Komatsu PC240LC-11 Hydraulic Excavator (A22001 and up) Shop Manual - CEBM028601

This complete service repair workshop manual PDF download for the Komatsu PC240LC-11 Hydraulic Excavator (SN: A22001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Machine Model : PC240LC-11
Serial Numbers : A22001 and up
Engine : 6D107E-3


TABLE OF CONTENTS :

- Index and foreword
- Specification
- Structure and function
- Standard value table
- Testing and adjusting
- Troubleshooting
- Disassembly and assembly
- Maintenance standard
- Appendix
- Diagrams and drawings


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : CEBM028601
Total Pages : 2510


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PC240LC-11 SHOP MANUAL S/N A22001

00 INDEX AND FOREWORD
INDEX
FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
SAFETY NOTICE FOR OPERATION
PRECAUTIONS TO PREVENT FIRE
ACTION IF FIRE OCCURS
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS
PRECAUTIONS FOR AdBlue/DEF
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING
PRECAUTIONS FOR ADDING
PRECAUTIONS FOR STORING
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE
THE OTHER PRECAUTIONS
STORE AdBlue/DEF
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT
PRACTICAL USE OF KOMTRAX
METHOD FOR DISCONNECTING AND CONNECTING PUSH-PULL TYPE COUPLER
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE
HOW TO READ ELECTRICAL WIRE CODE
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD
LIST OF ABBREVIATION
STANDARD TIGHTENING TORQUE TABLE
CONVERSION TABLE

01 SPECIFICATION
CONTENTS
SPECIFICATIONS
SPECIFICATION DRAWING
SPECIFICATION DRAWING: PC240LC-11
WORKING RANGE DRAWINGS
WORKING RANGE: PC240LC-11
SPECIFICATIONS
SPECIFICATIONS: PC240LC-11
WEIGHT TABLE
WEIGHT TABLE: PC240LC-11
TABLE OF FUEL, COOLANT, AND LUBRICANTS

