With Trailer...274
Loading...275
Securing Machine...278
Stowing Radio Antenna...280
Rear view Mirrors...280
Remove and Install Handrail...282
Unloading...283
LONG DISTANCE TRANSPORT MODE...285
Normal Mode Display...285
Long Distance Transport Mode Display...285
LIFTING MACHINE...287
Standard Specification Machines...287
Machines with Lifting Hook...289
COLD WEATHER OPERATION...290
Cold Weather Operation Information...290
Fuel and Lubricants...290
Coolant...290
Battery...291
AFTER DAILY WORK COMPLETION...292
AFTER COLD WEATHER SEASON...292
LONG TERM STORAGE...293
Before Storage...293
During Storage...293
After Storage...294
Starting Machine After Long-term Storage...294
TROUBLES AND ACTIONS...295
Running Out Of Fuel...295
Phenomena That Are Not Failures...295
Towing The Machine...296
Lightweight Towing Hole...297
Severe Job Condition...297
Discharged Battery...298
Battery Removal and Installation...298
Battery Charges...299
Starting Engine with Booster Cables...300
OTHER TROUBLE...302
Electrical System...302
Chassis...303
Engine...304
Electronic Control System...306
Point of Contact to Telephone when Error Occurs...306
MAINTENANCE INFORMATION...309
OUTLINE OF SERVICE...311
Handling Oil, Fuel, Coolant, And Performing Oil Clinic...311
Oil...311
Fuel...312
Coolant And Water For Dilution...312
Grease...313
Carrying Out KOWA (Komatsu Oil Wear Analysis)...313
Storing Oil And Fuel...314
Filters...314
Electric System Maintenance...314
WEAR PARTS...315
Wear Parts List...315
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...316
Lubrication Chart...316
Fuel, Coolant, and Lubricants to Match the Ambient Temperature...318
KDPF (Komatsu Diesel Particulate Filter)...318
Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil...319
TORQUE SPECIFICATIONS...320
Torque List...320
Torque Of Bolts...320
Torque Of Hose Nuts...321
Torque Of Split Flange Bolts...321
Torque For Flared Nuts...322
Torque For O-ring Boss Piping Joints...322
Torque For O-ring Boss Plugs...323
Torque For Hoses (Taper Seal Type And Face Seal Type)...323
SAFETY CRITICAL PARTS...325
Safety Critical Parts List...326
MAINTENANCE SCHEDULE...327
Maintenance Schedule Table...327
Maintenance Interval For Hydraulic Breaker...329
MAINTENANCE PROCEDURE...330
Initial 10 Hours Maintenance...330
Initial 250 Hours Maintenance (Only After The First 250 Hours)...330
Initial 500 Hours Maintenance (Only After The First 500 Hours)...330
When Required...331
Check, Clean And Replace Air Cleaner Element...331
Clean Inside Of Cooling System...338
Check And Tighten Track Shoe Bolts...343
Check And Adjust Track Tension...344
Replace Bucket Teeth (Vertical Pin Type)...346
Replace Bucket Teeth (Horizontal Pin Type)...349
Replace Bucket Side Cutter, Shroud...351
Adjust Bucket Clearance...352
Check Window Washer Fluid Level, Add Fluid...353
Check And Maintain Air Conditioner...354
Wash Washable Floor...355
Set Machine at Angle...357
Check Gas Spring...358
Bleeding Air From Hydraulic System...359
Check Before Starting...361
Every 100 Hours Maintenance...362
Lubricating...362
Every 250 Hours Maintenance...363
Check Level Of Battery Electrolyte...363
Check Air Conditioner Compressor Belt Tension, Adjust...365
Every 500 Hours Maintenance...367
Lubricating...367
Change Oil In Engine Oil Pan...369
Replace Engine Oil Filter Cartridge...369
Replace Fuel Pre-filter Cartridge...371
Check Swing Pinion Grease Level, Add Grease...373
Clean And Inspect Radiator Fins, Oil Cooler Fins, Aftercooler Fins, Fuel Cooler Fins, And Condenser Fins...374
Clean Air Conditioner Fresh/Recirc Filters...376
Replace Breather Element In Hydraulic Tank...378
Check Oil Level In Swing Machinery Case, Add Oil...379
Check Oil Level In Final Drive Case, Add Oil...380
Every 1000 Hours Maintenance...381
Replace Hydraulic Oil Filter Element...381
Change Oil In Swing Machinery Case...382
Check Oil Level In Damper Case, Add Oil...383
Replace Fuel Main Filter Cartridge...384
Check All Tightening Points Of Engine Exhaust Pipe Clamps...387
Check Fan Belt Tension And Replace Fan Belt...387
Check Nitrogen Gas Charge Pressure In Accumulator (For Breaker)...387
Every 2000 Hours Maintenance...388
Change Oil In Final Drive Case...388
Clean Hydraulic Tank Strainer...389
Check Charge Pressure Of Nitrogen Gas In Accumulator (For Control Circuit)...390
Check Alternator...393
Check Engine Valve Clearance, Adjust...393
Replace Komatsu Closed Crankcase Ventilation (KCCV) Filter Element...394
Every 4000 Hours Maintenance...397
Check Water Pump...397
Check Vibration Damper...397
Check Starting Motor...397
Replace Accumulator (For Control Circuit)...398
Check For Looseness Of High-pressure Piping Clamp, Hardening Of Rubber...399
Check For Missing Fuel Spray Prevention Cap, Hardening Of Rubber...399
Check Operating Condition Of Compressor...400
Every 4500 Hours Maintenance...401
Clean Komatsu Diesel Particulate Filter (KDPF)...401
Replace Komatsu Closed Crankcase Ventilation (KCCV) Hose...401
Every 5000 Hours Maintenance...402
Change Oil In Hydraulic Tank...402
Every 8000 Hours Maintenance...403
Replace Fuel Spray Prevention Cap...403
Replace High-pressure Piping Clamp...403
SPECIFICATIONS...405
GENERAL PRECAUTIONS FOR SAFETY...409
Precautions When Selecting...409
Read The Operation and Maintenance Manual Thoroughly...409
Precautions When Removing Or Installing...409
Precautions When Using...409
BUCKET WITH HOOK...410
Hook Condition...410
Prohibited Operations...410
CHANGING DIRECTION OF THE MACHINE...411
Straight Travel (Option)...412
CHANGING MACHINE CONTROL PATTERN...413
Control Pattern Change Procedure...413
MACHINE READY FOR ATTACHMENT...415
Locations...415
Stop Valve...415
Selector Valve...416
Attachment Control Pedal...416
Lock Pin...416
Breaker Circuit Additional Oil Filter...417
Accumulator...418
HYDRAULIC CIRCUIT...419
Switching Hydraulic Circuit...419
Switching Between Breaker and General Attachment...419
Hydraulic Circuit Connection...420
Oil Flow Path...421
Replace Additional Breaker Filter Element...422
Replace Additional Breaker Pilot Filter Element...425
ATTACHMENT REMOVAL AND INSTALLATION...428
Attachment Removal...428
Attachment Installation...430
ATTACHMENT OPERATIONS...432
When Using Breaker...432
When Using General Attachment Such as Crusher...435
LONG TERM STORAGE...436
Specifications...436
Attachment Guide...437
Attachment Combinations...437
TRACK SHOES SELECTION...439
BUCKET TEETH SELECTION...440
Selection Guide for Horizontal or Vertical Pin Type Tooth...440
HANDLING OF RUBBER PAD SHOE AND ROAD LINER...441
Check Road Liner...442
Handling Trapezoidal Bucket...443
Digging Work...443
HANDLING EXTENSION ARM...445
HANDLING CLAMSHELL BUCKET...446
RECOMMENDED ATTACHMENT OPERATIONS...447
Hydraulic Breaker...447
Prohibited Usage...449
CEBM024902 - Hydraulic Excavator PC240LC-10 Shop Manual...452
CEBM024902_PC240LC-10...0
CONTENTS...453
00 - FOREWORD...470
GENERAL...474
HOW TO READ THE SHOP MANUAL...475
Volumes...475
Distribution And Updating...475
Filing Method...475
Revised Edition Mark...475
Revisions...475
Symbols...475
HOISTING INSTRUCTIONS...476
Hoisting...476
Making Signs...476
Precautions...476
Precautions for Sling Work...476
Precautions for Using Mobile Crane...477
Precautions for Using Overhead Hoist Crane...477
Selecting Wire Ropes...478
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS...479
Points to Remember When Handling Electric Equipment...479
Points to Remember When Handling Hydraulic Equipment...490
PUSH PULL COUPLER...492
Type 1...492
Disconnection...492
Connection...492
Type 2...493
Disconnection...493
Connection...493
Type 3...494
Disconnection...494
Connection...494
EXPLANATION OF MAINTENANCE STANDARD TERMS...495
HANDLING OF FUEL SYSTEM DEVICES...496
HANDLING OF INTAKE SYSTEM PARTS...497
STANDARD TIGHTENING TORQUE...498
Bolts And Nuts...498
Tightening Torque Of Hose Nuts...499
Tightening Torque Of Split Flange Bolts...499
Tightening Torque For Flared Nuts...499
Tightening Torques for Split Flanged Bolts...500
Tightening Torques For O-ring Boss Piping Joints...500
Table Of Tightening Torques For O-ring Boss Plugs...500
Tightening Torque For Hoses (Taper Seal Type And Face Seal Type)...501
Tightening Torque For Face Seal Joints...501
For 102, 107, and 114 Engine Series (Bolts and Nuts)...501
For 102, 107, and 114 Engine Series (Eye Joints)...502
For 102, 107, and 114 Engine Series (Taper Screws)...502
ELECTRIC WIRE CODE...503
Classification By Thickness...503
Classification By Color And Code...503
How To Read Electric Wire Code...504
PRECAUTIONS FOR OPERATIONS...507
Precautions when Carrying Out Removal Work...507
Precautions when Carrying Out Installation Work...508
Precautions when Completing the Operation...509
CONVERSION TABLES...510
Method Of Using The Conversion Table...510
COATING MATERIALS...516
LIST OF ABBREVIATIONS...519
List of Abbreviations Used in the Shop Manual...519
List of Abbreviations Used in the Circuit Diagrams...523
Safety Notice...470
Important Safety Notice...470
General Precautions...470
Preparations For Work...471
Precautions During Work...471
01 - GENERAL...524
SPECIFICATION DIMENSION DRAWINGS...525
Dimensions...525
Working Ranges...526
SPECIFICATIONS...527
WEIGHT TABLE...531
FUEL, COOLANT AND LUBRICANTS...533
Lubrication Chart...535
10 - STRUCTURE AND FUNCTION...0
ENGINE AND COOLING SYSTEM...539
Engine Related Parts...539
Radiator, Oil Cooler, Aftercooler, and Fuel Cooler...541
POWER TRAIN...543
Power Train...543
Swing Machinery...545
Swing Circle...547
Final Drive...549
UNDERCARRIAGE AND FRAME...551
Track Frame and Idler Cushion...551
HYDRAULIC SYSTEM...553
Hydraulic Equipment Layout...553
Valve Control...555
Hydraulic Tank...557
Oil Filler Cap...558
CLSS...559
Structure of CLSS...559
Basic Principle...560
Main Pump...563
Operation...567
LS Valve...569
PC Valve...575
LS(PC)-EPC Valve...582
Control Valve...585
Functions and Operation by Valve...597
Hydraulic Circuit Diagram and Name of Valves...597
Unload Valve...601
Introduction of LS Pressure...602
LS By-Pass Plug...603
Pressure Compensation Valve...604
Shuttle Valve In Pressure Compensation Valve...607
Boom Regeneration Circuit...609
Arm Regeneration Circuit...611
Merge-Divider Valve...613
LS Selector Valve...616
Self-Pressure Reducing Valve...617
Travel Junction Valve...621
Travel PPC Shuttle Valve...625
Boom Hydraulic Drift Prevention Valve...627
Arm Hydraulic Drift Prevention Valve (If Equipped)...630
Suction Safety Valve For Drift Prevention Valve...633
Arm Quick Return Valve...635
Variable Back Pressure Valve...637
Main Relief Valve...639
Suction 2-Stage Safety Valve...641
Swing Motor...643
Swing Holding Brake...645
Relief Valve...647
Swing 2-Stage Relief Valve...649
Swing Motor Reverse Prevention Valve...650
Travel Motor...653
Operation of Travel Motor...656
Operation of Parking Brake...658
Brake Valve...659
Counterbalance Valve...660
Suction Safety Valve...661
PPC Valve...663
Work Equipment and Swing PPC Valve...663
Travel PPC Valve...669
1st-Line Attachment PPC Valve (with EPC Valve) (If Equipped)...673
EPC Valve (If Equipped)...675
2nd-Line Attachment PPC Valve (If Equipped)...679
Solenoid Valve...681
Attachment Circuit Selector Valve (For High Pressure Circuit) (If Equipped)...685
Attachment Circuit Selector Valve (For Low Pressure Circuit) (If Equipped)...687
Center Swivel Joint...689
Accumulator...690
PPC Accumulator...690
WORK EQUIPMENT...691
Work Equipment...691
Work Equipment Shim...692
Bucket Play Adjustment Shim...692
CAB AND ITS ATTACHMENTS...693
Cab Mount and Cab Tipping Stopper...693
ROPS Cab...695
ELECTRICAL SYSTEM...697
Electrical Control System...697
Machine Control System Diagram...697
Engine Control Function...699
Engine and Pump Combined Control Function...701
Pump and Valve Control Function...707
One-Touch Power Maximizing Function...709
Auto-Deceleration Function...711
Engine Automatic Warm-Up Function...713
Overheat Prevention Function...715
Turbocharger Protection Function...716
Swing Control Function...717
Quick Warm-Up Function...719
Swing 2-Stage Relief Function...719
Travel Control Function...721
PPC Lock Function...723
Attachment Flow Control Function...725
System Component Part...727
Engine Controller...727
Pump Controller...731
Fuel Control Dial...735
Resister for PC-EPC valve...736
CAN Terminating Resistor...737
Engine Oil Pressure Switch...738
PPC Oil Pressure Switch...739
MACHINE MONITOR SYSTEM...741
Machine Monitor...743
Input and Output Signals...744
Display...747
Gauges...749
Caution Monitor...751
Pilot Monitor...755
Switches...757
Guidance ICON and Function Switch...759
Operator Mode Function...763
Service Mode Function...765
KOMTRAX SYSTEM...767
KOMTRAX terminal...768
Input and Output Signals...769
SENSORS...771
Ambient Pressure Sensor...771
Charge (Boost) Pressure and Temperature Sensor...772
Coolant Temperature Sensor...773
Ne (Crankshaft) Speed Sensor...773
Bkup (Camshaft) Speed Sensor...774
Common Rail Pressure Sensor...774
Exhaust Manifold Pressure Sensor...775
EGR Orifice Temperature Sensor...775
EGR Valve Lift Sensor...776
Turbo Speed Sensor...777
KVGT Position Sensor...778
Mass Air Flow and Temperature Sensor...779
KDPF Differential Pressure and Outlet Pressure Sensor...779
KDOC Inlet Temperature Sensor...780
KDOC Outlet Temperature Sensor...780
KDPF Outlet Temperature Sensor...781
Crankcase Pressure Sensor...781
Engine Oil Level Sensor...782
Fuel Level Sensor...783
Coolant Level Sensor...784
Hydraulic Oil Temperature Sensor...784
Front Pump Oil Pressure Sensor...785
Rear Pump Oil Pressure Sensor...786
PPC Oil Pressure Sensor...787
Air Cleaner Clogging Sensor...788
Front Pump Swash Plate Sensor...789
Rear Pump Swash Plate Sensor...791
Water-In-Fuel Sensor...793
20 - STANDARD VALUE TABLES...0
STANDARD SERVICE VALUE TABLES...795
Standard Value Table for Engine Related Parts...795
Standard Value Table for Chassis Related Parts...797
Engine Speed...797
Control Valve Spool Stroke...797
Control Lever Stroke...798
Operating Effort of Control Lever and Pedal...798
Hydraulic Pressure...799
Swing...800
Travel...801
Work Equipment...802
Performance in Combined Operation...804
Pump Swash Plate Sensor...804
Characteristics of PC Flow Control...804
Hydraulic Pump...805
Posture of Machine for Measuring Performance and Measurement Procedure...806
Control Valve: Spool Stroke...806
Swing 1: Overrun When Stopping Swing, Time Taken to Start Swing, Time Taken to Swing...806
Swing 2: Hydraulic Drift of Swing...806
Travel 1: Travel Speed, Idle Running (Without Load)...806
Travel 2: Travel Speed (Actual Run), Travel Deviation...807
Travel 3: Travel Deviation...807
Travel 4: Hydraulic Drift of Travel...807
Work Equipment 1: Hydraulic Drift of Work Equipment...807
Work Equipment 2: Boom Speed...808
Work Equipment 3: Arm Speed...808
Work Equipment 4: Bucket Speed...808
Work Equipment 5: Boom Time Lag...808
Work Equipment 6: Arm Time Lag...809
Work Equipment 7: Bucket Time Lag...809
Work Equipment 8: PC Flow Characteristics Control...809
30 - TESTING AND ADJUSTING...0
GENERAL INFORMATION ON TESTING AND ADJUSTING...813
Tools for Testing, Adjusting, and Troubleshooting...813
Sketch of Tools for Testing and Adjusting...818
ENGINE AND COOLING SYSTEM...821
Checking Engine Speed...821
Measuring Boost Pressure...823
Measuring Exhaust Gas Color...825
Measuring and Adjusting Valve Clearance...827
Testing...827
Adjusting...830
Measuring Compression Pressure...831
Measuring Blow-By Pressure...837
Measuring Engine Oil Pressure...839
Measuring EGR Valve and KVGT Oil Pressure...841
Measuring Fuel Pressure...843
Testing Low-Pressure Circuit (Fuel Main Filter Inlet Side)...845
Testing Low-Pressure Circuit (Pressure Difference)...846
Testing Return Circuit...847
Testing Negative-Pressure Circuit...848
Measuring Fuel Delivery, Return and Leakage...849
Testing Supply Pump Delivery...851
Testing Supply Pump Return Rate...853
Testing Leakage from Pressure Limiter...854
Testing Injector Return Rate from Injector...855
Bleeding Air from Fuel System...857
Bleeding Air...857
Route for Bleeding Air from Fuel Circuit...858
Checking Fuel Circuit for Leakage...859
Handling Cylinder Cut-Out Mode Operation...860
Handling No-Injection Cranking Operation...860
Checking and Adjusting Air Conditioner Compressor Belt Tension...861
Checking...861
Adjusting...862
Replacing Fan Belt...863
POWER TRAIN...865
Testing Swing Circle Bearing Clearance...865
Testing...865
UNDERCARRIAGE AND FRAME...867
Testing and Adjusting Track Shoe Tension...867
Testing...867
Adjusting...867
HYDRAULIC SYSTEM...869
Releasing Remaining Pressure from Hydraulic Circuit...869
Measuring and Adjusting of Oil Pressure in Work Equipment, Swing, and Travel Circuits...871
Testing...871
Adjusting...873
Measuring Oil Pressure in Control Circuit...875
Measuring and Adjusting Oil Pressure in Pump PC Control Circuit...877
Testing...877
Adjusting...880
Measuring and Adjusting Oil Pressure in Pump LS Control Circuit...881
Testing...882
Checking Oil Pressure with Sensor Adapter (Special Tool)...886
Adjusting...887
Measuring Solenoid Valve Output Pressure...889
Testing...889
Operating Condition...891
Measuring PPC Valve Output Pressure...893
Adjusting Play of Work Equipment and Swing PPC Valves...895
Testing Pump Swash Plate Sensor...896
Isolating the Parts Causing Hydraulic Drift in Work Equipment...897
Measuring Oil Leakage...899
Bleeding Air From Hydraulic Circuit...902
CAB AND ITS ATTACHMENTS...905
Checking Cab Tipping Stopper...905
Adjusting Mirrors...907
ELECTRICAL SYSTEM...909
Special Functions of Machine Monitor...909
Upper Part of Machine Monitor (Display Portion)...910
Upper Part of Machine Monitor (Switch Portion)...910
Lower Part of Machine Monitor (Switch Portion)...910
Ordinary Functions and Special Functions of Machine Monitor...910
Operator Mode (Outline)...913
Display of KOMATSU Logo...915
Display of Inputting Password...915
Display of Check of Breaker Mode...915
Display of Check Before Starting...916
Display of Warning After Check Before Starting...916
Display of Ending of Maintenance Interval...916
Display of Check of Working Mode and Travel Speed...916
Display of Standard Screen...917
Display of End Screen...917
Display of Engine Shutdown Secondary Switch Screen...917
Selection of Auto-Deceleration...917
Selection of Working Mode...918
Selection of Travel Speed...919
Operation to Stop Alarm Buzzer...919
Operation of Windshield Wiper...919
Operation of Window Washer...919
Operation of Air Conditioner/Heater...919
Operation to Display Camera Mode (If Camera is Installed)...920
Operation to Display Clock and Service Meter...920
Check of Maintenance Information...921
Setting and Display of User Mode (Including KOMTRAX Messages for User)...921
Display of ECO Guidance...922
Display of Caution Monitor...923
Display of KDPF Regeneration...925
Display of Action Level and Failure Code...928
Function of Checking Display of LCD (Liquid Crystal Display)...929
Function of Checking Service Meter...929
Function of Changing Attachment/Maintenance Password...931
Service Mode...933
Monitoring / Pre-Defined...935
Monitoring / Custom...941
Monitoring Items Table...945
Abnormality Record (Mechanical Systems)...951
Abnormality Record (Electrical Systems)...953
Maintenance Record...955
Maintenance Mode Setting...957
Phone Number Entry...960
Default (Key-On Mode)...961
Default (Unit)...962
Default (With/Without Attachment)...963
Default (Camera)...965
Diagnostic Tests (Cylinder Cut-out)...967
Diagnostic Tests (Regeneration for Service)...969
Diagnostic Tests (KDPF Memory Reset)...971
Adjustment (Pump Absorption Torque (F))...973
Adjustment (Pump Absorption Torque (R))...974
Adjustment (Low Speed)...975
Adjustment (Attachment Flow Adjustment)...976
Adjustment (Cal F Pump Swash Plate Sensor)...977
Adjustment (Cal R Pump Swash Plate Sensor)...983
Adjustment (Pump Calibration: Matching Speed Calibration)...984
Adjustment (Pump Calibration: Matching Speed Check)...986
No Injection...993
KOMTRAX Settings (Terminal Status)...995
KOMTRAX Settings (GPS and Communication Status)...996
KOMTRAX Settings (Modem Information)...997
Service Message...998
Angle Adjustment of Rear View Camera...999
Handling Voltage Circuit of Engine Controller...1001
Handling Battery Disconnect Switch...1002
Testing Diodes...1003
PM CLINIC...1004
PM Clinic Service...1004
Check Items Related to Engine...1006
Check Items Related to Oil Pressure...1007
Check Sheet...1008
40 - TROUBLESHOOTING...1014
GENERAL INFORMATION ON TROUBLESHOOTING...1023
Points to Remember When Troubleshooting...1023
Sequence of Events in Troubleshooting...1025
Checks Before Troubleshooting...1027
Testing Procedure Before Troubleshooting...1029
Walk-Around Check...1029
Testing in Accordance with Testing Procedure...1031
Check of Water Separator, and Drainage of Water and Sediments...1033
Replacing Fuel Pre-Filter Cartridge...1035
Preparation Work for Troubleshooting of Electrical System...1057
Preparation Work...1057
Classification and Procedure for Troubleshooting...1063
Classification of Troubleshooting...1063
Procedure for Troubleshooting...1063
Symptom of Probable Failure and Troubleshooting No...1067