10 STRUCTURE AND FUNCTION
CONTENTS
UREA SCR SYSTEM
LAYOUT DRAWING OF UREA SCR SYSTEM
UREA SCR SYSTEM DIAGRAM
FUNCTION OF UREA SCR SYSTEM
FUNCTION OF AdBlue/DEF SUPPLY SYSTEM
INDUCEMENT STRATEGY
COMPONENT PARTS OF UREA SCR SYSTEM
AdBlue/DEF MIXING TUBE
SCR ASSEMBLY
AdBlue/DEF TANK
AdBlue/DEF PUMP
AdBlue/DEF INJECTOR
AdBlue/DEF HOSE
AdBlue/DEF TANK HEATING VALVE
BOOT-UP SYSTEM
LAYOUT DRAWING OF BOOT-UP SYSTEM
SYSTEM OPERATING LAMP SYSTEM
SYSTEM OPERATING LAMP SYSTEM DIAGRAM
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM
BATTERY DISCONNECT SWITCH
FUNCTION OF BATTERY DISCONNECT SWITCH
ENGINE SYSTEM
LAYOUT DRAWING OF ENGINE RELATED PARTS
SPECIFICATIONS OF ENGINE RELATED PARTS
FUNCTIONS OF ENGINE RELATED PARTS
ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM DIAGRAM
FUNCTION OF ENGINE CONTROL SYSTEM
AUTO-DECELERATION SYSTEM
AUTO-DECELERATION SYSTEM DIAGRAM
FUNCTION OF AUTO-DECELERATION SYSTEM
OPERATION OF AUTO-DECELERATION SYSTEM
ENGINE AUTOMATIC WARM-UP SYSTEM
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM
OVERHEAT PREVENTION SYSTEM
OVERHEAT PREVENTION SYSTEM DIAGRAM
FUNCTION OF OVERHEAT PREVENTION SYSTEM
TURBOCHARGER PROTECTION SYSTEM
TURBOCHARGER PROTECTION SYSTEM DIAGRAM
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM
AUTOMATIC IDLE STOP SYSTEM
AUTOMATIC IDLE STOP SYSTEM DIAGRAM
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM
COMPONENT PARTS OF ENGINE SYSTEM
KVGT
EGR SYSTEM
EGR VALVE
EGR COOLER
KCCV SYSTEM
KCCV VENTILATOR
KDPF
COOLING SYSTEM
LAYOUT DRAWING OF COOLING SYSTEM
SPECIFICATIONS OF COOLING SYSTEM
CONTROL SYSTEM
LAYOUT DRAWING OF ELECTRICAL CONTROL SYSTEM
MACHINE MONITOR SYSTEM
MACHINE MONITOR SYSTEM DIAGRAM
KOMTRAX SYSTEM
KOMTRAX SYSTEM DIAGRAM
FUNCTION OF KOMTRAX SYSTEM
COMPONENT PARTS OF CONTROL SYSTEM
MACHINE MONITOR
KOMTRAX TERMINAL
PUMP CONTROLLER
REGISTER FOR PC-EPC VALVE
CAN TERMINATING RESISTOR
ENGINE CONTROLLER
FUEL CONTROL DIAL
HYDRAULIC SYSTEM
LAYOUT DRAWING OF HYDRAULIC COMPONENT
CLSS
STRUCTURE OF CLSS
OPERATION OF UNLOAD VALVE AND LS PRESSURE
PUMP SWASH PLATE ANGLE (OILFLOW) CONTROL
PRESSURE COMPENSATION CONTROL
ENGINE AND PUMP COMBINED CONTROL SYSTEM
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM
PUMP AND VALVE CONTROL SYSTEM
PUMP AND VALVE CONTROL SYSTEM DIAGRAM
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM
COMPONENT PARTS OF HYDRAULIC SYSTEM
HYDRAULIC TANK
MAIN PUMP
PC-EPC VALVE
CONTROL VALVE
WORK EQUIPMENT SYSTEM
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
STRUCTURE OF VALVE CONTROL
ONE-TOUCH POWER MAXIMIZING SYSTEM
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM
PPC LOCK SYSTEM
PPC LOCK SYSTEM DIAGRAM
FUNCTION OF PPC LOCK SYSTEM
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM
WORK EQUIPMENT AND SWING PPC VALVE
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)
2ND-LINE ATTACHMENT PPC VALVE
SOLENOID VALVE
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)
PILOT CIRCUIT ACCUMULATOR
SWING CONTROL SYSTEM
LAYOUT DRAWING OF SWING SYSTEM
SWING CONTROL SYSTEM DIAGRAM
FUNCTION OF SWING CONTROL SYSTEM
COMPONENT PARTS OF SWING SYSTEM
SWING MOTOR
SWING MACHINERY
SWING CIRCLE
TRAVEL SYSTEM
LAYOUT DRAWING OF TRAVEL SYSTEM
TRAVEL CONTROL SYSTEM DIAGRAM
FUNCTION OF TRAVEL CONTROL SYSTEM
COMPONENT PARTS OF TRAVEL SYSTEM
TRAVEL MOTOR
FINAL DRIVE
TRAVEL PPC VALVE
CENTER SWIVEL JOINT
UNDERCARRIAGE AND FRAME
LAYOUT DRAWING OF UNDERCARRIAGE
SPECIFICATIONS OF UNDERCARRIAGE
WORK EQUIPMENT
STRUCTURE OF WORK EQUIPMENT
FUNCTION OF WORK EQUIPMENT
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM
BUCKET CLEARANCE ADJUSTMENT SHIM
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM
CAB AND ITS ATTACHMENTS
ROPS CAB
STRUCTURE OF ROPS CAB
FUNCTION OF ROPS CAB
CAB MOUNT
STRUCTURE OF CAB MOUNT
FUNCTION OF CAB MOUNT
CAB TIPPING STOPPER
STRUCTURE OF CAB TIPPING STOPPER
FUNCTION OF CAB TIPPING STOPPER

20 STANDARD VALUE TABLE
CONTENTS
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR ENGINE: PC240LC-11
STANDARD VALUE TABLE FOR MACHINE
STANDARD VALUE TABLE FOR MACHINE: PC240LC-11
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE
STANDARD VALUE TABLE FOR ELECTRICAL
STANDARD VALUE TABLE FOR ELECTRICAL