Information Mentioned in Troubleshooting Table...1071
Diagnostic Procedure for Wiring Harness Open Circuit of Pressure Sensor System...1073
Connection Table for Connector Pin Numbers...1077
T-Branch Box and T-Branch Adapter Table...1111
Fuse List and Location...1115
Connection Table of Fuse Box...1115
Locations of Fusible Links...1116
Location of Fuse Box and Fuse Numbers...1116
Precautions for Cleaning and Replacing KDPF (KCSF, KDOC)...1117
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)...1121
Failure Codes Table...1121
Failure Code [879AKA] A/C Inner Sensor Open Circuit...1131
Failure Code [879AKB] A/C Inner Sensor Short Circuit...1131
Failure Code [879BKA] A/C Outer Sensor Open Circuit...1131
Failure Code [879BKB] A/C Outer Sensor Short Circuit...1131
Failure Code [879CKA] Ventilating Sensor Open Circuit...1131
Failure Code [879CKB] Ventilating Sensor Short Circuit...1131
Failure Code [879DKZ] Sunlight Sensor Open or Short Circuit...1131
Failure Code [879EMC] Ventilation Damper Abnormality...1132
Failure Code [879FMC] Air Mix Damper Abnormality...1132
Failure Code [879GKX] Refrigerant Abnormality...1132
Failure Code [989L00] Engine Controller Lock Caution 1...1133
Failure Code [989M00] Engine Controller Lock Caution 2...1133
Failure Code [989N00] Engine Controller Lock Caution 2...1134
Failure Code [A1U0N3] HC Desorb Request 1...1135
Failure Code [A1U0N4] HC Desorb Request 2...1137
Failure Code [AA10NX] Air Cleaner Clogging...1139
Failure Code [AB00KE] Charge Voltage Low...1141
Failure Code [B@BAZG] Engine Oil Pressure Low...1143
Failure Code [B@BAZK] Eng Oil Level Low...1145
Failure Code [B@BCNS] Engine Coolant Overheat...1147
Failure Code [B@BCZK] Radiator Coolant Level Low...1149
Failure Code [B@HANS] Hyd Oil Overheat...1151
Failure Code [CA115] Eng Ne and Bkup Speed Sens Error...1152
Failure Code [CA122] Chg Air Press Sensor High Error...1153
Failure Code [CA123] Chg Air Press Sensor Low Error...1155
Failure Code [CA131] Throttle Sensor High Error...1157
Failure Code [CA132] Throttle Sensor Low Error...1159
Failure Code [CA144] Coolant Temp Sens High Error...1161
Failure Code [CA145] Coolant Temp Sens Low Error...1163
Failure Code [CA153] Chg Air Temp Sensor High Error...1165
Failure Code [CA154] Chg Air Temp Sensor High Error...1167
Failure Code [CA187] Sensor 2 Supply Volt Low Error...1169
Failure Code [CA221] Ambient Press Sensor High Error...1171
Failure Code [CA222] Ambient Press Sensor Low Error...1173
Failure Code [CA227] Sensor 2 Supply Volt High Error...1175
Failure Code [CA234] Eng Overspeed...1176
Failure Code [CA238] Ne Speed Sensor Supply Volt Error...1177
Failure Code [CA239] Ne Speed Sens Supply Volt High Error...1179
Failure Code [CA271] IMV/PCV1 Short Error...1181
Failure Code [CA272] IMV/PCV1 Open Error...1183
Failure Code [CA295] Ambient Press Sens In Range Error...1185
Failure Code [CA322] Inj #1 (L#1) Open/Short Error...1187
Failure Code [CA323] Inj #5 (L#5) Open/Short Error...1189
Failure Code [CA324] Inj #3 (L#3) Open/Short Error...1191
Failure Code [CA325] Inj #6 (L#6) Open/Short Error...1193
Failure Code [CA331] Inj #2 (L#2) Open/Short Error...1195
Failure Code [CA332] Inj #4 (L#4) Open/Short Error...1197
Failure Code [CA343] ECM Critical Internal Failure...1199
Failure Code [CA351] Injectors Drive Circuit Error...1200
Failure Code [CA352] Sensor 1 Supply Volt Low Error...1201
Failure Code [CA356] Mass Air Flow Sensor High Error...1203
Failure Code [CA357] Mass Air Flow Sensor Low Error...1205
Failure Code [CA386] Sensor 1 Supply Volt High Error...1208
Failure Code [CA428] Water in Fuel Sensor High Error...1209
Failure Code [CA429] Water in Fuel Sensor Low Error...1211
Failure Code [CA435] Eng Oil Press Sw Error...1213
Failure Code [CA441] Battery Voltage Low Error...1215
Failure Code [CA442] Battery Voltage High Error...1217
Failure Code [CA449] Rail Press Very High Error...1218
Failure Code [CA451] Rail Press Sensor High Error...1219
Failure Code [CA452] Rail Press Sensor Low Error...1221
Failure Code [CA488] Chg Air Temp High Torque Derate...1223
Failure Code [CA515] Rail Press Sens Sup Volt High Error...1225
Failure Code [CA516] Rail Press Sens Sup Volt Low Error...1227
Failure Code [CA553] Rail Press High Error...1229
Failure Code [CA555] Crankcase Press High Error 1...1230
Failure Code [CA556] Crankcase Press High Error 2...1231
Failure Code [CA559] Rail Press Low Error...1233
Failure Code [CA595] Turbo Speed High Error 2...1234
Failure Code [CA687] Turbo Speed Low Error...1235
Failure Code [CA689] Eng Ne Speed Sensor Error...1237
Failure Code [CA691] Intake Air Temp Sens High Error...1241
Failure Code [CA692] Intake Air Temp Sens Low Error...1243
Failure Code [CA697] ECM Int Temp Sensor High Error...1245
Failure Code [CA698] ECM Int Temp Sensor Low Error...1246
Failure Code [CA731] Eng Bkup Speed Sens Phase Error...1247
Failure Code [CA778] Eng Bkup Speed Sensor Error...1249
Failure Code [CA1117] Persistent Data Lost Error...1253
Failure Code [CA1664] KDOC Malfunction...1255
Failure Code [CA1691] Regeneration Ineffective...1257
Failure Code [CA1695] Sensor 5 Supply High Error...1261
Failure Code [CA1696] Sensor 5 Supply Volt Low Error...1263
Failure Code [CA1843] Crankcase Press Sens High Error...1265
Failure Code [CA1844] Crankcase Press Sens Low Error...1267
Failure Code [CA1879] KDPF Delta P Sensor High Error...1271
Failure Code [CA1881] KDPF Delta P Sensor Low Error...1273
Failure Code [CA1883] KDPF Delta P Sens In Range Error...1277
Failure Code [CA1921] KDPF Soot Load High Error 1...1281
Failure Code [CA1922] KDPF Soot Load High Error 2...1283
Failure Code [CA1942] Crankcase Press Sens In Range Error...1287
Failure Code [CA1993] KDPF Delta Pressure Low Error...1288
Failure Code [CA2185] Throt Sensor Sup Volt High Error...1289
Failure Code [CA2186] Throt Sensor Sup Volt Low Error...1291
Failure Code [CA2249] Rail Press Very Low Error...1293
Failure Code [CA2271] EGR Valve Pos Sens High Error...1295
Failure Code [CA2272] EGR Valve Pos Sens Low Error...1299
Failure Code [CA2288] Turbo Speed High Error 1...1303
Failure Code [CA2311] IMV Solenoid Error...1304
Failure Code [CA2349] EGR Valve Solenoid Open Error...1305
Failure Code [CA2353] EGR Valve Solenoid Short Error...1307
Failure Code [CA2357] EGR Differential Pressure...1309
Failure Code [CA2373] Exh Manifold Press. Sens Volt...1311
Failure Code [CA2374] Exhaust Manifold Press Sens Low Error...1313
Failure Code [CA2375] EGR Orifice Temp Sens High Error...1315
Failure Code [CA2376] EGR Orifice Temp Sens Low Error...1317
Failure Code [CA2381] KVGT Pos Sens High Error...1319
Failure Code [CA2382] KVGT Pos Sens Low Error...1321
Failure Code [CA2383] KVGT Solenoid Open Error...1325
Failure Code [CA2386] KVGT Solenoid Short Error...1327
Failure Code [CA2387] KVGT Servo Error...1329
Failure Code [CA2554] Exh Manifold Press Sens In Range Error...1330
Failure Code [CA2555] Grid Htr Relay Volt Low Error...1331
Failure Code [CA2556] Grid Htr Relay Volt High Error...1335
Failure Code [CA2637] KDOC Face Plugging...1339
Failure Code [CA2639] Manual Stationary Regeneration Request...1341
Failure Code [CA2961] EGR Orifice Temp High Error 1...1343
Failure Code [CA2973] Chg Air Press Sensor In Range Error...1344
Failure Code [CA3133] KDPF Outlet Press Sens High Error...1345
Failure Code [CA3134] KDPF Outlet Press Sens Low Error...1347
Failure Code [CA3135] KDPF Outlet Press Sens In Range Error...1351
Failure Code [CA3251] KDOC Inlet Temp High Error...1355
Failure Code [CA3253] KDOC Temp Error - Non Regeneration...1359
Failure Code [CA3254] KDOC Outlet Temp High Error 1...1361
Failure Code [CA3255] KDPF Temp Error - Non Regeneration...1364
Failure Code [CA3256] KDPF Outlet Temp High Error 1...1365
Failure Code [CA3311] KDOC Outlet Temp High Error 2...1366
Failure Code [CA3312] KDPF Outlet Temp High Error 2...1367
Failure Code [CA3313] KDOC Inlet Temp Sensor Low Error...1371
Failure Code [CA3314] KDOC Inlet Temp Sens High Error...1375
Failure Code [CA3315] KDOC Inlet Temp Sens In Range Error...1379
Failure Code [CA3316] KDOC Outlet Temp Sens Low Error...1383
Failure Code [CA3317] KDOC Outlet Temp Sens High Error...1387
Failure Code [CA3318] KDOC Outlet Temp Sens In Range Error...1391
Failure Code [CA3319] KDPF Outlet Temp Sens High Error...1395
Failure Code [CA3321] KDPF Outlet Temp Sens Low Error...1399
Failure Code [CA3322] KDPF Outlet Temp Sens In Range Error...1403
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error...1407
Failure Code [CA3421] Mass Air Flow Sensor Sup Volt Low Error...1409
Failure Code [CA3741] Rail Press Valve Trip Error...1411
Failure Code [D110KB] Battery Relay Output Voltage...1413
Failure Code [D19JKZ] Personal Code Relay Abnormality...1415
Failure Code [D811MC] KOMTRAX Error...1418
Failure Code [D862KA] GPS Antenna Open Circuit...1418
Failure Code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)...1419
Failure Code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)...1421
Failure Code [D8AQKR] CAN2 Discon (KOMTRAX)...1423
Failure Code [DA20MC] Pump Controller...1424
Failure Code [DA22KK] Pump Solenoid Power Low Error...1425
Failure Code [DA25KP] 5V Sensor 1 Power Abnormality...1427
Failure Code [DA29KQ] Model Selection Abnormality...1431
Failure Code [DA2LKA] Operating Lamp Open Circuit (Pump Con)...1433
Failure Code [DA2LKB] Operating Lamp Short Circuit (Pump Con)...1435
Failure Code [DA2QKR] CAN2 Discon (Pump Con)...1437
Failure Code [DA2QKR] CAN1 Discon (Pump Con)...1440
Failure Code [DAF0MB] Monitor ROM Abnormality...1441
Failure Code [DAF0MC] Monitor Error...1442
Failure Code [DAF8KB] Camera Power Supply Short Circuit...1443
Failure Code [DAF9KQ] Model Selection Abnormality...1445
Failure Code [DAFGMC] GPS Module Error...1446
Failure Code [DAFLKA] Operating Lamp Open Circuit (Monitor)...1447
Failure Code [DAFLKB] Operating Lamp Short Circuit (Monitor)...1449
Failure Code [DAFQKR] CAN2 Discon (Monitor)...1451
Failure Code [DAZ9KQ] A/C Model Selection Abnormality...1452
Failure Code [DAZQKR] CAN2 Discon (Aircon ECU)...1453
Failure Code [DB2QKR] CAN2 Discon (Engine Con)...1457
Failure Code [DB2RKR] CAN1 Discon (Engine Con)...1463
Failure Code [DGH2KB] Hyd Oil Sensor Short Circuit...1467
Failure Code [DHA4KA] Air Cleaner Clog Sensor Open Circuit...1469
Failure Code [DHPAMA] F Pump Press Sensor Abnormality...1471
Failure Code [DHPBMA] R Pump Press Sensor Abnormality...1475
Failure Code [DHS3MA] Arm Curl PPC Press Sensor Abnormality...1479
Failure Code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality...1483
Failure Code [DHS8MA] Boom Raise PPC Press Sensor Abnormality...1487
Failure Code [DHS9MA] Boom Lower PPC Press Sensor Abnormality...1491
Failure Code [DHSAMA] Swing RH PPC Press Sensor Abnormality...1495
Failure Code [DHSBMA] Swing LH PPC Press Sensor Abnormality...1499
Failure Code [DHSCMA] Arm Dump PPC Press Sensor Abnormality...1503
Failure Code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality...1507
Failure Code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality...1511
Failure Code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality...1515
Failure Code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality...1519
Failure Code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality...1523
Failure Code [DKR0MA] F Pump Swash Plate Sensor Abnormality...1527
Failure Code [DKR1MA] R Pump Swash Plate Sensor Abnormality...1531
Failure Code [DR21KX] Camera 2 Picture Rev. Drive Abnormality...1535
Failure Code [DR31KX] Camera 3 Picture Rev. Drive Abnormality...1537
Failure Code [DV20KB] Travel Alarm Short Circuit...1539
Failure Code [DW43KA] Travel Speed Sol Open Circuit...1541
Failure Code [DW43KB] Travel Speed Sol Short Circuit...1543
Failure Code [DW45KA] Swing Brake Sol Open Circuit...1545
Failure Code [DW45KB] Swing Brake Sol Short Circuit...1549
Failure Code [DW91KA] Travel Junction Sol Open Circuit...1553
Failure Code [DW91KB] Travel Junction Sol Short Circuit...1555
Failure Code [DWA2KA] Attachment Sol Open Circuit...1557
Failure Code [DWA2KB] Attachment Sol Short Circuit...1559
Failure Code [DWK0KA] 2-Stage Relief Sol Open Circuit...1561
Failure Code [DWK0KB] 2-Stage Relief Sol Short Circuit...1563
Failure Code [DWK2KA] Variable Back Press Sol Open Circuit...1565
Failure Code [DWK2KB] Variable Back Press Sol Short Circuit...1567
Failure Code [DWK8KA] Swing Press C/O Sol Open Circuit...1569
Failure Code [DWK8KB] Swing Press C/O Sol Short Circuit...1571
Failure Code [DXA8KA] PC-EPC (F) Sol Open Circuit...1573
Failure Code [DXA8KB] PC-EPC (F) Sol Short Circuit...1577
Failure Code [DXA9KA] PC-EPC (R) Sol Open Circuit...1579
Failure Code [DXA9KB] PC-EPC (R) Sol Short Circuit...1583
Failure Code [DXE0KA] LS-EPC Sol Open Circuit...1585
Failure Code [DXE0KB] LS-EPC Sol Short Circuit...1587
Failure Code [DXE4KA] Attachment Flow EPC Open Circuit...1589
Failure Code [DXE4KB] Attachment Flow EPC Short Circuit...1591
Failure Code [DXE5KA] Merge-divide Main Sol Open Circuit...1593
Failure Code [DXE5KB] Merge-divide Main Sol Short Circuit...1595
Failure Code [DXE6KA] Merge-divide LS Sol Open Circuit...1597
Failure Code [DXE6KB] Merge-divide LS Sol Short Circuit...1599
Failure Code [DY20KA] Wiper Working Abnormality...1601
Failure Code [DY20MA] Wiper Parking Abnormality...1605
Failure Code [DY2CKB] Washer Drive Short Circuit...1609
Failure Code [DY2DKB] Wiper Drive (Fwd) Short Circuit...1611
Failure Code [DY2EKB] Wiper Drive (Rev) Short Circuit...1613
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...1615
E-1 Engine Does Not Start (Engine Does Not Rotate)...1615
E-2 Manual Pre-Heating System Does Not Work...1623
E-3 Automatic Pre-Heating System Does Not Work...1627
E-4 Pre-Heating Monitor Does Not Light Up When Pre-Heater is Operated...1629
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing...1631
E-6 When Starting Switch is Turned to ON Position (Before Starting Engine), Engine Oil Level Monitor Lights Up in Yellow...1634
E-7 When Starting Switch is Turned to ON Position (Before Starting Engine), Radiator Coolant Level Monitor Lights Up in Yellow...1634
E-8 Coolant Temperature Monitor Lights Up in White While Engine is Running...1635
E-9 Hydraulic Oil Temperature Monitor Lights Up in White While Engine is Running...1635
E-10 Charge Level Monitor Lights Up While Engine is Running...1636
E-11 Fuel Level Monitor Lights Up in Red While Engine is Running...1636
E-12 Air Cleaner Clogging Monitor Lights Up in Yellow While Engine is Running...1636
E-13 Water Separator Monitor Lights Up While Engine is Running...1637
E-14 Coolant Temperature Monitor Lights Up in Red While Engine is Running...1637
E-15 Hydraulic Oil Temperature Monitor Lights Up in Red While Engine is Running...1638
E-16 Engine Oil Pressure Monitor Lights Up in Red While Engine is Running...1638
E-17 Fuel Gauge Indicates Either Full or Empty and Does Not Move...1639
E-18 Fuel Gauge Indicates Incorrect Amount (Indicates Neither Full Nor Empty)...1641
E-19 Coolant Temperature Gauge Indicates Either Min or Max and Does Not Move...1642
E-20 Coolant Temperature Gauge Indicates Incorrect Temperature (Indicates Neither Min Nor Max)...1643
E-21 Hydraulic Oil Temperature Gauge Indicates Either Min or Max and Does Not Move...1645
E-22 Hydraulic Oil Temperature Gauge Indicates Incorrect Temperature (Indicates Neither Min nor Max)...1647
E-23 Content of Display on Machine Monitor is Different From That of Actual Machine...1648
E-24 Machine Monitor Does Not Display Some Items...1648
E-25 Function Switch Does Not Work...1648
E-26 Automatic Pre-Heating System Does Not Work (In Cold Season)...1649
E-27 Auto-Deceleration Monitor Does Not Light Up or Does Not Go Out When Auto-Deceleration Switch is Operated...1650
E-28 Auto-Deceleration is Not Actuated or Canceled When Lever is Operated...1651
E-29 Working Mode Selector Screen Selection Screen is Not Displayed When Working Mode Switch is Operated...1652
E-30 Engine or Hydraulic Pump Setting Does Not Change When Working Mode is Changed...1652
E-31 Travel Speed Monitor Does Not Change When Travel Speed Switch is Operated...1653
E-32 Travel Speed Does Not Change When Travel Speed is Shifted...1654
E-33 Alarm Buzzer Does Not Stop Sounding...1655
E-34 When Starting Switch is Turned to OFF Position, Service Meter is Not Displayed...1655
E-35 Service Mode Cannot be Selected...1656
E-36 Any of Work Equipment, Swing and Travel Does Not Work...1657
E-37 Any of Work Equipment, Swing and Travel Can Not be Locked...1659
E-38 Machine Can Not Swing While Swing Brake Cancel Switch is Canceled...1661
E-39 Swing Brake Does Not Operate While Swing Brake Cancel Switch is Locked...1665
E-40 One-Touch Power Maximizing Function Does Not Work Or Monitor is Not Displayed...1667
E-41 One-Touch Power Maximizing Function Cannot be Released...1669
E-42 Travel Alarm Does Not Sound When Machine Travels...1670
E-43 Travel Alarm Does Not Stop Sounding When Machine Stops...1671
E-44 Horn Does Not Sound...1673
E-45 Horn Does Not Stop Sounding...1675
E-46 Wiper Monitor Does Not Light Up or Go Out When Wiper Switch is Operated...1676
E-47 Wiper Does Not Operate When Wiper Switch is Operated...1677
E-48 Window Washer Does Not Operate When Window Washer Switch is Operated...1679
E-49 BOOM LOWER Indication is Not Displayed Properly With Monitoring Function...1681
E-50 ARM DUMP Indication is Not Displayed Properly With Monitoring Function...1681
E-51 ARM IN Indication is Not Displayed Properly With Monitoring Function...1681
E-52 BOOM RAISE Indication is Not Displayed Properly With Monitoring Function...1681
E-53 BUCKET CURL Indication is Not Displayed Properly With Monitoring Function...1682
E-54 BUCKET DUMP Indication is Not Displayed Properly With Monitoring Function...1682
E-55 SWING Indication is Not Displayed Properly With Monitoring Function...1682
E-56 TRAVEL Indication is Not Displayed Properly With Monitoring Function...1682
E-57 Service is Not Displayed Properly With Monitoring Function...1683
E-58 Attachment Hydraulic Circuit Cannot be Changed...1686
E-59 KOMTRAX System Does Not Work Properly...1687
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...1689
Information Mentioned in Troubleshooting Table (H Mode)...1689
Failure Mode and Cause Table...1693
H-1 All of Work Equipment, Swing and Travel Operation Lacks Speed or Power...1701
H-2 Engine Speed Lowers Significantly or Engine Stalls...1705
H-3 Any of Work Equipment, Swing and Travel Does Not Work...1707
H-4 Unusual Sound is Heard from Around Hydraulic Pump...1707
H-5 Fine Control Performance or Response is Poor...1708
H-6 Boom Operation Lacks Speed or Power...1709
H-7 Arm Operation Lacks Speed or Power...1711
H-8 Bucket Operation Lacks Speed or Power...1713
H-9 Work Equipment Does Not Move in Single Operation...1714
H-10 Hydraulic Drift of Boom is Large...1714
H-11 Hydraulic Drift of Arm is Large...1715
H-12 Hydraulic Drift of Bucket is Large...1715
H-13 Time Lag of Work Equipment is Large...1716
H-14 When Part of Work Equipment is Relieved Singly, Other Parts of Work Equipment Move...1717
H-15 One-Touch Power Maximizing Function Does Not Work...1717
H-16 In Combined Operation of Work Equipment, Equipment Having Heavier Load Moves Slower...1718
H-17 In Combined Operations of Swing and Boom RAISE, Boom Rising Speed is Low...1719
H-18 In Combined Operations of Swing and Travel, Travel Speed Drops Largely...1720
H-19 Machine Does Not Travel Straight...1721
H-20 Travel Speed is Too Low...1723
H-21 Machine ishard to Steer or Travel Power is Low...1725
H-22 Travel Speed Does Not Change, or Travel Speed is Too Low or High...1727
H-23 One of Tracks Dose Not Run...1728
H-24 Upper Structure Does Not Swing to the Right or Left...1729
H-25 Upper Structure Swing Only to the Right or Left...1730
H-26 Swing Acceleration is Poor or Swing Speed is Low (Both Right and Left)...1731
H-27 Swing Aceleration is Poor or Swing Speed is Low (Either Right or Left)...1732
H-28 Upper Structure Overruns Excessively When it Stops Swinging (Both Right and Left)...1733
H-29 Upper Structure Overruns Excessively When it Stops Swinging (Either Right or Left)...1734
H-30 Shock is Large When Upper Structure Stops Swinging...1735
H-31 Large Unusual Noise is Heard When Upper Structure Stops Swinging...1735
H-32 Swing Drift on a Slope is Large While Swing Holding Brake is Applied...1736
H-33 Swing Drift On a Slope is Large While Swing Holding Brake is Released...1736
H-34 Attachment Circuit Cannot be Changed While Attachment is Installed...1737
H-35 Oil Flow in Attachment Circuit Cannot be Controlled...1737
TROUBLESHOOTING OF ENGINE (S-MODE)...1738
Information Mentioned in Troubleshooting Table (S-Mode)...1738
S-1 When Starting Switch is Turned to START Position, Engine Does Not Crank...1739
S-2 When Engine Cranks, Smoke Does Not Come Out...1740
S-3 Engine Does Not Start While Fuel is Injected (Incomplete Combustion)...1741
S-4 Startability is Poor...1743
S-5 Engine Does Not Pick Up Smoothly...1745
S-6 Engine Stops During Operation...1747
S-7 Engine Runs Rough or is Unstable...1749
S-8 Engine Lacks Power...1751