30 TESTING AND ADJUSTING
CONTENTS
RELATED INFORMATION ON TESTING AND ADJUSTING
TOOLS FOR TESTING AND ADJUSTING
SKETCH OF TOOLS FOR TESTING AND ADJUSTING
ENGINE AND COOLING SYSTEM
TEST ENGINE SPEED
METHOD FOR TESTING ENGINE SPEED
TEST BOOST PRESSURE
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR
METHOD FOR TESTING BOOST PRESSURE
TEST EXHAUST GAS COLOR
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER
TEST AND ADJUST VALVE CLEARANCE
METHOD FOR TESTING VALVE CLEARANCE
METHOD FOR ADJUSTING VALVE CLEARANCE
TEST COMPRESSION PRESSURE
METHOD FOR TESTING COMPRESSION PRESSURE
TEST BLOWBY PRESSURE
METHOD FOR TESTING BLOWBY PRESSURE
TEST ENGINE OIL PRESSURE
METHOD FOR TESTING ENGINE OIL PRESSURE
TEST EGR VALVE AND KVGT OIL PRESSURE
METHOD FOR TESTING EGR VALVE AND KVGT OIL PRESSURE
TEST FUEL PRESSURE
METHOD FOR TESTING FUEL PRESSURE
TEST FUEL DISCHARGE, RETURN AND LEAKAGE
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE
BLEEDING AIR FROM FUEL SYSTEM
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM
TEST FUEL CIRCUIT FOR LEAKAGE
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE
HANDLE CYLINDER CUT-OUT MODE OPERATION
HANDLE NO-INJECTION CRANKING OPERATION
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER
TEST SCR RELATED FUNCTIONS
TEST AdBlue/DEF PUMP RAISED PRESSURE
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR
TEST AdBlue/DEF LINE HEATER RELAY 1
TEST AdBlue/DEF LINE HEATER RELAY 2
TEST AdBlue/DEF PUMP HEATER RELAY
TEST AdBlue/DEF HEATER VALVE
TEST DENITRATION EFFICIENCY OF SCR
CLEAN AdBlue/DEF TANK
METHOD FOR CLEANING AdBlue/DEF TANK
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK
POWER TRAIN
TEST SWING CIRCLE BEARING CLEARANCE
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE
UNDERCARRIAGE AND FRAME
TEST AND ADJUST TRACK TENSION
METHOD FOR TESTING TRACK TENSION
METHOD FOR ADJUSTING TRACK TENSION
HYDRAULIC SYSTEM
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS
TEST OIL PRESSURE OF CONTROL CIRCUIT
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)
TEST PC-EPC VALVE OUTLET PRESSURE
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE
METHOD FOR ADJUSTING LS VALVE
TEST OUTLET PRESSURE OF SOLENOID VALVE
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE
OPERATING CONDITION OF SOLENOID VALVE
TEST PPC VALVE OUTLET PRESSURE
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE
ADJUST WORK EQUIPMENT AND SWING PPC VALVES
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES
TEST PUMP SWASH PLATE SENSOR
METHOD FOR TESTING PUMP SWASH PLATE SENSOR
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE
TEST OIL LEAKAGE
TEST OIL LEAKAGE OF BOOM CYLINDER
TEST OIL LEAKAGE OF ARM CYLINDER
TEST OIL LEAKAGE OF BUCKET CYLINDER
METHOD FOR TESTING OIL LEAKAGE OF SWING MOTOR
METHOD FOR TESTING OIL LEAKAGE OF TRAVEL MOTOR
BLEED AIR FROM HYDRAULIC CIRCUIT
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT
CAB AND ITS ATTACHMENTS
TEST CAB TIPPING STOPPER
METHOD FOR TESTING CAB TIPPING STOPPER
METHOD FOR ADJUSTING MIRRORS
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A)
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A)
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B)
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B)
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C)
ELECTRICAL SYSTEM
SET AND OPERATE MACHINE MONITOR
OPERATOR MODE
SERVICE MODE
METHOD FOR STARTING UP KOMTRAX TERMINAL
ADJUST REARVIEW CAMERA ANGLE
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE
HANDLING VOLTAGE CIRCUIT OF ENGINE CONTROLLER
HANDLE BATTERY DISCONNECT SWITCH
TEST DIODES
METHOD FOR TESTING DIODE USING DIGITAL TESTER
METHOD FOR TESTING DIODE USING ANALOG TESTER
Pm CLINIC
Pm CLINIC SERVICE
Pm CLINIC CHECK SHEET