S-9 Exhaust Smoke is Black (KDPF Clogs Up Early)...1755
S-10 Engine Oil Consumption is Too Much...1757
S-11 Oil Becomes Contaminated Early...1758
S-12 Fuel Consumption is Excessive...1759
S-13 Oil is in Coolant (or Coolant Spurts or Coolant Level Goes Down)...1760
S-14 Engine Oil Pressure Drops...1761
S-15 Fuel is Contaminated in Engine Oil...1763
S-16 Coolant is Contaminated in Engine Oil (Oil Becomes Cloudy White)...1764
S-17 Coolant Temperature Rises Too High (Overheating)...1765
S-18 Unusual Noise is Heard...1766
S-19 Vibration is Excessive...1767
S-20 Automatic Regeneration is Operated Frequently...1768
S-21 Active Regeneration is Operated for Long...1769
S-22 White Smoke Comes Out in the Process of Active Regeneration...1770
50 - DISASSEMBLY AND ASSEMBLY...1772
HOW TO READ THIS SECTION...1777
Removal And Installation Of Assemblies...1777
Special Tools...1777
Removal...1777
Installation...1777
Disassembly And Assembly Of Assemblies...1778
Special Tools...1778
Disassembly...1778
Assembly...1779
Coating Materials List...1780
SKETCHES OF SPECIAL TOOLS...1788
CONNECTOR REPAIR PROCEDURES...1791
Stripping Insulation...1791
Wire Inspection...1791
Contact Terminal Removal (HD30 Type)...1792
Crimping Contact Terminal (HD30 Type)...1793
Insertion Of Contact Terminal (HD30 Type)...1794
Contact Terminal Removal (DT Type)...1795
Crimping Contact Terminal (DT Type)...1796
Insertion Of Contact Terminal (DT Type)...1797
ENGINE AND COOLING SYSTEM...1798
Removal and Installation of Supply Pump Assembly...1798
Special Tools...1798
Removal...1798
Installation...1801
Fuel Injector Assembly...1804
Special Tools...1804
Removal...1804
Installation...1808
Removal and Installation of Cylinder Head Assembly...1816
Special Tools...1816
Removal...1816
Installation...1827
Removal and Installation of Radiator Assembly...1843
Removal...1843
Installation...1845
Removal and Installation of Hydraulic Oil Cooler Assembly...1847
Removal...1847
Installation...1850
Removal and Installation of Aftercooler Assembly...1851
Removal...1851
Installation...1852
Removal and Installation Engine And Main Pump Assembly...1853
Special Tools...1853
Removal...1853
Installation...1865
Removal and Installation of Engine Front Oil Seal...1871
Removal...1871
Installation...1874
Removal and Installation of Engine Rear Oil Seal...1877
Removal...1877
Installation...1878
Removal and Installation of Fuel Cooler Assembly...1881
Removal...1881
Installation...1881
Removal and Installation of Fuel Tank Assembly...1882
Removal...1882
Installation...1885
Removal and Installation of Engine Hood Assembly...1886
Removal...1886
Installation...1887
Removal and Installation of KDPF Assembly...1891
Removal...1891
Installation...1894
Disassembly and Assembly of KDPF...1902
Disassembly...1902
Assembly...1907
Removal and Installation of KCCV Assembly...1913
Removal...1913
Installation...1915
Removal and Installation of Air Cleaner Assembly...1917
Removal...1917
Installation...1919
POWER TRAIN...1921
Removal and Installation of Travel Motor and Final Drive Assembly...1921
Removal...1921
Installation...1922
Disassembly and Assembly of Final Drive...1923
Disassembly...1923
Assembly...1927
Removal and Installation of Swing Motor and Swing Machinery Assembly...1933
Installation...1936
Disassembly and Assembly of Swing Machinery...1937
Disassembly...1937
Assembly...1941
Removal and Installation of Swing Circle Assembly...1947
Removal...1947
Installation...1947
UNDERCARRIAGE AND FRAME...1948
Separation and Connection of Track Shoe Assembly...1948
Separating Track...1948
Connecting Track...1949
Removal and Installation of Sprocket...1951
Removal...1951
Installation...1951
Removal and Installation of Idler and Idler Cushion Assembly...1952
Removal...1952
Installation...1952
Disassembly and Assembly of Idler...1953
Disassembly...1953
Assembly...1954
Disassembly and Assembly of Idler Cushion...1957
Disassembly...1957
Assembly...1958
Disassembly and Assembly of Track Roller...1961
Disassembly...1961
Assembly...1962
Disassembly and Assembly of Carrier Roller...1964
Disassembly...1964
Assembly...1965
Removal and Installation of Revolving Frame Assembly...1968
Removal...1968
Installation...1970
Removal and Installation of Counterweight Assembly...1971
Removal...1971
Installation...1974
HYDRAULIC SYSTEM...1975
Center Swivel Joint...1975
Removal...1975
Installation...1977
Disassembly and Assembly of Swivel Joint...1979
Disassembly...1979
Assembly...1980
Removal and Installation of Hydraulic Tank Assembly...1981
Removal...1981
Installation...1986
Removal and Installation of Main Pump Assembly...1987
Removal...1987
Installation...1992
Removal and Installation of Control Valve...1993
Removal...1993
Installation...2000
Disassembly and Assembly of Control Valve...2003
Procedures for Replacing Pressure Compensation Valve Seal...2003
Assembly of Control Valve Assembly...2005
Disassembly and Assembly of Work Equipment PPC Valve...2011
Disassembly...2011
Assembly...2011
Disassembly and Assembly of Travel PPC Valve...2013
Disassembly...2014
Assembly...2014
WORK EQUIPMENT...2016
Removal and Installation of Work Equipment Assembly...2016
Special Tools...2016
Removal...2016
Installation...2018
Disassembly and Assembly of Work Equipment Cylinder...2020
Disassembly...2020
Assembly...2023
CAB AND ITS ATTACHMENTS...2028
Removal and Installation of Operator's Cab Assembly...2028
Removal...2028
Installation...2033
Removal and Installation of Operator Cab Glass (Fixed Glass)...2034
Removal...2035
Installation...2036
Removal and Installation of Front Window Assembly...2045
Removal...2045
Installation...2048
Removal and Installation of Floor Frame Assembly...2053
Removal...2053
Installation...2060
Removal and Installation of Air Conditioner Unit Assembly...2061
Removal...2061
Installation...2066
Removal and Installation of Operator’s Seat...2067
Removal...2067
Installation...2068
Removal and Installation of Seat Belt...2071
Removal...2071
Installation...2072
Removal and Installation of Front Wiper Assembly...2073
Removal...2073
Installation...2078
ELECTRICAL SYSTEM...2085
Removal and Installation of Air Conditioner Compressor Assembly...2085
Removal...2085
Installation...2087
Removal and Installation of Air Conditioner Condenser Assembly...2089
Removal...2089
Installation...2090
Removal and Installation of Engine Controller Assembly...2091
Removal...2091
Installation...2092
Removal and Installation of Pump Controller Assembly...2095
Removal...2095
Installation...2097
Removal and Installation of Machine Monitor Assembly...2099
Removal...2099
Installation...2101
Removal and Installation of Pump Swash Plate Sensor...2102
Removal...2102
Installation...2102
Removal and Installation of Mass Air Flow and Temperature Sensor...2103
Removal...2103
Installation...2103
Removal and Installation of KOMTRAX Terminal Assembly...2105
Removal...2105
Installation...2106
60 - MAINTENANCE STANDARD...2108
ENGINE AND COOLING SYSTEM...2111
Engine Mounts...2111
Cooling System...2113
POWER TRAIN...2115
Swing Circle...2115
Swing Machinery...2117
Final Drive...2119
Sprocket...2121
UNDERCARRIAGE AND FRAME...2123
Track Frame and Idler Cushion...2123
Idler...2125
Track Roller...2127
Carrier Roller...2129
Track Shoe...2130
Triple Grouser Shoe...2133
Swamp Shoe...2133
Road Liner...2134
HYDRAULIC SYSTEM...2135
Hydraulic Tank...2135
Main Pump...2136
Control Valve...2137
General View...2137
Sectional View (1/5)...2139
Sectional View (2/5)...2141
Sectional View (3/5)...2143
Sectional View (4/5)...2145
Sectional View (5/5)...2147
Swing Motor...2148
Travel Motor...2151
PPC Valve...2154
Work Equipment and Swing PPC Valve...2154
Travel PPC Valve...2157
1st-Line Attachment PPC Valve (with EPC Valve)...2161
EPC Valve...2163
2nd-Line Attachment PPC Valve...2165
Solenoid Valve...2167
Attachment Circuit Selector Valve...2169
For Low-Pressure Circuit...2169
For High-Pressure Circuit...2170
Center Swivel Joint...2171
WORK EQUIPMENT...2172
Dimensions of Components...2172
Dimensions of Arm...2177
Boom Cylinder...2183
Standard...2183
Large Diameter Piston...2184
Arm Cylinder...2185
Bucket Cylinder...2186
80 - AIR CONDITIONER...2188
AIR CONDITIONING SYSTEM...2190
Precautions for Refrigerant...2190
Air Conditioner Component...2191
Structure and Function of Refrigeration System...2193
Overview of Refrigeration System...2194
Air Conditioner Unit...2197
Function...2198
Functions of Major Components...2199
Evaporator...2199
Heater core...2199
Evaporator temperature sensor...2199
Servomotor...2199
Expansion valve...2201
Dual Pressure Switch...2203
Air Conditioner Controller...2203
Air Conditioner Compressor...2204
Air Conditioner Condenser...2205
Sunlight Sensor...2206
Outside Air Temperature Sensor...2206
Inspection and Troubleshooting Procedure of Air Conditioner...2207
Basic Inspection and Troubleshooting Sequence...2207
Air Conditioner Circuit Diagram and Arrangement of Connector Pins...2209
System Diagram...2210
Air Conditioner Controller Input and Output Signals...2211
Parts and Connectors Layout...2213
Layout of Air Conditioner Related Parts and Connectors...2214
Testing Air Leakage (Duct)...2217
Testing with Self-Diagnosis Function...2219
How to Enter Air Conditioner "Electrical Systems" Screen in Service Mode of the Machine Monitor...2220
Testing Vent (Mode) Changeover...2222
Testing FRESH/RECIRC Air Changeover...2224
Testing Sunlight Sensor...2225
Testing (Dual) Pressure Switch for Refrigerant...2226
Testing Relay...2227
Troubleshooting Chart 1...2228
Troubleshooting Chart 2...2229
Information Mentioned in Troubleshooting Table...2232
Information in Troubleshooting Table...2232
Failure Code List Related to Air Conditioner...2233
Failure Code [879AKA] A/C Inner Sensor Open Circuit...2234
Failure Code [879AKB] A/C Inner Sensor Short Circuit...2234
Failure Code [879BKA] A/C Outer Sensor Open Circuit...2235
Failure Code [879BKB] A/C Outer Sensor Short Circuit...2237
Failure Code [879CKA] Ventilating Sensor Open Circuit...2239
Failure Code [879CKB] Ventilating Sensor Short Circuit...2240
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit...2241
Failure Code [879EMC] Ventilation Damper Abnormality...2243
Failure Code [879FMC] Ventilation Damper Abnormality...2244
Failure Code [879GKX] Refrigerant Abnormality...2245
A-1 Troubleshooting for Power Supply System (The Air Conditioner Does Not Operate)...2246
A-2 Troubleshooting of Compressor System (Air is Not Cooled)...2248
A-3 Troubleshooting of Blower Motor System (Air Does Not Come Out or Air Flow is Normal)...2251
A-4 Troubleshooting for FRESH/RECIRC Air Changeover...2253
Troubleshooting with Gauge Pressure...2255
[Measurement Condition for Pressure]...2255
Testing Refrigerant Pressure...2258
Check...2259
Troubleshooting Table with Gauge Pressure Indicated by Gauge Manifold...2261
Precautions for Disconnecting and Connecting Refrigerant Piping...2263
Disconnection...2263
Connection...2263
Tightening Torque for Joint Portion of Refrigerant Piping...2264
Filling Compressor Oil...2265
Oil Level Control of Compressor...2265
Refilling of Compressor Oil...2265
Desiccant Replacement...2267
90 DIAGRAMS AND SCHEMATICS...2270
HYDRAULIC SYSTEM...2272
Symbols in Hydraulic Circuit Diagrams...2272
Hydraulic Circuit Diagram and Name of Valves...2273
Hydraulic Circuit Diagram (1/2)...2274
Hydraulic Circuit Diagram (2/2)...2275
ELECTRICAL SYSTEM...2276
Symbols in Electrical Circuit Diagrams...2276
Air Conditioner Electrical Circuit...2277
Electrical Control System Diagram...2278
Electrical Diagram (1/5)...2279
Electrical Diagram (2/5)...2280
Electrical Diagram (3/5)...2281
Electrical Diagram (4/5)...2282
Electrical Diagram (5/5)...2283
Connector List and Stereogram...2284
Chassis...2284
Operator's Compartment...2285
Engine compartment...2286
CEBM028601 - Hydraulic Excavator PC240LC-11 Shop Manual...2287
PC240LC-11 SHOP MANUAL S/N A22001-...2287
00 INDEX AND FOREWORD...2289
INDEX...2290
FOREWORD, SAFETY, BASIC INFORMATION...2306
HOW TO READ THE SHOP MANUAL...2306
SAFETY NOTICE FOR OPERATION...2308
PRECAUTIONS TO PREVENT FIRE...2314
ACTION IF FIRE OCCURS...2316
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS...2317
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...2318
PRECAUTIONS FOR AdBlue/DEF...2319
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING...2319
PRECAUTIONS FOR ADDING...2319
PRECAUTIONS FOR STORING...2319
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE...2319
THE OTHER PRECAUTIONS...2319
STORE AdBlue/DEF...2320
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT...2321
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS...2323
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT...2329
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT...2332
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT...2333
PRACTICAL USE OF KOMTRAX...2334
METHOD FOR DISCONNECTING AND CONNECTING PUSH-PULL TYPE COUPLER...2335
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER...2335
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER...2336
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER...2337
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS...2338
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR...2342
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR...2343
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL...2345
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH...2346
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE...2348
HOW TO READ ELECTRICAL WIRE CODE...2349
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD...2353
LIST OF ABBREVIATION...2356
STANDARD TIGHTENING TORQUE TABLE...2361
CONVERSION TABLE...2368
01 SPECIFICATION...2373
CONTENTS...2374
SPECIFICATIONS...2375
SPECIFICATION DRAWING...2375
SPECIFICATION DRAWING: PC240LC-11...2375
WORKING RANGE DRAWINGS...2376
WORKING RANGE: PC240LC-11...2376
SPECIFICATIONS...2377
SPECIFICATIONS: PC240LC-11...2377
WEIGHT TABLE...2380
WEIGHT TABLE: PC240LC-11...2380
TABLE OF FUEL, COOLANT, AND LUBRICANTS...2382
10 STRUCTURE AND FUNCTION...2383
CONTENTS...2384
UREA SCR SYSTEM...2387
LAYOUT DRAWING OF UREA SCR SYSTEM...2387
UREA SCR SYSTEM DIAGRAM...2393
FUNCTION OF UREA SCR SYSTEM...2394
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM...2394
INDUCEMENT STRATEGY...2396
COMPONENT PARTS OF UREA SCR SYSTEM...2408
AdBlue/DEF MIXING TUBE...2408
SCR ASSEMBLY...2408
AdBlue/DEF TANK...2411
AdBlue/DEF PUMP...2413
AdBlue/DEF INJECTOR...2414
AdBlue/DEF HOSE...2415
AdBlue/DEF TANK HEATING VALVE...2416
BOOT-UP SYSTEM...2417
LAYOUT DRAWING OF BOOT-UP SYSTEM...2417
SYSTEM OPERATING LAMP SYSTEM...2419
SYSTEM OPERATING LAMP SYSTEM DIAGRAM...2419
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM...2419
BATTERY DISCONNECT SWITCH...2420
FUNCTION OF BATTERY DISCONNECT SWITCH...2420
ENGINE SYSTEM...2421
LAYOUT DRAWING OF ENGINE RELATED PARTS...2421
SPECIFICATIONS OF ENGINE RELATED PARTS...2422
FUNCTIONS OF ENGINE RELATED PARTS...2422
ENGINE CONTROL SYSTEM...2423
ENGINE CONTROL SYSTEM DIAGRAM...2423
FUNCTION OF ENGINE CONTROL SYSTEM...2424
AUTO-DECELERATION SYSTEM...2426
AUTO-DECELERATION SYSTEM DIAGRAM...2426
FUNCTION OF AUTO-DECELERATION SYSTEM...2426
OPERATION OF AUTO-DECELERATION SYSTEM...2427
ENGINE AUTOMATIC WARM-UP SYSTEM...2428
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM...2428
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM...2429
OVERHEAT PREVENTION SYSTEM...2430
OVERHEAT PREVENTION SYSTEM DIAGRAM...2430
FUNCTION OF OVERHEAT PREVENTION SYSTEM...2431
TURBOCHARGER PROTECTION SYSTEM...2433
TURBOCHARGER PROTECTION SYSTEM DIAGRAM...2433
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM...2434
AUTOMATIC IDLE STOP SYSTEM...2435
AUTOMATIC IDLE STOP SYSTEM DIAGRAM...2435
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM...2435
COMPONENT PARTS OF ENGINE SYSTEM...2438
KVGT...2438
EGR SYSTEM...2441
EGR VALVE...2443
EGR COOLER...2445
KCCV SYSTEM...2446
KCCV VENTILATOR...2448
KDPF...2450
COOLING SYSTEM...2455
LAYOUT DRAWING OF COOLING SYSTEM...2455
SPECIFICATIONS OF COOLING SYSTEM...2456
CONTROL SYSTEM...2457
LAYOUT DRAWING OF ELECTRICAL CONTROL SYSTEM...2457
MACHINE MONITOR SYSTEM...2460
MACHINE MONITOR SYSTEM DIAGRAM...2460
KOMTRAX SYSTEM...2461
KOMTRAX SYSTEM DIAGRAM...2461
FUNCTION OF KOMTRAX SYSTEM...2461
COMPONENT PARTS OF CONTROL SYSTEM...2462
MACHINE MONITOR...2462
KOMTRAX TERMINAL...2473
PUMP CONTROLLER...2475
REGISTER FOR PC-EPC VALVE...2479
CAN TERMINATING RESISTOR...2480
ENGINE CONTROLLER...2481
FUEL CONTROL DIAL...2487
HYDRAULIC SYSTEM...2489
LAYOUT DRAWING OF HYDRAULIC COMPONENT...2489
CLSS...2495
STRUCTURE OF CLSS...2495
OPERATION OF UNLOAD VALVE AND LS PRESSURE...2497
PUMP SWASH PLATE ANGLE (OILFLOW) CONTROL...2498
PRESSURE COMPENSATION CONTROL...2510
ENGINE AND PUMP COMBINED CONTROL SYSTEM...2513
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM...2513
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM...2514
PUMP AND VALVE CONTROL SYSTEM...2519
PUMP AND VALVE CONTROL SYSTEM DIAGRAM...2519
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM...2520
COMPONENT PARTS OF HYDRAULIC SYSTEM...2522
HYDRAULIC TANK...2522
MAIN PUMP...2524
PC-EPC VALVE...2547
CONTROL VALVE...2548
WORK EQUIPMENT SYSTEM...2605
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM...2605
STRUCTURE OF VALVE CONTROL...2610
ONE-TOUCH POWER MAXIMIZING SYSTEM...2612
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM...2612
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM...2613
PPC LOCK SYSTEM...2614
PPC LOCK SYSTEM DIAGRAM...2614
FUNCTION OF PPC LOCK SYSTEM...2614
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM...2615
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM...2615
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM...2615
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM...2616
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT...2617
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT...2617
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT...2618
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM...2619
WORK EQUIPMENT AND SWING PPC VALVE...2619
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)...2624
2ND-LINE ATTACHMENT PPC VALVE...2630
SOLENOID VALVE...2632
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)...2634
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)...2636
PILOT CIRCUIT ACCUMULATOR...2638
SWING CONTROL SYSTEM...2639
LAYOUT DRAWING OF SWING SYSTEM...2639
SWING CONTROL SYSTEM DIAGRAM...2643
FUNCTION OF SWING CONTROL SYSTEM...2643
COMPONENT PARTS OF SWING SYSTEM...2647
SWING MOTOR...2647
SWING MACHINERY...2658
SWING CIRCLE...2659
TRAVEL SYSTEM...2661
LAYOUT DRAWING OF TRAVEL SYSTEM...2661
TRAVEL CONTROL SYSTEM DIAGRAM...2665
FUNCTION OF TRAVEL CONTROL SYSTEM...2665
COMPONENT PARTS OF TRAVEL SYSTEM...2667
TRAVEL MOTOR...2667
FINAL DRIVE...2679
TRAVEL PPC VALVE...2680
CENTER SWIVEL JOINT...2685
UNDERCARRIAGE AND FRAME...2687
LAYOUT DRAWING OF UNDERCARRIAGE...2687
SPECIFICATIONS OF UNDERCARRIAGE...2688
WORK EQUIPMENT...2689
STRUCTURE OF WORK EQUIPMENT...2689
FUNCTION OF WORK EQUIPMENT...2690
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM...2691
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM...2691
BUCKET CLEARANCE ADJUSTMENT SHIM...2692
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM...2692
CAB AND ITS ATTACHMENTS...2693
ROPS CAB...2693
STRUCTURE OF ROPS CAB...2693
FUNCTION OF ROPS CAB...2693
CAB MOUNT...2694
STRUCTURE OF CAB MOUNT...2694
FUNCTION OF CAB MOUNT...2694
CAB TIPPING STOPPER...2695
STRUCTURE OF CAB TIPPING STOPPER...2695
FUNCTION OF CAB TIPPING STOPPER...2695
20 STANDARD VALUE TABLE...2697
CONTENTS...2698
STANDARD VALUE TABLE FOR ENGINE...2699
STANDARD VALUE TABLE FOR ENGINE: PC240LC-11...2699
STANDARD VALUE TABLE FOR MACHINE...2703
STANDARD VALUE TABLE FOR MACHINE: PC240LC-11...2703
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE...2716
STANDARD VALUE TABLE FOR ELECTRICAL...2720
STANDARD VALUE TABLE FOR ELECTRICAL...2720
30 TESTING AND ADJUSTING...2731
CONTENTS...2732
RELATED INFORMATION ON TESTING AND ADJUSTING...2735
TOOLS FOR TESTING AND ADJUSTING...2735
SKETCH OF TOOLS FOR TESTING AND ADJUSTING...2741
ENGINE AND COOLING SYSTEM...2742
TEST ENGINE SPEED...2742
METHOD FOR TESTING ENGINE SPEED...2742
TEST BOOST PRESSURE...2745
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR...2745
METHOD FOR TESTING BOOST PRESSURE...2746
TEST EXHAUST GAS COLOR...2747
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER...2747
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER...2748
TEST AND ADJUST VALVE CLEARANCE...2750
METHOD FOR TESTING VALVE CLEARANCE...2750
METHOD FOR ADJUSTING VALVE CLEARANCE...2751
TEST COMPRESSION PRESSURE...2752
METHOD FOR TESTING COMPRESSION PRESSURE...2752
TEST BLOWBY PRESSURE...2757
METHOD FOR TESTING BLOWBY PRESSURE...2757
TEST ENGINE OIL PRESSURE...2759
METHOD FOR TESTING ENGINE OIL PRESSURE...2759
TEST EGR VALVE AND KVGT OIL PRESSURE...2760
METHOD FOR TESTING EGR VALVE AND KVGT OIL PRESSURE...2760
TEST FUEL PRESSURE...2762
METHOD FOR TESTING FUEL PRESSURE...2763
TEST FUEL DISCHARGE, RETURN AND LEAKAGE...2768