40 TROUBLESHOOTING
CONTENTS
RELATED INFORMATION ON TROUBLESHOOTING
GENERAL TROUBLESHOOTING POINTS
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM
SEQUENCE OF EVENTS IN TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
CHECKS BEFORE TROUBLESHOOTING
WALK-AROUND CHECK
TESTING IN ACCORDANCE WITH TESTING PROCEDURE
FUEL - CHECK LEVEL AND TYPE
FUEL - CHECK FOR FOREIGN MATERIAL
FUEL PREFILTER - CHECK
WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE
MAIN FILTER - CHECK
OIL PAN - CHECK ENGINE OIL LEVEL
RESERVOIR TANK - CHECK COOLANT LEVEL
AIR CLEANER - CHECK FOR CLOGGING
OUTER ELEMENT - CLEAN
ELEMENTS - REPLACE
HYDRAULIC OIL - CHECK OIL LEVEL
HYDRAULIC OIL STRAINER - CHECK
HYDRAULIC OIL FILTER - CHECK
SWING MACHINERY CASE - CHECK OIL LEVEL
DAMPER CASE - CHECK OIL LEVEL
FINAL DRIVE CASE - CHECK OIL LEVEL
FUEL SYSTEM - BLEED AIR
HYDRAULIC CIRCUIT - BLEED AIR
ELECTRICAL EQUIPMENT - CHECK METHOD
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION
PROCEDURE FOR TESTING AND TROUBLESHOOTING
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS
INFORMATION IN TROUBLESHOOTING TABLE
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM
CONNECTOR LIST AND LAYOUT
CONNECTOR PIN NUMBERS - CONNECTION TABLE
T-BOXES AND T-ADAPTERS LIST
FUSE LOCATION TABLE
PRECAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])
FAILURE CODES TABLE
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit
FAILURE CODE [879EMC] Ventilation Damper Malfunction
FAILURE CODE [879FMC] Air Mix Damper Malfunction
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range
FAILURE CODE [989L00] Engine Controller Lock Caution 1
FAILURE CODE [989M00] Engine Controller Lock Caution 2
FAILURE CODE [989N00] Engine Controller Lock Caution 3
FAILURE CODE [A1U0N3] HC Desorb Request 1
FAILURE CODE [A1U0N4] HC Desorb Request 2
FAILURE CODE [A900FR] Abrupt Engine Stop by Auto Idling Stop 3
FAILURE CODE [A900N6] Abrupt Engine Stop by Auto Idling Stop 1
FAILURE CODE [A900NY] Abrupt Engine Stop by Auto Idling Stop 2
FAILURE CODE [AA10NX] Air Cleaner Clogging
FAILURE CODE [AB00KE] Charge Voltage Low
FAILURE CODE [AQ10N3] Manual Stationary Regeneration Request (KDOC Face Plugging)
FAILURE CODE [AS00N3] Manual Stationary Regeneration Request (SCR)
FAILURE CODE [AS00R2] Warning 2 (SCR Device Abnormality)
FAILURE CODE [AS00R3] Inducement 1 (SCR Device Abnormality)
FAILURE CODE [AS00R4] Inducement 2 (SCR Device Abnormality)
FAILURE CODE [AS00R5] Inducement 3 (SCR Device Abnormality)
FAILURE CODE [AS00R6] Temporary Recovery of Inducement
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Error 5
FAILURE CODE [AS10KM] AdBlue/DEF Injector Overheat Warning
FAILURE CODE [AS10NR] AdBlue/DEF Injector High Temperature Warning
FAILURE CODE [AS10NT] AdBlue/DEF Injector Overheat Caution
FAILURE CODE [[email protected]] Engine Oil Pressure Low
FAILURE CODE [[email protected]] Eng Oil Level Low
FAILURE CODE [[email protected]] Eng Water Overheat
FAILURE CODE [[email protected]] Eng Water Level Low
FAILURE CODE [[email protected]] Hyd Oil Overheat
FAILURE CODE [CA115] Engine NE and Backup Speed Sensor Error
FAILURE CODE [CA122] Charge Air Pressure Sensor High Error
FAILURE CODE [CA123] Charge Air Pressure Sensor Low Error
FAILURE CODE [CA131] Throttle Sensor High Error
FAILURE CODE [CA132] Throttle Sensor Low Error
FAILURE CODE [CA144] Coolant Temperature Sensor High Error
FAILURE CODE [CA145] Coolant Temperature Sensor Low Error
FAILURE CODE [CA153] Charge Air Temperature Sensor High Error
FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error
FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error
FAILURE CODE [CA221] Ambient Pressure Sensor High Error
FAILURE CODE [CA222] Ambient Pressure Sensor Low Error
FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error
FAILURE CODE [CA234] Engine Overspeed
FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error
FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Error
FAILURE CODE [CA249] Ambient Air Temp Sensor High Error
FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error
FAILURE CODE [CA271] IMV/PCV 1 Short Circuit Error