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE...2769
BLEEDING AIR FROM FUEL SYSTEM...2774
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM...2774
TEST FUEL CIRCUIT FOR LEAKAGE...2775
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE...2775
HANDLE CYLINDER CUT-OUT MODE OPERATION...2777
HANDLE NO-INJECTION CRANKING OPERATION...2778
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION...2779
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT...2779
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT...2779
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER...2781
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER...2781
TEST SCR RELATED FUNCTIONS...2782
TEST AdBlue/DEF PUMP RAISED PRESSURE...2785
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR...2786
TEST AdBlue/DEF LINE HEATER RELAY 1...2790
TEST AdBlue/DEF LINE HEATER RELAY 2...2793
TEST AdBlue/DEF PUMP HEATER RELAY...2795
TEST AdBlue/DEF HEATER VALVE...2798
TEST DENITRATION EFFICIENCY OF SCR...2801
CLEAN AdBlue/DEF TANK...2805
METHOD FOR CLEANING AdBlue/DEF TANK...2805
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK...2809
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK...2809
POWER TRAIN...2811
TEST SWING CIRCLE BEARING CLEARANCE...2811
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE...2811
UNDERCARRIAGE AND FRAME...2812
TEST AND ADJUST TRACK TENSION...2812
METHOD FOR TESTING TRACK TENSION...2812
METHOD FOR ADJUSTING TRACK TENSION...2812
HYDRAULIC SYSTEM...2814
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM...2814
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT...2814
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS...2815
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS...2816
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS...2822
TEST OIL PRESSURE OF CONTROL CIRCUIT...2825
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT...2825
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT...2827
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)...2827
TEST PC-EPC VALVE OUTLET PRESSURE...2828
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT...2829
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT...2830
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR...2830
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL...2831
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)...2834
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE...2835
METHOD FOR ADJUSTING LS VALVE...2836
TEST OUTLET PRESSURE OF SOLENOID VALVE...2837
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE...2837
OPERATING CONDITION OF SOLENOID VALVE...2838
TEST PPC VALVE OUTLET PRESSURE...2841
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE...2841
ADJUST WORK EQUIPMENT AND SWING PPC VALVES...2843
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES...2843
TEST PUMP SWASH PLATE SENSOR...2844
METHOD FOR TESTING PUMP SWASH PLATE SENSOR...2844
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT...2845
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER...2845
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER...2845
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE...2846
TEST OIL LEAKAGE...2847
TEST OIL LEAKAGE OF BOOM CYLINDER...2847
TEST OIL LEAKAGE OF ARM CYLINDER...2847
TEST OIL LEAKAGE OF BUCKET CYLINDER...2848
METHOD FOR TESTING OIL LEAKAGE OF SWING MOTOR...2848
METHOD FOR TESTING OIL LEAKAGE OF TRAVEL MOTOR...2848
BLEED AIR FROM HYDRAULIC CIRCUIT...2850
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT...2851
CAB AND ITS ATTACHMENTS...2853
TEST CAB TIPPING STOPPER...2853
METHOD FOR TESTING CAB TIPPING STOPPER...2853
METHOD FOR ADJUSTING MIRRORS...2854
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A)...2854
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A)...2855
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B)...2856
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B)...2857
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C)...2858
ELECTRICAL SYSTEM...2860
SET AND OPERATE MACHINE MONITOR...2860
OPERATOR MODE...2863
SERVICE MODE...2868
METHOD FOR STARTING UP KOMTRAX TERMINAL...2934
ADJUST REARVIEW CAMERA ANGLE...2939
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE...2939
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER...2942
HANDLE BATTERY DISCONNECT SWITCH...2943
TEST DIODES...2944
METHOD FOR TESTING DIODE USING DIGITAL TESTER...2944
METHOD FOR TESTING DIODE USING ANALOG TESTER...2944
Pm CLINIC...2945
Pm CLINIC SERVICE...2945
Pm CLINIC CHECK SHEET...2946
40 TROUBLESHOOTING...2957
CONTENTS...2958
RELATED INFORMATION ON TROUBLESHOOTING...2968
GENERAL TROUBLESHOOTING POINTS...2968
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM...2969
SEQUENCE OF EVENTS IN TROUBLESHOOTING...2982
CHECKS BEFORE TROUBLESHOOTING...2984
CHECKS BEFORE TROUBLESHOOTING...2986
WALK-AROUND CHECK...2986
TESTING IN ACCORDANCE WITH TESTING PROCEDURE...2988
FUEL - CHECK LEVEL AND TYPE...2988
FUEL - CHECK FOR FOREIGN MATERIAL...2988
FUEL PREFILTER - CHECK...2989
WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT...2989
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE...2990
MAIN FILTER - CHECK...2991
OIL PAN - CHECK ENGINE OIL LEVEL...2993
RESERVOIR TANK - CHECK COOLANT LEVEL...2994
AIR CLEANER - CHECK FOR CLOGGING...2994
OUTER ELEMENT - CLEAN...2995
ELEMENTS - REPLACE...2997
HYDRAULIC OIL - CHECK OIL LEVEL...2998
HYDRAULIC OIL STRAINER - CHECK...2999
HYDRAULIC OIL FILTER - CHECK...3000
SWING MACHINERY CASE - CHECK OIL LEVEL...3001
DAMPER CASE - CHECK OIL LEVEL...3001
FINAL DRIVE CASE - CHECK OIL LEVEL...3002
FUEL SYSTEM - BLEED AIR...3002
HYDRAULIC CIRCUIT - BLEED AIR...3002
ELECTRICAL EQUIPMENT - CHECK METHOD...3003
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION...3010
PROCEDURE FOR TESTING AND TROUBLESHOOTING...3020
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS...3023
INFORMATION IN TROUBLESHOOTING TABLE...3027
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM...3029
CONNECTOR LIST AND LAYOUT...3032
CONNECTOR PIN NUMBERS - CONNECTION TABLE...3045
T-BOXES AND T-ADAPTERS LIST...3084
FUSE LOCATION TABLE...3090
PRECAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE...3092
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])...3096
FAILURE CODES TABLE...3098
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)...3115
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit...3115
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit...3116
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit...3117
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit...3119
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit...3121
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit...3122
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit...3123
FAILURE CODE [879EMC] Ventilation Damper Malfunction...3125
FAILURE CODE [879FMC] Air Mix Damper Malfunction...3126
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range...3127
FAILURE CODE [989L00] Engine Controller Lock Caution 1...3129
FAILURE CODE [989M00] Engine Controller Lock Caution 2...3130
FAILURE CODE [989N00] Engine Controller Lock Caution 3...3131
FAILURE CODE [A1U0N3] HC Desorb Request 1...3132
FAILURE CODE [A1U0N4] HC Desorb Request 2...3134
FAILURE CODE [A900FR] Abrupt Engine Stop by Auto Idling Stop 3...3136
FAILURE CODE [A900N6] Abrupt Engine Stop by Auto Idling Stop 1...3137
FAILURE CODE [A900NY] Abrupt Engine Stop by Auto Idling Stop 2...3138
FAILURE CODE [AA10NX] Air Cleaner Clogging...3139
FAILURE CODE [AB00KE] Charge Voltage Low...3141
FAILURE CODE [AQ10N3] Manual Stationary Regeneration Request (KDOC Face Plugging)...3144
FAILURE CODE [AS00N3] Manual Stationary Regeneration Request (SCR)...3146
FAILURE CODE [AS00R2] Warning 2 (SCR Device Abnormality)...3148
FAILURE CODE [AS00R3] Inducement 1 (SCR Device Abnormality)...3149
FAILURE CODE [AS00R4] Inducement 2 (SCR Device Abnormality)...3150
FAILURE CODE [AS00R5] Inducement 3 (SCR Device Abnormality)...3151
FAILURE CODE [AS00R6] Temporary Recovery of Inducement...3152
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Error 5...3153
FAILURE CODE [AS10KM] AdBlue/DEF Injector Overheat Warning...3154
FAILURE CODE [AS10NR] AdBlue/DEF Injector High Temperature Warning...3155
FAILURE CODE [AS10NT] AdBlue/DEF Injector Overheat Caution...3156
FAILURE CODE [B@BAZG] Engine Oil Pressure Low...3157
FAILURE CODE [B@BAZK] Eng Oil Level Low...3158
FAILURE CODE [B@BCNS] Eng Water Overheat...3160
FAILURE CODE [B@BCZK] Eng Water Level Low...3161
FAILURE CODE [B@HANS] Hyd Oil Overheat...3163
FAILURE CODE [CA115] Engine NE and Backup Speed Sensor Error...3164
FAILURE CODE [CA122] Charge Air Pressure Sensor High Error...3165
FAILURE CODE [CA123] Charge Air Pressure Sensor Low Error...3167
FAILURE CODE [CA131] Throttle Sensor High Error...3169
FAILURE CODE [CA132] Throttle Sensor Low Error...3171
FAILURE CODE [CA144] Coolant Temperature Sensor High Error...3173
FAILURE CODE [CA145] Coolant Temperature Sensor Low Error...3175
FAILURE CODE [CA153] Charge Air Temperature Sensor High Error...3177
FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error...3180
FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error...3182
FAILURE CODE [CA221] Ambient Pressure Sensor High Error...3184
FAILURE CODE [CA222] Ambient Pressure Sensor Low Error...3186
FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error...3188
FAILURE CODE [CA234] Engine Overspeed...3189
FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error...3190
FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Error...3192
FAILURE CODE [CA249] Ambient Air Temp Sensor High Error...3194
FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error...3196
FAILURE CODE [CA271] IMV/PCV 1 Short Circuit Error...3198
FAILURE CODE [CA272] IMV/PCV 1 Open Circuit Error...3200
FAILURE CODE [CA322] Injector #1 (L#1) Open Circuit Error or Short Circuit Error...3202
FAILURE CODE [CA323] Injector #5 (L#5) Open Circuit Error or Short Circuit Error...3204
FAILURE CODE [CA324] Injector #3 (L#3) Open Circuit Error or Short Circuit Error...3206
FAILURE CODE [CA325] Injector #6 (L#6) Open Circuit Error or Short Circuit Error...3208
FAILURE CODE [CA331] Injector #2 (L#2) Open Circuit Error or Short Circuit Error...3210
FAILURE CODE [CA332] Injector #4 (L#4) Open Circuit Error or Short Circuit Error...3212
FAILURE CODE [CA343] Engine Controller Internal Failure...3214
FAILURE CODE [CA351] Injectors Drive Circuit Error...3215
FAILURE CODE [CA352] Sensor 1 Supply Voltage Low Error...3216
FAILURE CODE [CA356] MAF Sensor High Error...3218
FAILURE CODE [CA357] MAF Sensor Low Error...3220
FAILURE CODE [CA386] Sensor 1 Supply Voltage High Error...3222
FAILURE CODE [CA428] Water in Fuel Sensor High Error...3223
FAILURE CODE [CA429] Water in Fuel Sensor Low Error...3225
FAILURE CODE [CA435] Engine Oil Pressure SW Error...3227
FAILURE CODE [CA441] Battery Voltage Low Error...3229
FAILURE CODE [CA442] Battery Voltage High Error...3231
FAILURE CODE [CA449] Common Rail Pressure High Error 2...3232
FAILURE CODE [CA451] Common Rail Pressure Sensor High Error...3233
FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error...3235
FAILURE CODE [CA488] Charge Air Temperature High Torque Derate...3237
FAILURE CODE [CA515] Common Rail Pressure Sensor Supply Voltage High Error...3238
FAILURE CODE [CA516] Common Rail Pressure Sensor Supply Voltage Low Error...3240
FAILURE CODE [CA553] Common Rail Pressure High Error 1...3242
FAILURE CODE [CA555] Crankcase Pressure High Error 1...3243
FAILURE CODE [CA556] Crankcase Pressure High Error 2...3244
FAILURE CODE [CA559] Common Rail Pressure Low Error 1...3245
FAILURE CODE [CA595] Turbocharger Speed High Error 2...3248
FAILURE CODE [CA687] Turbocharger Speed Low Error...3249
FAILURE CODE [CA689] Engine NE Speed Sensor Error...3251
FAILURE CODE [CA691] Intake Air Temperature Sensor High Error...3254
FAILURE CODE [CA692] Intake Air Temperature Sensor Low Error...3256
FAILURE CODE [CA697] Engine Controller Internal Temperature Sensor High Error...3258
FAILURE CODE [CA698] Engine Controller Internal Temperature Sensor Low Error...3259
FAILURE CODE [CA731] Engine Backup Speed Sensor Phase Error...3260
FAILURE CODE [CA778] Engine Backup Speed Sensor Error...3262
FAILURE CODE [CA1117] Engine Controller Partial Data Lost Error...3267
FAILURE CODE [CA1664] KDOC Abnormality...3268
FAILURE CODE [CA1669] AdBlue/DEF Level Sensor Voltage High Error...3270
FAILURE CODE [CA1673] AdBlue/DEF Level Low Error 3...3271
FAILURE CODE [CA1677] AdBlue/DEF Temperature Sensor Low Error...3272
FAILURE CODE [CA1678] AdBlue/DEF Temperature Sensor High Error...3273
FAILURE CODE [CA1682] AdBlue/DEF Pump Priming Error...3274
FAILURE CODE [CA1683] AdBlue/DEF Tank Heating Valve Voltage High Error...3276
FAILURE CODE [CA1684] AdBlue/DEF Tank Heating Valve Voltage Low Error...3278
FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High Error...3280
FAILURE CODE [CA1691] Defective Regeneration...3281
FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error...3284
FAILURE CODE [CA1695] Sensor 5 Supply Voltage High Error...3287
FAILURE CODE [CA1696] Sensor 5 Supply Voltage Low Error...3288
FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error...3290
FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Error...3293
FAILURE CODE [CA1714] AdBlue/DEF Quality Sensor Out of Calibration Error...3295
FAILURE CODE [CA1715] AdBlue/DEF Quality Sensor Internal Circuit Error...3296
FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error...3297
FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error...3300
FAILURE CODE [CA1843] Crankcase Pressure Sensor High Error...3303
FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error...3305
FAILURE CODE [CA1879] KDPF Differential Pressure Sensor High Error...3308
FAILURE CODE [CA1881] KDPF Differential Pressure Sensor Low Error...3310
FAILURE CODE [CA1883] KDPF Differential Pressure Sensor In Range Error...3312
FAILURE CODE [CA1885] Turbo Outlet NOx Sensor Circuit Error...3315
FAILURE CODE [CA1887] SCR Outlet NOx Sensor Circuit Error...3317
FAILURE CODE [CA1921] KDPF Soot Accumulation High Error 1...3319
FAILURE CODE [CA1922] KDPF Soot Accumulation High Error 2...3322
FAILURE CODE [CA1942] Crankcase Pressure Sensor In Range Error...3327
FAILURE CODE [CA1993] KDPF Differential Pressure Low Error...3328
FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error...3331
FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error...3332
FAILURE CODE [CA2249] Common Rail Pressure Low Error 2...3334
FAILURE CODE [CA2271] EGR Valve Position Sensor High Error...3335
FAILURE CODE [CA2272] EGR Valve Position Sensor Low Error...3338
FAILURE CODE [CA2288] Turbocharger Speed High Error 1...3341
FAILURE CODE [CA2311] lMV Solenoid Error...3342
FAILURE CODE [CA2349] EGR Valve Solenoid Open Circuit Error...3343
FAILURE CODE [CA2353] EGR Valve Solenoid Short Circuit Error...3346
FAILURE CODE [CA2357] EGR Valve Servo Error...3348
FAILURE CODE [CA2381] KVGT Position Sensor High Error...3349
FAILURE CODE [CA2382] KVGT Position Sensor Low Error...3352
FAILURE CODE [CA2383] KVGT Solenoid Open Circuit Error...3355
FAILURE CODE [CA2386] KVGT Solenoid Short Circuit Error...3358
FAILURE CODE [CA2387] KVGT Servo Error...3360
FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error...3361
FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error...3364
FAILURE CODE [CA2637] KDOC Face Plugging...3367
FAILURE CODE [CA2639] Manual Stationary Regeneration Request...3369
FAILURE CODE [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error...3371
FAILURE CODE [CA2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable...3377
FAILURE CODE [CA2976] AdBlue/DEF Pump Temperature Sensor Signal Error...3380
FAILURE CODE [CA3133] KDPF Outlet Pressure Sensor High Error...3382
FAILURE CODE [CA3134] KDPF Outlet Pressure Sensor Low Error...3385
FAILURE CODE [CA3135] KDPF Outlet Pressure Sensor In Range Error...3387
FAILURE CODE [CA3142] SCR Temperature Sensor High Error...3390
FAILURE CODE [CA3143] SCR Temperature Sensor Low Error...3391
FAILURE CODE [CA3144] SCR Temperature Sensor In Range Error...3392
FAILURE CODE [CA3146] SCR Outlet Temperature Sensor High Error...3394
FAILURE CODE [CA3147] SCR Outlet Temperature Sensor Low Error...3395
FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range Error...3396
FAILURE CODE [CA3151] SCR Catalyst Efficiency Low Error 2...3398
FAILURE CODE [CA3165] SCR Outlet Temperature High Error...3404
FAILURE CODE [CA3229] SCR Temperature High Error...3406
FAILURE CODE [CA3231] SCR Temperature High Error - Non Regeneration...3408
FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error...3410
FAILURE CODE [CA3235] SCR Outlet Temperature High Error - Non Regeneration...3414
FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error...3416
FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error...3419
FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error...3422
FAILURE CODE [CA3251] KDOC Inlet Temperature High Error...3425
FAILURE CODE [CA3253] KDOC Temperature Error - Non Regeneration...3427
FAILURE CODE [CA3254] KDOC Outlet Temperature High Error 1...3430
FAILURE CODE [CA3255] KDPF Temperature Error - Non Regeneration...3433
FAILURE CODE [CA3256] KDPF Outlet Temperature High Error 1...3436
FAILURE CODE [CA3311] KDOC Outlet Temperature High Error 2...3438
FAILURE CODE [CA3312] KDPF Outlet Temperature High Error 2...3440
FAILURE CODE [CA3313] KDOC Inlet Temperature Sensor Low Error...3443
FAILURE CODE [CA3314] KDOC Inlet Temperature Sensor High Error...3445
FAILURE CODE [CA3315] KDOC Inlet Temperature Sensor In Range Error...3446
FAILURE CODE [CA3316] KDOC Outlet Temperature Sensor Low Error...3448
FAILURE CODE [CA3317] KDOC Outlet Temperature Sensor High Error...3449
FAILURE CODE [CA3318] KDOC Outlet Temperature Sensor In Range Error...3450
FAILURE CODE [CA3319] KDPF Outlet Temperature Sensor High Error...3452
FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Error...3453
FAILURE CODE [CA3322] KDPF Outlet Temperature Sensor In Range Error...3455
FAILURE CODE [CA3419] MAF Sensor Supply Voltage High Error...3457
FAILURE CODE [CA3421] MAF Sensor Supply Voltage Low Error...3459
FAILURE CODE [CA3497] AdBlue/DEF Level Low Error 1...3461
FAILURE CODE [CA3498] AdBlue/DEF Level Low Error 2...3462
FAILURE CODE [CA3543] AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low)...3463
FAILURE CODE [CA3545] SCR Outlet NOx Sensor Unstable Error...3469
FAILURE CODE [CA3547] AdBlue/DEF Level Low Error 4...3471
FAILURE CODE [CA3558] AdBlue/DEF Pump Voltage High Error...3472
FAILURE CODE [CA3559] AdBlue/DEF Pump Voltage Low Error...3474
FAILURE CODE [CA3562] AdBlue/DEF LineHeater Relay 1 Voltage High Error...3476
FAILURE CODE [CA3563] AdBlue/DEF LineHeater Relay 1 Voltage Low Error...3478
FAILURE CODE [CA3567] AdBlue/DEF Injector Open Circuit Error or Short Circuit Error...3481
FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction...3484
FAILURE CODE [CA3571] AdBlue/DEF Pump Pressure Sensor High Error...3488
FAILURE CODE [CA3572] AdBlue/DEF Pump Pressure Sensor Low Error...3490
FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Error...3492
FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Error...3494
FAILURE CODE [CA3577] AdBlue/DEF FCV Voltage High Error...3496
FAILURE CODE [CA3578] AdBlue/DEF FCV Voltage Low Error...3498
FAILURE CODE [CA3582] SCR Catalyst Efficiency Low Error 1...3500
FAILURE CODE [CA3583] SCR Outlet NOx Sensor Heater Warming up Error...3506
FAILURE CODE [CA3596] AdBlue/DEF Pump Pressure Unstable Error...3508
FAILURE CODE [CA3649] Turbo Outlet NOx Sensor Heater Warming up Error...3510
FAILURE CODE [CA3681] SCR Outlet NOx Sensor Power Voltage Error...3512
FAILURE CODE [CA3682] Turbo Outlet NOx Sensor Power Voltage Error...3517
FAILURE CODE [CA3713] AdBlue/DEF Line Heater 1 Voltage High Error...3523
FAILURE CODE [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error...3526
FAILURE CODE [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Error...3527
FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error...3528
FAILURE CODE [CA3741] Rail Press Valve Trip Error...3531
FAILURE CODE [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error...3532
FAILURE CODE [CA3751] SCR Catalyst Degradation Error...3534
FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degradation Error...3536
FAILURE CODE [CA3866] AdBlue/DEF Low Concentration Error 2...3538
FAILURE CODE [CA3867] AdBlue/DEF Low Concentration Error 1...3541
FAILURE CODE [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout Error...3544
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error...3548
FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error...3550
FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error...3554
FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Error...3556
FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error...3558
FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error...3560
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error...3563
FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error...3565
FAILURE CODE [CA4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error...3567
FAILURE CODE [CA4152] SCR Temperature Sensor Datalink Timeout Error...3571
FAILURE CODE [CA4155] AdBlue/DEF Pump Heater Relay Voltage High Error...3575
FAILURE CODE [CA4156] AdBlue/DEF Pump Heater Relay Voltage Low Error...3578
FAILURE CODE [CA4157] AdBlue/DEF FCV Malfunction...3581
FAILURE CODE [CA4158] KDOC and KDPF Temperature Sensor Internal Circuit Error...3583
FAILURE CODE [CA4159] SCR Temperature Sensor Internal Circuit Error...3584
FAILURE CODE [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error...3585
FAILURE CODE [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error...3588
FAILURE CODE [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error...3591
FAILURE CODE [CA4164] SCR Temperature Sensor ECU Voltage High Error...3593
FAILURE CODE [CA4165] SCR Temperature Sensor ECU Voltage Low Error...3595
FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Temperature Error...3597
FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error...3599
FAILURE CODE [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error...3602
FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error...3604
FAILURE CODE [CA4249] AdBlue/DEF Pump Temperature Sensor 1 In Range Error...3607
FAILURE CODE [CA4251] AdBlue/DEF Pump Temperature Sensor 2 In Range Error...3609
FAILURE CODE [CA4259] KDOC and KDPF Temperature Sensor Power Interrupt Error...3611
FAILURE CODE [CA4261] SCR Temperature Sensor Power Interrupt Error...3614
FAILURE CODE [CA4277] AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error...3617
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error...3620
FAILURE CODE [CA4459] AdBlue/DEF LineHeater Relay 2 Voltage High Error...3623
FAILURE CODE [CA4461] AdBlue/DEF LineHeater Relay 2 Voltage Low Error...3626
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error...3629
FAILURE CODE [CA4731] AdBlue/DEF Temperature Sensor Transmission Data Error...3633
FAILURE CODE [CA4732] AdBlue/DEF Level Sensor Transmission Data Error...3634
FAILURE CODE [CA4739] AdBlue/DEF Level Sensor Internal Circuit Error...3635
FAILURE CODE [CA4768] Fuel in AdBlue/DEF Tank Error...3636
FAILURE CODE [CA4769] AdBlue/DEF Level Measurement Impossible...3638
FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error...3641
FAILURE CODE [CA4952] System Operating Lamp Short Circuit (Engine Controller)...3644
FAILURE CODE [CA5115] AdBlue/DEF Line Heater 1 Voltage Low Error...3646
FAILURE CODE [CA5179] Engine Room Temperature Sensor High Error...3649
FAILURE CODE [CA5181] Engine Room Temperature Sensor Low Error...3651
FAILURE CODE [CA5383] Ash Accumulation High Error...3653
FAILURE CODE [D110KB] Battery Relay Output Short Circuit...3655
FAILURE CODE [D19JKZ] Personal Code Relay Open Circuit or Short Circuit...3657
FAILURE CODE [D811MC] KOMTRAX Malfunction...3660
FAILURE CODE [D862KA] GPS Antenna Open Circuit...3661
FAILURE CODE [D8ALKA] System Operating Lamp Open Circuit (KOMTRAX)...3662
FAILURE CODE [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX)...3664
FAILURE CODE [D8AQKR] CAN 2 Defective Communication (KOMTRAX)...3666
FAILURE CODE [DA20MC] Pump Controller Malfunction...3668
FAILURE CODE [DA22KK] Pump Controller Solenoid Power Voltage Low Error...3669
FAILURE CODE [DA25KP] 5V Sensor 1 Power Voltage Low Error...3672
FAILURE CODE [DA29KQ] Model Selection Signal Mismatch (Pump Controller)...3675
FAILURE CODE [DA2LKA] System Operating Lamp Open Circuit (Pump Controller)...3677
FAILURE CODE [DA2LKB] System Operating Lamp Short Circuit (Pump Controller)...3679
FAILURE CODE [DA2QKR] Controller Area Network 2 Defective Communication (Pump Controller)...3681
FAILURE CODE [DA2RKR] Controller Area Network 1 Defective Communication (Pump Controller)...3684
FAILURE CODE [DAF0MB] Monitor ROM Abnormality...3685
FAILURE CODE [DAF0MC] Monitor Malfunction...3686
FAILURE CODE [DAF8KB] Camera Power Supply Short Circuit...3687
FAILURE CODE [DAF9KQ] Model Selection Signal Mismatch (Monitor)...3689
FAILURE CODE [DAFGMC] GPS Module Malfunction...3690
FAILURE CODE [DAFLKA] System Operating Lamp Open Circuit (Monitor)...3691
FAILURE CODE [DAFLKB] System Operating Lamp Short Circuit (Monitor)...3693
FAILURE CODE [DAFQKR] CAN 2 Defective Communication (Monitor)...3695
FAILURE CODE [DAZ9KQ] Model Selection Signal Mismatch (A/C)...3696
FAILURE CODE [DAZQKR] CAN 2 Defective Communication (A/C ECU)...3697
FAILURE CODE [DB2QKR] CAN 2 Defective Communication (Engine Controller)...3702
FAILURE CODE [DB2RKR] CAN 1 Defective Communication (Engine Controller)...3707
FAILURE CODE [DDNRKA] W/E Lever Lock SW Open Circuit...3712
FAILURE CODE [DDNRKY] W/E Lever Lock SW Short Circuit...3714
FAILURE CODE [DDNS00] Lock Lever Auto Lock Release SW On...3716
FAILURE CODE [DGH2KA] Hydraulic Oil Temperature Sensor Open Circuit...3718
FAILURE CODE [DGH2KB] Hydraulic Oil Temperature Sensor Ground Fault...3720
FAILURE CODE [DHA4KA] Air Cleaner Clog Sensor Open Circuit...3722
FAILURE CODE [DHAAMA] KDPF Differential Pressure Sensor Frozen...3724
FAILURE CODE [DHACMA] KDPF Outlet Pressure Sensor Frozen...3725
FAILURE CODE [DHPAMA] Front Pump Pressure Sensor Defective Function...3726
FAILURE CODE [DHPBMA] Rear Pump Pressure Sensor Defective Function...3729
FAILURE CODE [DHS3MA] Arm IN PPC Pressure Sensor Defective Function...3732
FAILURE CODE [DHS4MA] Bucket CURL PPC Pressure Sensor Defective Function...3735
FAILURE CODE [DHS8MA] Boom RAISE PPC Pressure Sensor Defective Function...3738
FAILURE CODE [DHS9MA] Boom LOWER PPC Pressure Sensor Defective Function...3741
FAILURE CODE [DHSAMA] Swing Right PPC Pressure Sensor Defective Function...3744
FAILURE CODE [DHSBMA] Swing Left PPC Pressure Sensor Defective Function...3747
FAILURE CODE [DHSCMA] Arm OUT PPC Pressure Sensor Defective Function...3750
FAILURE CODE [DHSDMA] Bucket DUMP PPC Pressure Sensor Defective Function...3753
FAILURE CODE [DHSFMA] Travel Forward Left PPC Pressure Sensor Defective Function...3756
FAILURE CODE [DHSGMA] Travel Forward Right PPC Pressure Sensor Defective Function...3759
FAILURE CODE [DHSHMA] Travel Reverse Left PPC Pressure Sensor Defective Function...3762
FAILURE CODE [DHSJMA] Travel Reverse Right PPC Pressure Sensor Defective Function...3765
FAILURE CODE [DKR0MA] Front Pump Swash Plate Sensor Defective Function...3768
FAILURE CODE [DKR1MA] Rear Pump Swash Plate Sensor Defective Function...3771
FAILURE CODE [DKULKA] PPC Lock Relay Open Circuit...3774
FAILURE CODE [DKULKB] PPC Lock Relay Short Circuit...3776
FAILURE CODE [DKULKY] PPC Lock Relay Hot Short Circuit...3778
FAILURE CODE [DR21KX] Camera 2 Picture Reverse Drive Input Out of Range...3780
FAILURE CODE [DR31KX] Camera 3 Picture Reverse Drive Input Out of Range...3782
FAILURE CODE [DV20KB] Travel Alarm Short Circuit...3784
FAILURE CODE [DW43KA] Travel Speed Solenoid Open Circuit...3786
FAILURE CODE [DW43KB] Travel Speed Solenoid Short Circuit...3788
FAILURE CODE [DW43KY] Travel Speed Solenoid Hot Short Circuit...3790
FAILURE CODE [DW45KA]Swing Parking Brake Solenoid Open Circuit...3792
FAILURE CODE [DW45KB] Swing Parking Brake Solenoid Short Circuit...3795
FAILURE CODE [DW45KY] Swing Parking Brake Solenoid Hot Short Circuit...3798
FAILURE CODE [DW4CKY] PPC Lock Solenoid Hot Short Circuit...3800
FAILURE CODE [DW91KA] Travel Junction Solenoid Open Circuit...3802
FAILURE CODE [DW91KB] Travel Junction Solenoid Short Circuit...3804
FAILURE CODE [DW91KY] Travel Junction Solenoid Hot Short Circuit...3806
FAILURE CODE [DWA2KA] Attachment Single or 2-Way Change Solenoid Open Circuit...3808
FAILURE CODE [DWA2KB] Attachment Single or 2-Way Change Solenoid Short Circuit...3810
FAILURE CODE [DWA2KY] Attachment Single or 2-Way Change Solenoid Hot Short Circuit...3812
FAILURE CODE [DWK0KA] 2-Stage Relief Solenoid Open Circuit...3814
FAILURE CODE [DWK0KB] 2-Stage Relief Solenoid Open Circuit...3816
FAILURE CODE [DWK0KY] 2-Stage Relief Solenoid Hot Short Circuit...3818
FAILURE CODE [DWK2KA] Variable Back Pressure Solenoid Open Circuit...3820
FAILURE CODE [DWK2KB] Variable Back Pressure Solenoid Short Circuit...3822
FAILURE CODE [DWK2KY] Variable Back Pressure Solenoid Hot Short Circuit...3824
FAILURE CODE [DWK8KA] Swing Pressure Cutoff Solenoid Open Circuit...3826
FAILURE CODE [DWK8KB] Swing Pressure Cutoff Solenoid Short Circuit...3828
FAILURE CODE [DWK8KY] Swing Pressure Cutoff Solenoid Hot Short Circuit...3830
FAILURE CODE [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit...3832
FAILURE CODE [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit...3834
FAILURE CODE [DXA9KA] Rear Pump PC-EPC Solenoid Open Circuit...3836
FAILURE CODE [DXA9KB] Rear Pump PC-EPC Solenoid Short Circuit...3838
FAILURE CODE [DXE0KA] LS-EPC Solenoid Open Circuit...3840
FAILURE CODE [DXE0KB] LS-EPC Solenoid Short Circuit...3841
FAILURE CODE [DXE4KA] Attachment Flow Regulating EPC Solenoid Open Circuit...3843
FAILURE CODE [DXE4KB] Attachment Flow Regulating EPC Solenoid Short Circuit...3845
FAILURE CODE [DXE4KY] Attachment Flow EPC Hot Short Circuit...3847
FAILURE CODE [DXE5KA] Merge-divider Main Solenoid Open Circuit...3849
FAILURE CODE [DXE5KB] Merge-divider Main Solenoid Short Circuit...3851
FAILURE CODE [DXE6KA] Merge-divider LS Solenoid Open Circuit...3853
FAILURE CODE [DXE6KB] Merge-divider LS Solenoid Short Circuit...3855
FAILURE CODE [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid Open Circuit...3857
FAILURE CODE [DXE7KB] Attachment Flow Regulating EPC 2 Solenoid Short Circuit...3859
FAILURE CODE [DXE7KY] Attachment Flow Regulating EPC 2 Hot Short Circuit...3861
FAILURE CODE [DXE8KA] Attachment Flow Regulating EPC 3 Solenoid Open Circuit...3863
FAILURE CODE [DXE8KB] Attachment Flow Regulating EPC 3 Solenoid Short Circuit...3865
FAILURE CODE [DXE8KY] Attachment Flow Regulating EPC 3 Hot Short Circuit...3867
FAILURE CODE [DXE9KA] Attachment Flow Regulating EPC 4 Solenoid Open Circuit...3869
FAILURE CODE [DXE9KB] Attachment Flow Regulating EPC 4 Solenoid Short Circuit...3871
FAILURE CODE [DXE9KY] Attachment Flow Regulating EPC 4 Hot Short Circuit...3873
FAILURE CODE [DXEAKA] Attachment Flow Regulating EPC 5 Solenoid Open Circuit...3875
FAILURE CODE [DXEAKB] Attachment Flow Regulating EPC 5 Solenoid Short Circuit...3877
FAILURE CODE [DXEAKY] Attachment Flow Regulating EPC 1 Hot Short Circuit...3879
FAILURE CODE [DY20KA]Wiper Motor Open Circuit...3881
FAILURE CODE [DY20MA] Wiper Motor Defective Function...3883
FAILURE CODE [DY2CKB] Washer Motor Short Circuit...3885
FAILURE CODE [DY2DKB] Wiper Motor (Normal Rotation) Short Circuit...3888
FAILURE CODE [DY2EKB] Wiper Motor (Reverse Rotation) Short Circuit...3890
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...3892
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)...3892
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK...3898
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK...3901
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP...3903
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING...3905
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW...3908
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW...3909
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING...3910
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING...3911
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING...3912
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...3913
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...3914
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...3915
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...3916
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...3917
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...3918
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM...3919
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL...3921
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM...3922
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE...3923
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM...3924
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE...3926
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED...3927
E-24 FUNCTION SWITCH DOES NOT OPERATE...3928
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)...3929
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF...3931
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER...3932
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED...3933
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED...3934
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE...3935
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE...3936
E-32 ALARM BUZZER CANNOT BE CANCELED...3938
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION...3939
E-34 SERVICE MODE CANNOT BE SELECTED...3940
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE...3941
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK...3944
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING...3946
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE...3949
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR...3951
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED...3954
E-41 ALARM DOES NOT SOUND DURING TRAVEL...3955
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED...3957
E-43 HORN DOES NOT SOUND...3958
E-44 HORN DOES NOT STOP SOUNDING...3961
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF...3963
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE...3964
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE...3966
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...3967
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...3968
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...3969
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...3970
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...3971
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...3972
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...3973
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...3974
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...3975
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED...3977
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY...3978
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)...3979
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)...3979
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS...3980
FAILURE MODE AND CAUSE TABLE...3982
H-1 All of work equipments, swing and travel operation lack speed or power...3991
H-2 Engine speed lowers significantly or engine stalls...3993
H-3 Any of work equipment, swing and travel does not work...3995
H-4 Unusual sound is heard from around hydraulic pump...3996
H-5 Fine control performance or response is poor...3997
H-6 Speed or power of boom is low...3998
H-7 Speed or power of arm is low...4002
H-8 Speed or power of bucket is low...4006
H-9 Work equipment does not move in single operation...4009
H-10 Hydraulic drift of boom is large...4010
H-11 Hydraulic drift of arm is large...4012
H-12 Hydraulic drift of bucket is large...4014
H-13 Other work equipment moves when one of work equipment is relieved...4015
H-14 In combined operation of work equipment , equipment having heavier load moves slower...4016
H-15 Time lag of work equipment is large...4017
H-16 Machine does not travel straight...4018
H-17 Machine is hard to steer or travel power is low...4020
H-18 Travel speed is low...4023
H-19 One of tracks does not run...4025
H-20 Travel speed does not change, or travel speed is too low or high...4026
H-21 Upper structure does not swing in both right and left directions...4027
H-22 Upper structure does not swing in only one direction...4028
H-23 Swing acceleration or swing speed of upper structure is low in both right and left directions...4029
H-24 Swing acceleration or swing speed is low in only one direction...4030
H-25 Overrun of upper structure is large in both right and left directions...4031
H-26 Upper structure overruns excessively when it stops swing in only one direction...4032
H-27 Shock is large when upper structure stops swinging...4033
H-28 Large unusual noise is heard when upper structure stops swinging...4034
H-29 Swing drift on a slope is large (while swing parking brake is applied)...4035
H-30 Swing drift on a slope is large (while swing parking brake is released)...4036
H-31 Travel speed drops largely in combined operation of swing and trave...4037
H-32 In combined operation of swing and boom RAISE, boom rising speed is low...4038
H-33 One-touch power maximizing function does not work...4039
H-34 Attachment circuit cannot be changed...4040
H-35 Oil flow in attachment circuit cannot be controlled...4041
TROUBLESHOOTING OF ENGINE (S-MODE)...4042
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)...4042
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION...4043
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT...4044
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)...4045
S-4 ENGINE STARTABILITY IS POOR...4047
S-5 ENGINE DOES NOT PICK UP SMOOTHLY...4049
S-6 ENGINE STOPS DURING OPERATION...4051
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE...4053
S-8 ENGINE LACKS POWER...4054
S-9 KDPF GETS CLOGGED IN A SHORT TIME...4056
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE...4058
S-11 OIL BECOMES CONTAMINATED QUICKLY...4059
S-12 FUEL CONSUMPTION IS EXCESSIVE...4060
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)...4061
S-14 OIL PRESSURE DROPS...4062
S-15 FUEL MIXES INTO ENGINE OIL...4064
S-16 WATER MIXES INTO ENGINE OIL (MILKY)...4065
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)...4066
S-18 UNUSUAL NOISE IS HEARD...4067
S-19 VIBRATION IS EXCESSIVE...4068
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT...4069
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY...4070
S-22 ACTIVE REGENERATION TAKES TIME...4072
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION...4073
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE...4074
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)...4076
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)...4077
50 DISASSEMBLY AND ASSEMBLY...4079
CONTENTS...4080
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY...4085
HOW TO READ THIS MANUAL...4085
COATING MATERIALS LIST...4086
SPECIAL TOOLS LIST...4091
SKETCHES OF SPECIAL TOOLS...4103
ENGINE AND COOLING SYSTEM...4109
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY...4109
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY...4109
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY...4112
REMOVE AND INSTALL INJECTOR ASSEMBLY...4116
METHOD FOR REMOVING INJECTOR ASSEMBLY...4116
METHOD FOR INSTALLING INJECTOR ASSEMBLY...4121
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY...4129
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY...4130
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY...4139
REMOVE AND INSTALL EGR VALVE ASSEMBLY...4155
METHOD FOR REMOVING EGR VALVE ASSEMBLY...4155
METHOD FOR INSTALLING EGR VALVE ASSEMBLY...4156
REMOVE AND INSTALL EGR COOLER ASSEMBLY...4159
METHOD FOR REMOVING EGR COOLER ASSEMBLY...4159
METHOD FOR INSTALLING EGR COOLER ASSEMBLY...4162
REMOVE AND INSTALL STARTER ASSEMBLY...4167
METHOD FOR REMOVING STARTER ASSEMBLY...4167
METHOD FOR INSTALLING STARTER ASSEMBLY...4169
REMOVE AND INSTALL ALTERNATOR BELT...4171
METHOD FOR REMOVING ALTERNATOR BELT...4171
METHOD FOR INSTALLING ALTERNATOR BELT...4173
REMOVE AND INSTALL RADIATOR ASSEMBLY...4175
METHOD FOR REMOVING RADIATOR ASSEMBLY...4175
METHOD FOR INSTALLING RADIATOR ASSEMBLY...4177
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY...4179
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY...4179
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY...4182
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY...4185
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY...4185
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY...4186
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY...4188
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY...4189
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY...4197
REMOVE AND INSTALL ENGINE FRONT OIL SEAL...4208
METHOD FOR REMOVING ENGINE FRONT OIL SEAL...4208
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL...4211
REMOVE AND INSTALL ENGINE REAR OIL SEAL...4215
METHOD FOR REMOVING ENGINE REAR OIL SEAL...4215
METHOD FOR INSTALLING ENGINE REAR OIL SEAL...4216
REMOVE AND INSTALL FUEL COOLER ASSEMBLY...4219
METHOD FOR REMOVING FUEL COOLER ASSEMBLY...4219
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY...4220
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY...4221
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY...4221
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY...4223
REMOVE AND INSTALL FUEL TANK ASSEMBLY...4228
METHOD FOR REMOVING FUEL TANK ASSEMBLY...4228
METHOD FOR INSTALLING FUEL TANK ASSEMBLY...4232
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY...4236
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY...4236
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY...4241
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...4247
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...4247
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...4252
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR...4258
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR...4258
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR...4258
REMOVE AND INSTALL AdBlue/DEF STRAINER...4260
METHOD FOR REMOVING AdBlue/DEF STRAINER...4260
METHOD FOR INSTALLING AdBlue/DEF STRAINER...4260
REMOVE AND INSTALL KDPF ASSEMBLY...4262
METHOD FOR REMOVING KDPF ASSEMBLY...4262
METHOD FOR INSTALLING KDPF ASSEMBLY...4264
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY...4266
METHOD FOR DISASSEMBLING KDPF ASSEMBLY...4267
METHOD FOR ASSEMBLING KDPF ASSEMBLY...4270
REMOVE AND INSTALL SCR ASSEMBLY...4275
METHOD FOR REMOVING SCR ASSEMBLY...4275
METHOD FOR INSTALLING SCR ASSEMBLY...4277
REMOVE AND INSTALL KDPF, SCR ASSEMBLY...4279
METHOD FOR REMOVING KDPF, SCR ASSEMBLY...4279
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY...4285
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET...4291
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET...4291
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET...4298
REMOVE AND INSTALL KCCV ASSEMBLY...4306
METHOD FOR REMOVING KCCV ASSEMBLY...4306
METHOD FOR INSTALLING KCCV ASSEMBLY...4308
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE...4313
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE...4313
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE...4318
REMOVE AND INSTALL AdBlue/DEF INJECTOR...4323
METHOD FOR REMOVING AdBlue/DEF INJECTOR...4323
METHOD FOR INSTALLING AdBlue/DEF INJECTOR...4325
REMOVE AND INSTALL AdBlue/DEF PUMP...4327
METHOD FOR REMOVING AdBlue/DEF PUMP...4327
METHOD FOR INSTALLING AdBlue/DEF PUMP...4329
REMOVE AND INSTALL AdBlue/DEF HOSE...4332
METHOD FOR REMOVING AdBlue/DEF HOSE...4332
METHOD FOR INSTALLING AdBlue/DEF HOSE...4336
REMOVE AND INSTALL AIR CLEANER ASSEMBLY...4342
METHOD FOR REMOVING AIR CLEANER ASSEMBLY...4342
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY...4343
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY...4345
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY...4345
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY...4347
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...4350
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY...4350
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY...4351
POWER TRAIN...4352
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...4352
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...4352
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...4353
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY...4355
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY...4355
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY...4359
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY...4367
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY...4367
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY...4370
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY...4373
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY...4373
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY...4377
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY...4384
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY...4384
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY...4385
UNDERCARRIAGE AND FRAME...4386
SEPARATION AND CONNECTION OF TRACK ASSEMBLY...4386
METHOD FOR SEPARATING TRACK ASSEMBLY...4386
METHOD FOR INSTALLING TRACK ASSEMBLY...4388
REMOVE AND INSTALL SPROCKET...4391
METHOD FOR REMOVING SPROCKET...4391
METHOD FOR INSTALLING SPROCKET...4391
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY...4393
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY...4393
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY...4394
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY...4395
METHOD FOR DISASSEMBLING IDLER ASSEMBLY...4395
METHOD FOR ASSEMBLING IDLER ASSEMBLY...4396
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY...4400
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY...4401
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY...4402
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY...4403
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY...4404
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY...4405
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY...4407
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY...4407
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY...4409
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY...4411
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY...4411
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY...4413
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY...4416
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY...4416
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY...4419
HYDRAULIC SYSTEM...4423
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY...4423
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY...4423
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY...4425
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY...4428
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY...4429
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY...4430
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY...4431
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY...4431
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY...4433
REMOVE AND INSTALL MAIN PUMP ASSEMBLY...4436
METHOD FOR REMOVING MAIN PUMP ASSEMBLY...4436
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY...4439
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY...4442
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY...4442
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY...4449
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY...4457
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING...4457
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY...4459
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY...4463
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY...4463
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY...4463
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY...4465
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY...4465
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY...4466
WORK EQUIPMENT...4468
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY...4468
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY...4468
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY...4472
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY...4478
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY...4478
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY...4481
CAB AND ITS ATTACHMENTS...4487
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY...4487
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY...4487
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY...4492
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)...4499
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)...4501
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)...4501
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY...4511
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY...4511
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY...4514
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY...4520
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY...4520
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY...4527
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY...4534
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY...4534
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY...4539
REMOVE AND INSTALL OPERATOR'S SEAT...4545
METHOD FOR REMOVING OPERATOR'S SEAT...4545
METHOD FOR INSTALLING OPERATOR'S SEAT...4547
REMOVE AND INSTALL SEAT BELT...4550
METHOD FOR REMOVING SEAT BELT...4550
METHOD FOR INSTALLING SEAT BELT...4551
REMOVE AND INSTALL FRONT WIPER ASSEMBLY...4552
METHOD FOR REMOVING FRONT WIPER ASSEMBLY...4552
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY...4557
ELECTRICAL SYSTEM...4565
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...4565
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY...4565
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY...4567
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY...4568
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY...4568
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY...4572
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY...4577
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY...4577
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY...4580
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR...4583
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR...4583
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR...4584
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR...4585
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR...4585
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR...4586
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR...4587
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR...4587
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR...4588
REMOVE AND INSTALL SCR TEMPERATURE SENSOR...4589
METHOD FOR REMOVING SCR TEMPERATURE SENSOR...4589
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR...4591
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY...4593
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY...4593
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY...4596
60 MAINTENANCE STANDARD...4599
CONTENTS...4600
ENGINE AND COOLING SYSTEM...4601
MAINTENANCE STANDARD OF ENGINE MOUNT...4601
MAINTENANCE STANDARD OF COOLING SYSTEM...4602
POWER TRAIN...4603
MAINTENANCE STANDARD OF SWING CIRCLE...4603
MAINTENANCE STANDARD OF SWING MACHINERY...4604
MAINTENANCE STANDARD OF FINAL DRIVE...4606
MAINTENANCE STANDARD OF SPROCKET...4608
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING...4609
UNDERCARRIAGE AND FRAME...4611
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION...4611
MAINTENANCE STANDARD OF IDLER...4613
MAINTENANCE STANDARD OF TRACK ROLLER...4615
MAINTENANCE STANDARD OF CARRIER ROLLER...4616
MAINTENANCE STANDARD OF TRACK SHOE...4617
MAINTENANCE STANDARD OF TRIPLE SHOE...4620
MAINTENANCE STANDARD OF SWAMP SHOE...4621
MAINTENANCE STANDARD OF ROAD LINER...4622
HYDRAULIC SYSTEM...4623
MAINTENANCE STANDARD OF HYDRAULIC TANK...4623
MAINTENANCE STANDARD OF MAIN PUMP...4624
MAINTENANCE STANDARD OF PC-EPC VALVE...4625
MAINTENANCE STANDARD OF SWING MOTOR...4626
MAINTENANCE STANDARD OF TRAVEL MOTOR...4629
MAINTENANCE STANDARD OF CONTROL VALVE...4632
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE...4642
MAINTENANCE STANDARD OF TRAVEL PPC VALVE...4645
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)...4648
MAINTENANCE STANDARD OF EPC VALVE...4649
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE...4651
MAINTENANCE STANDARD OF SOLENOID VALVE...4653
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)...4654
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)...4655
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT...4656
WORK EQUIPMENT...4657
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE...4657
DIMENSION OF ARM...4662
DIMENSIONS OF BUCKET...4664
MAINTENANCE STANDARD OF BOOM CYLINDER...4666
MAINTENANCE STANDARD OF BOOM CYLINDER (FOR LARGE DIAMETER PISTON)...4667
MAINTENANCE STANDARD OF ARM CYLINDER...4668
MAINTENANCE STANDARD OF BUCKET CYLINDER...4669
80 APPENDIX...4671
CONTENTS...4672
AIR CONDITIONER SYSTEM...4674
PRECAUTIONS FOR REFRIGERANT...4674
AIR CONDITIONER COMPONENT...4675
SPECIFICATIONS OF AIR CONDITIONER...4677
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE...4678
OUTLINE OF REFRIGERATION CYCLE...4679
COMPONENT PARTS OF AIR CONDITIONER SYSTEM...4681
AIR CONDITIONER UNIT...4681
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT...4681
FUNCTION OF AIR CONDITIONER UNIT...4683
COMPONENT PARTS OF AIR CONDITIONER UNIT...4685
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT...4686
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT...4686
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT...4686
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT...4686
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...4687
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...4687
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...4688
FUNCTION OF DUAL PRESSURE SWITCH...4688
AIR CONDITIONER CONTROLLER...4689
STRUCTURE OF AIR CONDITIONER CONTROLLER...4689
COMPRESSOR...4690
STRUCTURE OF COMPRESSOR...4690
SPECIFICATIONS OF COMPRESSOR...4690
FUNCTION OF COMPRESSOR...4691
CONDENSER...4692
STRUCTURE OF CONDENSER...4692
SPECIFICATIONS OF CONDENSER...4692
FUNCTION OF CONDENSER...4692
SENSORS FOR AIR CONDITIONER SYSTEM...4694
STRUCTURE OF SUNLIGHT SENSOR...4694
FUNCTION OF SUNLIGHT SENSOR...4694
STRUCTURE OF AMBIENT TEMPERATURE SENSOR...4694
FUNCTION OF AMBIENT TEMPERATURE SENSOR...4694
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER...4696
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER...4698
AIR CONDITIONER SYSTEM DIAGRAM...4700
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER...4701
FUNCTION OF AIR CONDITIONER CONTROLLER...4702
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS...4703
TESTING AIR LEAKAGE (DUCT)...4707
METHOD FOR TESTING AIR LEAKAGE (DUCT)...4707
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION...4709
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR...4710
TEST VENT (MODE) CHANGEOVER...4711
METHOD FOR TESTING VENT (MODE) CHANGEOVER...4711
TESTING FRESH/RECIRC AIR CHANGEOVER...4713
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER...4713
TEST SUNLIGHT SENSOR...4714
METHOD FOR TESTING SUNLIGHT SENSOR...4714
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT...4715
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT...4715
TEST RELAYS...4716
METHOD FOR TESTING RELAYS...4716
AIR CONDITIONER TROUBLESHOOTING CHART 1...4717
AIR CONDITIONER TROUBLESHOOTING CHART 2...4719
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...4722
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit...4724
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit...4725
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit...4726
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit...4728
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit...4730
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit...4731
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit...4732
FAILURE CODE [879EMC] Ventilation Damper Malfunction...4734
FAILURE CODE [879FMC] Air Mix Damper Malfunction...4735
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range...4736
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)...4738
A-2 TROUBLESHOOTING OF COMPRESSOR SYSTEM (AIR IS NOT COOLED)...4740
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)...4743
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER...4745
TROUBLESHOOTING USING GAUGE PRESSURE...4747
CONNECTION OF SERVICE TOOL...4749
METHOD FOR CONNECTING SERVICE TOOL...4749
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS...4751
HANDLE COMPRESSOR OIL...4753
METHOD FOR REPLACING DESICCANT...4755
90 CIRCUIT DIAGRAMS...4757
CONTENTS...4758
HYDRAULIC CIRCUIT DIAGRAM...4759
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM...4759
HYDRAULIC CIRCUIT DIAGRAM...4763
ELECTRICAL CIRCUIT DIAGRAM...4764
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM...4764
ELECTRICAL CIRCUIT DIAGRAM (1/7)...4768
ELECTRICAL CIRCUIT DIAGRAM (2/7)...4769
ELECTRICAL CIRCUIT DIAGRAM (3/7)...4770
ELECTRICAL CIRCUIT DIAGRAM (4/7)...4771
ELECTRICAL CIRCUIT DIAGRAM (5/7)...4772
ELECTRICAL CIRCUIT DIAGRAM (6/7)...4773
ELECTRICAL CIRCUIT DIAGRAM (7/7)...4774
INDEX...4775
SEN05538-02 - Hydraulic Excavator PC240LC-10 Shop Manual...4797
00 Index and foreword ...4799
Index ...4800
Foreword, safety and general information ...4811
Important safety notice ...4811
How to read the shop manual ...4816
Explanation of terms for maintenance standard ...4818
Handling of hydraulic equipment ...4820
Method of disconnecting and connecting push-pull type coupler ...4822
Handling of electrical equipment ...4825
How to read electric wire code ...4833
Precautions when performing operation ...4836
Standard tightening torque table ...4839
List of abbreviation ...4843
Conversion table ...4848
01 Specification ...4854
Specifications ...4855
Specification drawings ...4855
Working range drawings ...4856
Specifications ...4857
Weight table ...4860
Table of fuel, coolant and lubricants ...4861
10 Structure and function ...4864
Engine and cooling system ...4865
Engine related parts ...4865
Cooling system ...4867
Power train ...4869
Power train ...4869
Swing circle ...4871
Swing machinery ...4872
Final drive ...4874
Undercarriage and frame ...4876
Track frame and idler cushion ...4876
Hydraulic system ...4878
Hydraulic equipment layout drawing ...4878
Valve control ...4880
Hydraulic tank ...4882
CLSS ...4884
Main pump ...4889
Control valve ...4913
Swing motor ...4967
Travel motor ...4978
PPC valve ...4991
Solenoid valve ...5012
Attachment circuit selector valve (for high pressure circuit) ...5015
Attachment circuit selector valve (for low pressure circuit) ...5017
Center swivel joint ...5020
Accumulator ...5022
Work equipment ...5023
Work equipment ...5023
Work equipment shim ...5024
Bucket play adjustment shim ...5025
Cab and its attachments ...5026
Cab mount and cab tipping stopper ...5026
ROPS cab ...5027
Electrical system ...5028
Electrical control system ...5028
Machine monitor system ...5071
KOMTRAX system ...5092
Sensors ...5094
20 Standard value table ...5112
Standard service value table ...5113
Standard value table for engine related parts ...5113
Standard value table for chassis related parts ...5114
Posture of machine for measuring performance and measurement procedure ...5123
40 Troubleshooting ...5292
General information on troubleshooting ...5293
Instruction on troubleshooting ...5293
How to proceed troubleshooting ...5295
Testing before troubleshooting ...5296
Testing procedure before troubleshooting ...5298
Preparation work for troubleshooting of electrical system ...5326
Classification and procedure for troubleshooting ...5330
Symptom of probable failure and troubleshooting No. ...5333
Information mentioned in troubleshooting table ...5336
Diagnostic procedure for wiring harness open curcuit of pressure sensor system ...5339
Connector list and layout ...5341
Connector contact identification ...5352
T-branch box and T-branch adapter table ...5389
Fuse list and location ...5395
Precautions for cleaning and replacing KDPF (KCSF, KDOC) ...5397
Failure codes table ...5399
Troubleshooting by failure code (Display of code) ...5408
Failure code [879AKA] A/C Inner Sensor Open Circuit ...5408
Failure code [879AKB] A/C Inner Sensor Short Circuit ...5409
Failure code [879BKA] A/C Outer Sensor Open Circuit ...5410
Failure code [879BKB] A/C Outer Sensor Short Circuit ...5411
Failure code [879CKA] Ventilating Sensor Open Circuit ...5412
Failure code [879CKB] Ventilating Sensor Short Circuit ...5413
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ...5414
Failure code [879EMC] Ventilation Damper Abnormality ...5415
Failure code [879FMC] Air Mix Damper Abnormality ...5416
Failure code [879GKX] Refrigerant Abnormality ...5417
Failure code [989L00] Engine Controller Lock Caution1 ...5418
Failure code [989M00] Engine Controller Lock Caution2 ...5419
Failure code [989N00] Engine Controller Lock Caution3 ...5420
Failure code [A1U0N3] HC desorb request1 ...5421
Failure code [A1U0N4] HC desorb request2 ...5423
Failure code [AA10NX] Air Cleaner Clogging ...5425
Failure code [AB00KE] Charge Voltage Low ...5427
Failure code [B@BAZG] Engine Oil Pressure Low ...5429
Failure code [B@BAZK] Eng Oil Level Low ...5430
Failure code [B@BCNS] Engine Coolant Overheat ...5431
Failure code [B@BCZK] Radiator Coolant Level Low ...5432
Failure code [B@HANS] Hyd Oil Overheat ...5434
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ...5435
Failure code [CA122] Chg Air Press Sensor High Error ...5436
Failure code [CA123] Chg Air Press Sensor Low Error ...5438
Failure code [CA131] Throttle Sensor High Error ...5440
Failure code [CA132] Throttle Sensor Low Error ...5442
Failure code [CA144] Coolant Temp Sens High Error ...5444
Failure code [CA145] Coolant Temp Sens Low Error ...5446
Failure code [CA153] Chg Air Temp Sensor High Error ...5448
Failure code [CA154] Chg Air Temp Sensor Low Error ...5450
Failure code [CA187] Sensor 2 Supply Volt Low Error ...5452
Failure code [CA221] Ambient Press Sensor High Error ...5454
Failure code [CA222] Ambient Press Sensor Low Error ...5456
Failure code [CA227] Sensor 2 Supply Volt High Error ...5458