FAILURE CODE [CA272] IMV/PCV 1 Open Circuit Error
FAILURE CODE [CA322] Injector #1 (L#1) Open Circuit Error or Short Circuit Error
FAILURE CODE [CA323] Injector #5 (L#5) Open Circuit Error or Short Circuit Error
FAILURE CODE [CA324] Injector #3 (L#3) Open Circuit Error or Short Circuit Error
FAILURE CODE [CA325] Injector #6 (L#6) Open Circuit Error or Short Circuit Error
FAILURE CODE [CA331] Injector #2 (L#2) Open Circuit Error or Short Circuit Error
FAILURE CODE [CA332] Injector #4 (L#4) Open Circuit Error or Short Circuit Error
FAILURE CODE [CA343] Engine Controller Internal Failure
FAILURE CODE [CA351] Injectors Drive Circuit Error
FAILURE CODE [CA352] Sensor 1 Supply Voltage Low Error
FAILURE CODE [CA356] MAF Sensor High Error
FAILURE CODE [CA357] MAF Sensor Low Error
FAILURE CODE [CA386] Sensor 1 Supply Voltage High Error
FAILURE CODE [CA428] Water in Fuel Sensor High Error
FAILURE CODE [CA429] Water in Fuel Sensor Low Error
FAILURE CODE [CA435] Engine Oil Pressure SW Error
FAILURE CODE [CA441] Battery Voltage Low Error
FAILURE CODE [CA442] Battery Voltage High Error
FAILURE CODE [CA449] Common Rail Pressure High Error 2
FAILURE CODE [CA451] Common Rail Pressure Sensor High Error
FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error
FAILURE CODE [CA488] Charge Air Temperature High Torque Derate
FAILURE CODE [CA515] Common Rail Pressure Sensor Supply Voltage High Error
FAILURE CODE [CA516] Common Rail Pressure Sensor Supply Voltage Low Error
FAILURE CODE [CA553] Common Rail Pressure High Error 1
FAILURE CODE [CA555] Crankcase Pressure High Error 1
FAILURE CODE [CA556] Crankcase Pressure High Error 2
FAILURE CODE [CA559] Common Rail Pressure Low Error 1
FAILURE CODE [CA595] Turbocharger Speed High Error 2
FAILURE CODE [CA687] Turbocharger Speed Low Error
FAILURE CODE [CA689] Engine NE Speed Sensor Error
FAILURE CODE [CA691] Intake Air Temperature Sensor High Error
FAILURE CODE [CA692] Intake Air Temperature Sensor Low Error
FAILURE CODE [CA697] Engine Controller Internal Temperature Sensor High Error
FAILURE CODE [CA698] Engine Controller Internal Temperature Sensor Low Error
FAILURE CODE [CA731] Engine Backup Speed Sensor Phase Error
FAILURE CODE [CA778] Engine Backup Speed Sensor Error
FAILURE CODE [CA1117] Engine Controller Partial Data Lost Error
FAILURE CODE [CA1664] KDOC Abnormality
FAILURE CODE [CA1669] AdBlue/DEF Level Sensor Voltage High Error
FAILURE CODE [CA1673] AdBlue/DEF Level Low Error 3
FAILURE CODE [CA1677] AdBlue/DEF Temperature Sensor Low Error
FAILURE CODE [CA1678] AdBlue/DEF Temperature Sensor High Error
FAILURE CODE [CA1682] AdBlue/DEF Pump Priming Error
FAILURE CODE [CA1683] AdBlue/DEF Tank Heating Valve Voltage High Error
FAILURE CODE [CA1684] AdBlue/DEF Tank Heating Valve Voltage Low Error
FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High Error
FAILURE CODE [CA1691] Defective Regeneration
FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error
FAILURE CODE [CA1695] Sensor 5 Supply Voltage High Error
FAILURE CODE [CA1696] Sensor 5 Supply Voltage Low Error
FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error
FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Error
FAILURE CODE [CA1714] AdBlue/DEF Quality Sensor Out of Calibration Error
FAILURE CODE [CA1715] AdBlue/DEF Quality Sensor Internal Circuit Error
FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error
FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error
FAILURE CODE [CA1843] Crankcase Pressure Sensor High Error
FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error
FAILURE CODE [CA1879] KDPF Differential Pressure Sensor High Error
FAILURE CODE [CA1881] KDPF Differential Pressure Sensor Low Error
FAILURE CODE [CA1883] KDPF Differential Pressure Sensor In Range Error
FAILURE CODE [CA1885] Turbo Outlet NOx Sensor Circuit Error
FAILURE CODE [CA1887] SCR Outlet NOx Sensor Circuit Error
FAILURE CODE [CA1921] KDPF Soot Accumulation High Error 1
FAILURE CODE [CA1922] KDPF Soot Accumulation High Error 2
FAILURE CODE [CA1942] Crankcase Pressure Sensor In Range Error
FAILURE CODE [CA1993] KDPF