Failure code [CA234] Eng Overspeed ...5459
Failure code [CA238] Ne Speed Sensor Supply Volt Error ...5460
Failure code [CA239] Ne Speed Sens Supply Volt High Error ...5461
Failure code [CA271] IMV/PCV1 Short Error ...5462
Failure code [CA272] IMV/PCV1 Open Error ...5464
Failure code [CA295] Ambient Press Sens In Range Error ...5465
Failure code [CA322] Inj #1(L#1) Open/Short Error ...5466
Failure code [CA323] Inj #5(L#5) Open/Short Error ...5468
Failure code [CA324] Inj #3(L#3) Open/Short Error ...5470
Failure code [CA325] Inj #6(L#6) Open/Short Error ...5472
Failure code [CA331] Inj #2(L#2) Open/Short Error ...5474
Failure code [CA332] Inj #4(L#4) Open/Short Error ...5476
Failure code [CA343] ECM Critical Internal Failure ...5478
Failure code [CA351] Injectors Drive Circuit Error ...5479
Failure code [CA352] Sensor 1 Supply Volt Low Error ...5480
Failure code [CA356] Mass Air Flow Sensor High Error ...5482
Failure code [CA357] Mass Air Flow Sensor Low Error ...5484
Failure code [CA386] Sensor 1 Supply Volt High Error ...5486
Failure code [CA428] Water in Fuel Sensor High Error ...5487
Failure code [CA429] Water in Fuel Sensor Low Error ...5489
Failure code [CA435] Eng Oil Press Sw Error ...5491
Failure code [CA441] Battery Voltage Low Error ...5492
Failure code [CA442] Battery Voltage High Error ...5494
Failure code [CA449] Rail Press Very High Error ...5495
Failure code [CA451] Rail Press Sensor High Error ...5496
Failure code [CA452] Rail Press Sensor Low Error ...5498
Failure code [CA488] Chg Air Temp High Torque Derate ...5499
Failure code [CA515] Rail Press Sens Sup Volt High Error ...5500
Failure code [CA516] Rail Press Sens Sup Volt Low Error ...5502
Failure code [CA553] Rail Press High Error ...5504
Failure code [CA555] Crankcase Press High Error 1 ...5505
Failure code [CA556] Crankcase Press High Error 2 ...5506
Failure code [CA559] Rail Press Low Error ...5507
Failure code [CA595] Turbo Speed High Error 2 ...5509
Failure code [CA687] Turbo Speed Low Error ...5510
Failure code [CA689] Eng Ne Speed Sensor Error ...5512
Failure code [CA691] Intake Air Temp Sens High Error ...5514
Failure code [CA692] Intake Air Temp Sens Low Error ...5516
Failure code [CA697] ECM Int Temp Sensor High Error ...5518
Failure code [CA698] ECM Int Temp Sensor Low Error ...5519
Failure code [CA731] Eng Bkup Speed Sens Phase Error ...5520
Failure code [CA778] Eng Bkup Speed Sensor Error ...5521
Failure code [CA1117] Persistent Data Lost Error ...5525
Failure code [CA1664] KDOC Malfunction ...5526
Failure code [CA1691] Regeneration Ineffective ...5528
Failure code [CA1695] Sensor 5 Supply Volt Low Error ...5530
Failure code [CA1696] Sensor 5 Supply Volt High Error ...5532
Failure code [CA1843] Crankcase Press Sens High Error ...5534
Failure code [CA1844] Crankcase Press Sens Low Error ...5536
Failure code [CA1879] KDPF Delta P Sensor High Error ...5538
Failure code [CA1881] KDPF Delta P Sensor Low Error ...5540
Failure code [CA1883] KDPF Delta P Sens In Range Error ...5542
Failure code [CA1921] KDPF Soot Load High Error 1 ...5545
Failure code [CA1922] KDPF Soot Load High Error 2 ...5547
Failure code [CA1942] Crankcase Press Sens In Range Error ...5551
Failure code [CA1993] KDPF Delta Pressure Low Error ...5552
Failure code [CA2185] Throt Sensor Sup Volt High Error ...5553
Failure code [CA2186] Throt Sensor Sup Volt Low Error ...5554
Failure code [CA2249] Rail Press Very Low Error ...5555
Failure code [CA2271] EGR Valve Pos Sens High Error ...5556
Failure code [CA2272] EGR Valve Pos Sens Low Error ...5558
Failure code [CA2288] Turbo Speed High Error 1 ...5561
Failure code [CA2311] IMV Solenoid Error ...5562
Failure code [CA2349] EGR Valve Solenoid Open Error ...5563
Failure code [CA2353] EGR Valve Solenoid Short Error ...5565
Failure code [CA2357] EGR Differential Pressure ...5567
Failure code [CA2373] Exh Manifold Press. Sens Volt ...5568
Failure code [CA2374] Exhaust Manifold Press Sens Low Error ...5570
Failure code [CA2375] EGR Orifice Temp Sens High Error ...5572
Failure code [CA2376] EGR Orifice Temp Sens Low Error ...5574
Failure code [CA2381] KVGT Pos Sens High Error ...5576
Failure code [CA2382] KVGT Pos Sens Low Error ...5578
Failure code [CA2383] KVGT Solenoid Open Error ...5580
Failure code [CA2386] KVGT Solenoid Short Error ...5582
Failure code [CA2387] KVGT Servo Error ...5584
Failure code [CA2554] Exh Manifold Press Sens In Range Error ...5585
Failure code [CA2555] Grid Htr Relay Volt Low Error ...5586
Failure code [CA2556] Grid Htr Relay Volt High Error ...5588
Failure code [CA2637] KDOC Face Plugging ...5590
Failure code [CA2639] Manual Stationary Regeneration Request ...5592
Failure code [CA2961] EGR Orifice Temp High Error 1 ...5594
Failure code [CA2973] Chg Air Press Sensor In Range Error ...5595
Failure code [CA3133] KDPF Outlet Press Sens High Error ...5596
Failure code [CA3134] KDPF Outlet Press Sens Low Error ...5598
Failure code [CA3135] KDPF Outlet Press Sens In Range Error ...5600
Failure code [CA3251] DOC Inlet Temp High Error ...5603
Failure code [CA3253] KDOC Temp Error - Non Regeneration ...5606
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...5607
Failure code [CA3255] KDPF Temp Error - Non Regeneration ...5610
Failure code [CA3256] KDPF Outlet Temp High Error 1 ...5611
Failure code [CA3311] KDOC Outlet Temp High Error 2 ...5612
Failure code [CA3312] KDPF Outlet Temp High Error 2 ...5613
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ...5615
Failure code [CA3314] KDOC Inlet Temp Sens High Error ...5618
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ...5622
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ...5626
Failure code [CA3317] KDOC Outlet Temp Sens High Error ...5629
Failure code [CA3318] KDOC Inlet Temp Sens In Range Error ...5633
Failure code [CA3319] KDPF Outlet Temp Sens High Error ...5637
Failure code [CA3321] KDPF Outlet Temp Sens Low Error ...5641
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ...5644
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ...5648
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ...5649
Failure code [CA3741] Rail Press Valve Trip Error ...5651
Failure code [D110KB] Battery Relay Output Voltage ...5652
Failure code [D19JKZ] Personal Code Relay Abnormality ...5654
Failure code [D811MC] KOMTRAX Error ...5657
Failure code [D862KA] GPS Antenna Open Circuit ...5658
Failure code [D8ALKA] Operating Lamp Open Circuit(KOMTRAX) ...5659
Failure code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX) ...5661
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ...5662
Failure code [DA20MC] Pump Controller ...5663
Failure code [DA22KK] Pump Solenoid Power Low Error ...5664
Failure code [DA25KP] 5V Sensor 1 Power Abnormality ...5666
Failure code [DA29KQ] Model Selection Abnormality ...5669
Failure code [DA2LKA] Operating Lamp Open Circuit(Pump Con) ...5671
Failure code [DA2LKB] Operating Lamp Short Circuit(Pump Con) ...5673
Failure code [DA2QKR] CAN2 Discon (Pump Con) ...5674
Failure code [DA2QKR] CAN1 Discon (Pump Con) ...5676
Failure code [DAF0MB] Monitor ROM Abnormality ...5677
Failure code [DAF0MC] Monitor Error ...5678
Failure code [DAF8KB] Camera Power Supply Short Circuit ...5679
Failure code [DAF9KQ] Model Selection Abnormality ...5681
Failure code [DAFGMC] GPS Module Error ...5682
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) ...5683
Failure code [DAFLKB] Operating Lamp Short Circuit(Monitor) ...5685
Failure code [DAFQKR] CAN2 Discon (Monitor) ...5686
Failure code [DAZ9KQ] A/C Model Selection Abnormality ...5687
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ...5688
Failure code [DB2QKR] CAN2 Discon (Engine Con) ...5692
Failure code [DB2RKR] CAN1 Discon (Engine Con) ...5697
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit ...5701
Failure code [DHA4KA] Air Cleaner Clog Sensor Open Circuit ...5703
Failure code [DHPAMA] F Pump Press Sensor Abnormality ...5704
Failure code [DHPBMA] R Pump Press Sensor Abnormality ...5707
Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality ...5710
Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality ...5712
Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality ...5715
Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality ...5718
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnormality ...5721
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnormality ...5724
Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality ...5727
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ...5730
Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality ...5733
Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality ...5736
Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality ...5739
Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality ...5742
Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality ...5745
Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality ...5748
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ...5751
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ...5753
Failure code [DV20KB] Travel Alarm Short Circuit ...5755
Failure code [DW43KA] Travel Speed Sol Open Circuit ...5757
Failure code [DW43KB] Travel Speed Sol Short Circuit ...5759
Failure code [DW45KA] Swing Brake Sol Open Circuit ...5761
Failure code [DW45KB] Swing Brake Sol Short Circuit ...5763
Failure code [DW91KA] Travel Junction Sol Open Circuit ...5766
Failure code [DW91KB] Travel Junction Sol Short Circuit ...5768
Failure code [DWA2KA] Attachment Sol Open Circuit ...5770
Failure code [DWA2KB] Attachment Sol Short Circuit ...5772
Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit ...5774
Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit ...5776
Failure code [DWK2KA] Variable Back Press Sol Open Circuit ...5778
Failure code [DWK2KB] Variable Back Press Sol Short Circuit ...5780
Failure code [DWK8KA] Swing Press C/O Sol Open Circuit ...5782
Failure code [DWK8KB] Swing Press C/O Sol Short Circuit ...5784
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit ...5786
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit ...5788
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ...5790
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ...5792
Failure code [DXE0KA] LS-EPC Sol Open Circuit ...5794
Failure code [DXE0KB] LS-EPC Sol Short Circuit ...5796
Failure code [DXE4KA] Attachment Flow EPC Open Circuit ...5798
Failure code [DXE4KB] Attachment Flow EPC Short Circuit ...5800
Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ...5802
Failure code [DXE5KB] Merge-divide Main Sol Short Circuit ...5804
Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ...5806
Failure code [DXE6KB] Merge-divide LS Sol Short Circuit ...5808
Failure code [DY20KA] Wiper Working Abnormality ...5810
Failure code [DY20MA] Wiper Parking Abnormality ...5812
Failure code [DY2CKB] Washer Drive Short Circuit ...5814
Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ...5816
Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit ...5818
Troubleshooting of electrical system (E-mode) ...5820
E-1 Engine does not start (Engine does not rotate) ...5820
E-2 Manual preheating system does not work ...5826
E-3 Automatic preheating system does not work ...5829
E-4 Preheating monitor does not light up when preheater is operated ...5831
E-5 When starting switch is turned to ON position, machine monitor displays nothing ...5833
E-6 When starting switch is turned to ON position (before starting engine), engine oil level monitor lights up in yellow ...5836
E-7 When starting switch is turned to ON position (before starting engine), radiator coolant level monitor lights up in yellow ...5837
E-8 Coolant temperature monitor lights up in white while engine is running ...5838
E-9 Hydraulic oil temperature monitor lights up in white while engine is running ...5839
E-10 Charge level monitor lights up while engine is running ...5840
E-11 Fuel level monitor lights up in red while engine is running ...5841
E-12 Air cleaner clogging monitor lights up in yellow while engine is running ...5842
E-13 Water separator monitor lights up while engine is running ...5843
E-14 Coolant temperature monitor lights up in red while engine is running ...5844
E-15 Hydraulic oil temperature monitor lights up in red while engine is running ...5845
E-16 Engine oil pressure monitor lights up in red while engine is running ...5846
E-17 Fuel gauge indicate either full or empty and does not move ...5847
E-18 Fuel gauge indicates incorrect amount (indicates neither full nor empty) ...5848
E-19 Coolant temperature gauge indicate either Min or Max and does not move ...5849
E-20 Coolant temperature gauge indicates incorrect temperature (indicates neither Min nor Max) ...5850
E-21 Hydraulic oil temperature gauge indicate either Min or Max and does not move ...5851
E-22 Hydraulic oil temperature gauge indicates incorrect temperature (indicates neither Min nor Max) ...5853
E-23 Content of display on machine monitor is different from that of actual machine ...5854
E-24 Machine monitor does not display some items ...5855
E-25 Function switch does not work ...5856
E-26 Automatic preheating system does not work (In cold season) ...5857
E-27 Auto-deceleration monitor does not light up or does not go out when auto-deceleration switch is operated ...5858
E-28 Auto-deceleration is not actuated or canceled when lever is operated ...5859
E-29 Working mode selector screen selection screen is not diplayed when working mode switch is operated ...5861
E-30 Engine or hydraulic pump setting does not change when working mode is changed ...5862
E-31 Travel speed monitor does not change when travel speed switch is operated ...5863
E-32 Travel speed does not change when travel speed is shifted ...5864
E-33 Alarm buzzer does not stop sounding ...5865
E-34 When starting switch is turned to OFF position, service meter is not displayed ...5866
E-35 Service mode cannot be selected ...5867
E-36 Any of work equipment, swing and travel does not work ...5868
E-37 Any of work equipment, swing and travel can not be locked ...5870
E-38 Machine can not swing while swing brake cancel switch is canceled ...5871
E-39 Swing brake does not operate while swing brake cancel switch is locked ...5873
E-40 One-touch power maximizing function does not work or monitor is not displayed ...5875
E-41 One-touch power maximizing function cannot be released ...5877
E-42 Travel alarm does not sound when machine travels ...5878
E-43 Travel alarm does not stop sounding when machine stops ...5879
E-44 Horn does not sound ...5880
E-45 Horn does not stop sounding ...5882
E-46 Wiper monitor does not light up or go out when wipper switch is operated ...5883
E-47 Wiper does not operate when wipper switch is operated ...5884
E-48 Window washer does not operate when window washer switch is operated ...5886
E-49 BOOM LOWER indication is not displayed properly with monitoring function ...5887
E-50 ARM DUMP indication is not displayed properly with monitoring function ...5888
E-51 ARM IN indication is not displayed properly with monitoring function ...5889
E-52 BOOM RAISE indication is not displayed properly with monitoring function ...5890
E-53 BUCKET CURL indication is not displayed properly with monitoring function ...5891
E-54 BUCKET DUMP indication is not displayed properly with monitoring function ...5892
E-55 SWING indication is not displayed properly with monitoring function ...5893
E-56 TRAVEL indication is not displayed properly with monitoring function ...5894
E-57 Service is not displayed properly with monitoring function ...5895
E-58 Attachment hydraulic circuit cannot be changed ...5898
E-59 KOMTRAX system does not work properly ...5899
Troubleshooting of hydraulic and mechanical system (H-mode) ...5900
Information mentioned in troubleshooting table (H mode) ...5900
System chart for hydraulic system ...5901
Failure mode and cause table ...5903
H-1 All of work equipment, swing and travel operation lacks speed or power ...5911
H-2 Engine speed lowers significantly or engine stalls ...5914
H-3 Any of work equipment, swing and travel does not work ...5916
H-4 Unusual sound is heard from around hydraulic pump ...5917
H-5 Fine control performance or response is poor ...5918
H-6 Boom operation lacks speed or power ...5919
H-7 Arm operation lacks speed or power ...5921
H-8 Bucket operation lacks speed or power ...5923
H-9 Work equipment does not move in single operation ...5924
H-10 Hydraulic drift of boom is large ...5925
H-11 Hydraulic drift of arm is large ...5926
H-12 Hydraulic drift of bucket is large ...5927
H-13 Time lag of work equipment is large ...5928
H-14 When part of work equipment is relieved singly, other parts of work equipment move ...5930
E-15 One-touch power maximizing function does not work ...5931
H-16 In combined operation of work equipment, equipment having heavier load moves slower ...5932
H-17 In combined operations of swing and boom RAISE, boom rising speed is low ...5933
H-18 In combined operations of swing and travel, travel speed drops largely ...5934
H-19 Machine does not travel straight ...5935
H-20 Travel speed is too low ...5936
H-21 Machine is hard to steer or travel power is low ...5938
H-22 Travel speed does not change, or travel speed is too low or high ...5940
H-23 One of tracks dose not run ...5941
H-24 Upper structure does not swing to the right or left ...5942
H-25 Upper structure swing only to the right or left ...5943
H-26 Swing acceleration is poor or swing speed is low (both right and left) ...5944
H-27 Swing acceleration is poor or swing speed is low (either right or left) ...5945
H-28 Upper structure overruns excessively when it stops swinging (both right and left) ...5946
H-29 Upper structure overruns excessively when it stops swinging (either right or left) ...5947
H-30 Shock is large when upper structure stops swinging ...5948
H-31 Large unusual noise is heard when upper structure stops swinging ...5949
H-32 Swing drift on a slope is large while swing holding brake is applied ...5950
H-33 Swing drift on a slope is large while swing holding brake is released ...5951
H-34 Attachment circuit cannot be changed while attachment is installed ...5952
H-35 Oil flow in attachment circuit cannot be controlled ...5953
Troubleshooting of engine (S-mode) ...5954
Information mentioned in troubleshooting table (S mode) ...5954
S-1 When starting switch is turned to START position, engine does not crank ...5955
S-2 When engine cranks, smoke does not come out ...5956
S-3 Engine does not start while fuel is injected (Incomplete combustion) ...5957
S-4 Startability is poor ...5958
S-5 Engine does not pick up smoothly ...5960
S-6 Engine stops during operation ...5961
S-7 Engine runs rough or is unstable ...5963
S-8 Engine lacks power ...5964
S-9 Exhaust smoke is black (KDPF clogs up early) ...5966
S-10 Engine oil consumption is too much ...5968
S-11 Oil becomes contaminated early ...5969
S-12 Fuel consumption is excessive ...5970
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ...5971
S-14 Engine oil pressure drops ...5972
S-15 Fuel is contaminated in engine oil ...5973
S-16 Coolant is contaminated in engine oil (Oil becomes cloudy white) ...5974
S-17 Coolant temperature rises too high (Overheating) ...5975
S-18 Unusual noise is heard ...5976
S-19 Vibration is excessive ...5977
S-20 Automatic regeneration is operated frequently ...5978
S-21 Active regeneration is operated for long ...5979
S-22 White smoke comes out in the process of active regeneration ...5980
50 Disassembly and assembly ...5983
General information on disassembly and assembly ...5984
How to read this manual ...5984
Coating materials list ...5986
Special tools list ...5990
Sketches of special tools ...5998
Engine and cooling system ...6001
Removal and installation of supply pump assembly ...6001
Removal and installation of injector assembly ...6006
Removal and installation of cylinder head assembly ...6015
Removal and installation of radiator assembly ...6035
Removal and installation of hydraulic oil cooler assembly ...6037
Removal and installation of aftercooler assembly ...6040
Removal and installation of engine and main pump assembly ...6042
Removal and installation of engine front oil seal ...6054
Removal and installation of engine rear oil seal ...6058
Removal and installation of fuel cooler assembly ...6061
Removal and installation of fuel tank assembly ...6062
Removal and installation of engine hood assembly ...6065
Removal and installation of KDPF assembly ...6068
Disassembly and assembly of KDPF ...6076
Removal and installation of KCCV assembly ...6084
Removal and installation of air cleaner assembly ...6087
Power train ...6090
Removal and installation of travel motor and final drive assembly ...6090
Disassembly and assembly of final drive ...6092
Removal and installation of swing motor and swing machinery assembly ...6100
Disassembly and assembly of swing machinery ...6103
Removal and installation of swing circle assembly ...6111
Undercarriage and frame ...6112
Separation and connection of track shoe assembly ...6112
Removal and installation of sprocket ...6115
Removal and installation of idler and idler cushion assembly ...6116
Disassembly and assembly of idler ...6117
Disassembly and assembly of idler cushion ...6120
Disassembly and assembly of track roller ...6122
Disassembly and assembly of carrier roller ...6125
Removal and installation of revolving frame assembly ...6128
Removal and installation of counterweight assembly ...6130
Hydraulic system ...6133
Removal and installation of center swivel joint assembly ...6133
Disassembly and assembly of center swivel joint ...6135
Removal and installation of hydraulic tank assembly ...6137
Removal and installation of main pump assembly ...6141
Removal and installation of control valve assembly ...6145
Disassembly and assembly of control valve ...6152
Disassembly and assembly of work equipment PPC valve ...6157
Disassembly and assembly of travel PPC valve ...6159
Work equipment ...6162
Removal and installation of work equipment assembly ...6162
Disassembly and assembly of work equipment cylinder ...6165
Cab and its attachments ...6171
Removal and installation of operator's cab assembly ...6171
Removal and installation of operator cab glass (adhered glass) ...6176
Removal and installation of front window assembly ...6186
Removal and installation of floor frame assembly ...6192
Removal and installation of air conditioner unit assembly ...6198
Removal and installation of operator's seat ...6202
Removal and installation of seat belt ...6204
Removal and installation of front wiper assembly ...6206
Electric system ...6213
Removal and installation of air conditioner compressor assembly ...6213
Removal and installation of air conditioner condenser assembly ...6216
Removal and installation of engine controller assembly ...6218
Removal and installation of pump controller assembly ...6220
Removal and installation of machine monitor assembly ...6223
Removal and installation of pump swash plate sensor ...6225
Removal and installation of Mass air flow and temperature sensor ...6226
Removal and installation of KOMTRAX terminal assembly ...6227
60 Maintenance standard ...6230
Engine and cooling system ...6231
Engine mount ...6231
Cooling system ...6232
Power train ...6233
Swing circle ...6233
Swing machinery ...6234
Final drive ...6236
Sprocket ...6238
Undercarriage and frame ...6240
Truck frame and idler cushion ...6240
Idler ...6242
Truck roller ...6244
Carrier roller ...6245
Truck shoe ...6246
Hydraulic system ...6251
Hydraulic tank ...6251
Main pump ...6252
Control valve ...6253
Swing motor ...6261
Travel motor ...6263
PPC valve ...6266
Solenoid valve ...6276
Attachment circuit selector valve (for high-pressure circuit) ...6277
Attachment circuit selector valve (for low-pressure circuit) ...6278
Center swivel joint ...6279
Work equipment ...6280
Work equipment cylinder ...6280
80 Appendix ...6294
Air conditioner ...6295
Precautions for refrigerant ...6295
Air conditioner component ...6296
Structure and function of refrigeration system ...6298
Overview of refrigeration system ...6299
Air conditioner unit ...6301
Dual pressure switch ...6307
Air conditioner controller ...6308
Air conditioner compressor ...6309
Air conditioner condenser ...6310
Sunlight sensor ...6312
Outside air temperature sensor ...6313
Inspection and troubleshooting procedure of air conditioner ...6314
Air conditioner circuit diagram and arrangement of connector pins ...6316
System diagram ...6318
Air conditioner controller input and output signals ...6319
Parts and connectors layout ...6321
Layout of air conditioner related parts and connectors ...6322
Testing air leakage (duct) ...6325
Testing with self-diagnosis function ...6328
How to enter air conditioner "Electrical Systems" screen in service mode of the machine monitor. ...6329
Testing vent (mode) changeover ...6331
Testing FRESH/RECIRC air changeover ...6333
Testing sunlight sensor ...6334
Testing (dual) pressure switch for refrigerant ...6335
Testing relay ...6337
Troubleshooting chart 1 ...6338
Troubleshooting chart 2 ...6339
Information mentioned in troubleshooting table ...6342
Failure code list related to air conditioner ...6343
Failure code [879AKA] A/C Inner Sensor Open Circuit ...6345
Failure code [879AKB] A/C Inner Sensor Short Circuit ...6346
Failure code [879BKA] A/C Outer Sensor Open Circuit ...6347
Failure code [879BKB] A/C Outer Sensor Short Circuit ...6349
Failure code [879CKA] Ventilating Sensor Open Circuit ...6351
Failure code [879CKB] Ventilating Sensor Short Circuit ...6352
Failure code [879DKZ] Sunlight Sensor Open or Short Circuit ...6353
Failure code [879EMC] Ventilation Damper Abnormality ...6355
Failure code [879FMC] Air Mix Damper Abnormality ...6356
Failure code [879GKX] Refrigerant Abnormality ...6357
A-1 Troubleshooting for power supply system (The air conditioner does not operate) ...6358
A-2 Troubleshooting of compressor system (Air is not cooled) ...6360
A-3 Troubleshooting of blower motor system (Air does not come out or air flow is abnormal) ...6363
A-4 Troubleshooting for FRESH/RECIRC air changeover ...6365
Troubleshooting with gauge pressure ...6367
Testing refrigerant pressure ...6369
Precautions for disconnecting and connecting refrigerant piping ...6372
Filling compressor oil ...6374
Desiccant replacement ...6376
90 Diagrams and drawings ...6380
Hydraulic circuit diagram ...6381
Symbols in hydraulic circuit diagram ...6381
Electric circuit diagram ...6384
Symbols in electric circuit diagram ...6384
...0
30 Testing Adjusting ...5128
General information on testing and adjusting ...5129
Tools for testing and adjusting ...5129
Sketch of tools for testing and adjusting ...5133
Engine and cooling system ...5135
Checking engine speed ...5135
Measuring boost pressure ...5136
Measuring exhaust gas color ...5137
Measuring and adjusting valve clearance ...5139
Measuring compression pressure ...5142
Measuring blowby pressure ...5146
Measuring engine oil pressure ...5147
Measuring EGR valve and KVGT oil pressure ...5148
Measuring fuel pressure ...5149
Measuring fuel delivery, return and leakage ...5155
Bleeding air from fuel system ...5160
Checking fuel circuit for leakage ...5162
Handling cylinder cutout mode operation ...5163
Handling no injection cranking operation ...5164
Checking and adjusting air conditioner compressor belt tension ...5165
Replacing fan belt ...5166
Power train ...5167
Testing swing circle bearing clearance ...5167
Undercarriage and frame ...5168
Testing and adjusting track shoe tension ...5168
Hydraulic system ...5169
Releasing remaining pressure from hydraulic circuit ...5169
Measuring and adjusting of oil pressure in work equipment, swing, and travel circuits ...5170
Measuring oil pressure in control circuit ...5174
Measuring and adjusting oil pressure in pump PC control circuit ...5175
Measuring and adjusting oil pressure in pump LS control circuit ...5178
Measuring solenoid valve output pressure ...5183
Measuring PPC valve output pressure ...5186
Adjusting play of work equipment and swing PPC valves ...5188
Testing pump swash plate sensor ...5189
Isolating the parts causing hydraulic drift in work equipment ...5190
Measuring oil leakage ...5191
Bleeding air from hydraulic circuit ...5194
Cab and its attachments ...5196
Checking cab tipping stopper ...5196
Adjusting mirrors ...5197
Electrical system ...5199
Special functions of machine monitor ...5199
Angle adjustment of rear view camera ...5269
Handling voltage circuit of engine controller ...5271
Handling battery disconnect switch ...5272
Testing diodes ...5273
Pm clinic ...5274
Pm clinic service ...5274
TEN00509-02 - Hydraulic Excavator PC240LC-10 Operation & Maintenance Manual...6402
COVER...6402
FOREWORD ...6403
BEFORE READING THIS MANUAL ...6404
SAFETY INFORMATION ...6405
INTRODUCTION ...6406
USE OF MACHINE ...6406
DIRECTIONS OF MACHINE ...6406
VISIBILITY FROM OPERATOR’S SEAT ...6406
PRODUCT INFORMATION ...6407
PRODUCT IDENTIFICATION NUMBER (PIN)／MACHINE SERIAL NO. PLATE ...6407
EPA REGULATIONS, ENGINE NUMBER PLATE ...6407
SERVICE METER LOCATION ...6408
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR ...6408
CONTENTS ...6409
SAFETY ...6413
SAFETY ...6414
SAFETY LABELS ...6416
LOCATION OF SAFETY LABELS ...6417
SAFETY LABELS ...6418
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ...6426
PRECAUTIONS BEFORE STARTING OPERATION ...6426
PREPARATIONS FOR SAFE OPERATION ...6427
FIRE PREVENTION ...6429
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE ...6431
DO NOT GET CAUGHT IN WORK EQUIPMENT ...6432
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES ...6433
PROTECTION AGAINST FALLING, FLYING, OR INTRUDING OBJECTS ...6434
UNAUTHORIZED MODIFICATION ...6434
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ...6435
PRECAUTIONS RELATED TO CAB GLASS ...6435
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ...6435
PRECAUTIONS FOR OPERATION ...6436
PRECAUTIONS FOR JOBSITE ...6436
STARTING ENGINE ...6439
OPERATION ...6442
TRANSPORTATION ...6449
TOWING ...6450
SAFETY RULES FOR LIFTING OPERATIONS ...6451
PRECAUTIONS FOR MAINTENANCE ...6452
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ...6452
PRECAUTIONS FOR INSPECTION AND MAINTENANCE ...6456
OPERATION ...6463
GENERAL VIEW ...6464
GENERAL VIEW OF MACHINE ...6464
GENERAL VIEW OF CAB ...6466
GENERAL VIEW OF CONTROLS AND GAUGES ...6467
EXPLANATION OF COMPONENTS ...6469
MACHINE MONITOR ...6469
SWITCHES ...6540
CONTROL LEVERS AND PEDALS ...6549
OPENING AND CLOSING CEILING WINDOW ...6552
OPENING AND CLOSING CAB FRONT WINDOW ...6553
EMERGENCY ESCAPE HAMMER ...6558
DOOR LOCK ...6559
CAB DOOR HINGE ...6560
OPENING AND CLOSING ENGINE HOOD ...6561
CAPS AND COVERS WITH LOCK ...6566
DRINK BOX ...6569
MAGAZINE BOX ...6569
CUP HOLDER ...6569
ASHTRAY ...6570
HANDLING AIR CONDITIONER ...6571
HANDLING RADIO ...6583
AUXILIARY ELECTRIC POWER ...6588
FUSE ...6589
FUSIBLE LINK ...6590
TOOL BOX ...6591
GREASE PUMP HOLDER ...6591
FIRE EXTINGUISHER ...6591
BATTERY DISCONNECT SWITCH ...6592
SYSTEM OPERATING LAMP ...6593
HANDLING Komatsu Diesel Particulate Filter (KDPF) ...6594
HANDLING Komatsu Closed Crankcase Ventilation (KCCV) ...6604
HANDLING MACHINES EQUIPPED WITH KOMTRAX ...6605
MACHINE OPERATIONS AND CONTROLS ...6607
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ...6607
STARTING ENGINE ...6628
OPERATIONS AND CHECKS AFTER STARTING ENGINE ...6631
STOPPING ENGINE ...6643
MACHINE OPERATION ...6644
STEERING MACHINE ...6648
SWINGING MACHINE ...6650
WORK EQUIPMENT CONTROLS AND OPERATIONS ...6651
WORKING MODE ...6653
PROHIBITED OPERATIONS ...6656
RULES FOR OPERATION ...6659
TRAVELING ON SLOPES ...6661
ESCAPE FROM MUD ...6663
RECOMMENDED APPLICATIONS ...6664
REPLACING AND INVERTING BUCKET ...6666
WHEN PARKING MACHINE ...6669
AFTER DAILY WORK COMPLETION ...6670
LOCKING ...6671
TRANSPORTATION ...6672
TRANSPORTATION PROCEDURE ...6672
LOADING AND UNLOADING WITH TRAILER ...6673
LIFTING MACHINE ...6684
COLD WEATHER OPERATION ...6688
COLD WEATHER OPERATION INFORMATION ...6688
AFTER DAILY WORK COMPLETION ...6690
AFTER COLD WEATHER SEASON ...6690
LONG-TERM STORAGE ...6691
BEFORE STORAGE ...6691
DURING STORAGE ...6691
AFTER STORAGE ...6692
STARTING MACHINE AFTER LONG-TERM STORAGE ...6692
TROUBLES AND ACTIONS ...6693
RUNNING OUT OF FUEL ...6693
PHENOMENA THAT ARE NOT FAILURES ...6693
TOWING MACHINE ...6694
LIGHTWEIGHT TOWING HOLE ...6695
SEVERE JOB CONDITION ...6695
DISCHARGED BATTERY ...6696
OTHER TROUBLE ...6700
MAINTENANCE ...6705
RULES FOR MAINTENANCE ...6706
SERVICE METER READING ...6706
KOMATSU GENUINE REPLACEMENT PARTS ...6706
KOMATSU GENUINE LUBRICANTS ...6706
ALWAYS USE CLEAN WASHER FLUID ...6706
FRESH AND CLEAN LUBRICANTS ...6706
CHECK DRAINED OIL AND USED FILTER ...6706
CAUTION FOR REFILLING OIL OR FUEL ...6706
WELDING INSTRUCTIONS ...6706
DO NOT DROP THINGS INSIDE MACHINE ...6706
DUSTY JOBSITES ...6706
AVOID MIXING OIL ...6707
LOCKING INSPECTION COVERS ...6707
BLEEDING AIR FROM HYDRAULIC CIRCUIT ...6707
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES ...6707
CHECKS AFTER INSPECTION AND MAINTENANCE ...6707
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE ...6707
CLOSE ENGINE HOOD SECURELY ...6707
OUTLINE OF SERVICE ...6708
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ...6708
HANDLING ELECTRICAL COMPONENTS ...6712
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS ...6713
TIGHTENING TORQUE LIST ...6713
MAINTENANCE SCHEDULE ...6715
MAINTENANCE SCHEDULE TABLE ...6715
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER ...6717
MAINTENANCE PROCEDURE ...6718
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ...6718
WHEN REQUIRED ...6719
CHECKS BEFORE STARTING ...6748
EVERY 100 HOURS MAINTENANCE ...6749
EVERY 250 HOURS MAINTENANCE ...6750
EVERY 500 HOURS MAINTENANCE ...6754
EVERY 1000 HOURS MAINTENANCE ...6766
EVERY 2000 HOURS MAINTENANCE ...6772
EVERY 4000 HOURS MAINTENANCE ...6781
EVERY 4500 HOURS MAINTENANCE ...6785
EVERY 5000 HOURS MAINTENANCE ...6786
EVERY 8000 HOURS MAINTENANCE ...6787
SPECIFICATIONS ...6789
SPECIFICATIONS ...6790
ATTACHMENTS AND OPTIONS ...6793
GENERAL PRECAUTIONS FOR SAFETY ...6794
PRECAUTIONS WHEN SELECTING ...6794
READ THE OPERATION AND MAINTENANCE MANUAL THOROUGHLY ...6794
PRECAUTIONS WHEN REMOVING OR INSTALLING ...6794
PRECAUTIONS WHEN USING ...6795
BUCKET WITH HOOK ...6796
HOOK CONDITION ...6796
PROHIBITED OPERATIONS ...6796
MACHINE READY FOR INSTALLATION OF ATTACHMENT ...6797
EXPLANATION OF COMPONENTS ...6797
HYDRAULIC CIRCUIT ...6800
REMOVAL AND INSTALLATION OF ATTACHMENT ...6807
ATTACHMENT OPERATIONS ...6810
LONG-TERM STORAGE ...6813
SPECIFICATIONS ...6813
ATTACHMENTS AND OPTIONS ...6814
ATTACHMENT COMBINATIONS ...6815
TRACK SHOES SELECTION ...6816
BUCKET TEETH SELECTION ...6817
HANDLING OF RUBBER PAD SHOE AND ROAD LINER ...6818
HANDLING TRAPEZOIDAL BUCKET ...6820
HANDLING EXTENSION ARM ...6822
HANDLING CLAMSHELL BUCKET ...6823
RECOMMENDED ATTACHMENT OPERATIONS ...6824
HYDRAULIC BREAKER ...6824
REPLACEMENT PARTS ...6829
SAFETY CRITICAL PARTS ...6830
SAFETY CRITICAL PARTS LIST ...6830
CONSUMABLE PARTS ...6831
CONSUMABLE PARTS LIST ...6831
RECOMMENDED FUEL, COOLANT, AND LUBRICANT ...6832
LUBRICATION CHART ...6833
FUEL, COOLANT, AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE ...6834
RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL ...6836
INDEX ...6837
TEN00592-01 - Hydraulic Excavator PC240LC-10 Operation & Maintenance Manual...6843
COVER...6843
FOREWORD ...6844
BEFORE READING THIS MANUAL ...6845
SAFETY INFORMATION ...6846
INTRODUCTION ...6847
USE OF MACHINE ...6847
DIRECTIONS OF MACHINE ...6847
VISIBILITY FROM OPERATOR’S SEAT ...6847
PRODUCT INFORMATION ...6848
PRODUCT IDENTIFICATION NUMBER (PIN)／MACHINE SERIAL NO. PLATE ...6848
EPA REGULATIONS, ENGINE NUMBER PLATE ...6848
SERVICE METER LOCATION ...6849
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR ...6849
CONTENTS ...6850
SAFETY ...6854
SAFETY ...6855
SAFETY LABELS ...6857
LOCATION OF SAFETY LABELS ...6858
SAFETY LABELS ...6859
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ...6867
PRECAUTIONS BEFORE STARTING OPERATION ...6867
PREPARATIONS FOR SAFE OPERATION ...6868
FIRE PREVENTION ...6870
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE ...6872
DO NOT GET CAUGHT IN WORK EQUIPMENT ...6873
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES ...6874
PROTECTION AGAINST FALLING, FLYING, OR INTRUDING OBJECTS ...6875
UNAUTHORIZED MODIFICATION ...6875
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ...6876
PRECAUTIONS RELATED TO CAB GLASS ...6876
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ...6876
PRECAUTIONS FOR OPERATION ...6877
PRECAUTIONS FOR JOBSITE ...6877
STARTING ENGINE ...6880
OPERATION ...6883
TRANSPORTATION ...6890
TOWING ...6891
SAFETY RULES FOR LIFTING OPERATIONS ...6892
PRECAUTIONS FOR MAINTENANCE ...6893
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ...6893
PRECAUTIONS FOR INSPECTION AND MAINTENANCE ...6897
OPERATION ...6904
GENERAL VIEW ...6905
GENERAL VIEW OF MACHINE ...6905
GENERAL VIEW OF CAB ...6907
GENERAL VIEW OF CONTROLS AND GAUGES ...6908
EXPLANATION OF COMPONENTS ...6910
MACHINE MONITOR ...6910
SWITCHES ...6981
CONTROL LEVERS AND PEDALS ...6990
OPENING AND CLOSING CEILING WINDOW ...6993
OPENING AND CLOSING CAB FRONT WINDOW ...6994
EMERGENCY ESCAPE HAMMER ...6999
DOOR LOCK ...7000
CAB DOOR HINGE ...7001
OPENING AND CLOSING ENGINE HOOD ...7001
CAPS AND COVERS WITH LOCK ...7004
DRINK BOX ...7007
MAGAZINE BOX ...7007
CUP HOLDER ...7007
ASHTRAY ...7008
HANDLING AIR CONDITIONER ...7009
HANDLING RADIO ...7021
AUXILIARY ELECTRIC POWER ...7026
FUSE ...7027
FUSIBLE LINK ...7028
TOOL BOX ...7029
GREASE PUMP HOLDER ...7029
FIRE EXTINGUISHER ...7029
BATTERY DISCONNECT SWITCH ...7030
SYSTEM OPERATING LAMP ...7031
HANDLING Komatsu Diesel Particulate Filter (KDPF) ...7032
HANDLING Komatsu Closed Crankcase Ventilation (KCCV) ...7042
HANDLING MACHINES EQUIPPED WITH KOMTRAX ...7043
MACHINE OPERATIONS AND CONTROLS ...7045
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ...7045
STARTING ENGINE ...7066
OPERATIONS AND CHECKS AFTER STARTING ENGINE ...7069
STOPPING ENGINE ...7081
MACHINE OPERATION ...7082
STEERING MACHINE ...7086
SWINGING MACHINE ...7088
WORK EQUIPMENT CONTROLS AND OPERATIONS ...7089
WORKING MODE ...7091
PROHIBITED OPERATIONS ...7094
RULES FOR OPERATION ...7097
TRAVELING ON SLOPES ...7099
ESCAPE FROM MUD ...7101
RECOMMENDED APPLICATIONS ...7102
REPLACING AND INVERTING BUCKET ...7104
WHEN PARKING MACHINE ...7107
AFTER DAILY WORK COMPLETION ...7108
LOCKING ...7109
TRANSPORTATION ...7110
TRANSPORTATION PROCEDURE ...7110
LOADING AND UNLOADING WITH TRAILER ...7111
LIFTING MACHINE ...7122
COLD WEATHER OPERATION ...7126
COLD WEATHER OPERATION INFORMATION ...7126
AFTER DAILY WORK COMPLETION ...7128
AFTER COLD WEATHER SEASON ...7128
LONG-TERM STORAGE ...7129
BEFORE STORAGE ...7129
DURING STORAGE ...7129
AFTER STORAGE ...7130
STARTING MACHINE AFTER LONG-TERM STORAGE ...7130
TROUBLES AND ACTIONS ...7131
RUNNING OUT OF FUEL ...7131
PHENOMENA THAT ARE NOT FAILURES ...7131
TOWING MACHINE ...7132
LIGHTWEIGHT TOWING HOLE ...7133
SEVERE JOB CONDITION ...7133
DISCHARGED BATTERY ...7134
OTHER TROUBLE ...7138
MAINTENANCE ...7144
RULES FOR MAINTENANCE ...7145
SERVICE METER READING ...7145
KOMATSU GENUINE REPLACEMENT PARTS ...7145
KOMATSU GENUINE LUBRICANTS ...7145
ALWAYS USE CLEAN WASHER FLUID ...7145
FRESH AND CLEAN LUBRICANTS ...7145
CHECK DRAINED OIL AND USED FILTER ...7145
CAUTION FOR REFILLING OIL OR FUEL ...7145
WELDING INSTRUCTIONS ...7145
DO NOT DROP THINGS INSIDE MACHINE ...7145
DUSTY JOBSITES ...7146
AVOID MIXING OIL ...7146
LOCKING INSPECTION COVERS ...7146
BLEEDING AIR FROM HYDRAULIC CIRCUIT ...7146
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES ...7146
CHECKS AFTER INSPECTION AND MAINTENANCE ...7146
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE ...7146
CLOSE ENGINE HOOD SECURELY ...7146
OUTLINE OF SERVICE ...7147
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ...7147
HANDLING ELECTRICAL COMPONENTS ...7151
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS ...7152
TIGHTENING TORQUE LIST ...7152
MAINTENANCE SCHEDULE ...7154
MAINTENANCE SCHEDULE TABLE ...7154
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER ...7156
MAINTENANCE PROCEDURE ...7157
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ...7157
WHEN REQUIRED ...7158
CHECKS BEFORE STARTING ...7185
EVERY 100 HOURS MAINTENANCE ...7186
EVERY 250 HOURS MAINTENANCE ...7187
EVERY 500 HOURS MAINTENANCE ...7191
EVERY 1000 HOURS MAINTENANCE ...7204
EVERY 2000 HOURS MAINTENANCE ...7210
EVERY 4000 HOURS MAINTENANCE ...7219
EVERY 4500 HOURS MAINTENANCE ...7223
EVERY 5000 HOURS MAINTENANCE ...7224
EVERY 8000 HOURS MAINTENANCE ...7225
SPECIFICATIONS ...7226
SPECIFICATIONS ...7227
ATTACHMENTS AND OPTIONS ...7230
GENERAL PRECAUTIONS FOR SAFETY ...7231
PRECAUTIONS WHEN SELECTING ...7231
READ THE OPERATION AND MAINTENANCE MANUAL THOROUGHLY ...7231
PRECAUTIONS WHEN REMOVING OR INSTALLING ...7231
PRECAUTIONS WHEN USING ...7232
BUCKET WITH HOOK ...7233
HOOK CONDITION ...7233
PROHIBITED OPERATIONS ...7233
MACHINE READY FOR INSTALLATION OF ATTACHMENT ...7234
EXPLANATION OF COMPONENTS ...7234
HYDRAULIC CIRCUIT ...7237
REMOVAL AND INSTALLATION OF ATTACHMENT ...7244
ATTACHMENT OPERATIONS ...7247
LONG-TERM STORAGE ...7250
SPECIFICATIONS ...7250
ATTACHMENTS AND OPTIONS ...7251
ATTACHMENT COMBINATIONS ...7252
TRACK SHOES SELECTION ...7253
BUCKET TEETH SELECTION ...7254
HANDLING OF RUBBER PAD SHOE AND ROAD LINER ...7255
HANDLING TRAPEZOIDAL BUCKET ...7257
HANDLING EXTENSION ARM ...7259
HANDLING CLAMSHELL BUCKET ...7260
RECOMMENDED ATTACHMENT OPERATIONS ...7261
HYDRAULIC BREAKER ...7261
REPLACEMENT PARTS ...7266
SAFETY CRITICAL PARTS ...7267
SAFETY CRITICAL PARTS LIST ...7267
CONSUMABLE PARTS ...7268
CONSUMABLE PARTS LIST ...7268
RECOMMENDED FUEL, COOLANT, AND LUBRICANT ...7269
LUBRICATION CHART ...7270
FUEL, COOLANT, AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE ...7271
RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL ...7273
INDEX ...7274
Komatsu Hydraulic Excavator PC240LC Repair Service Manuals
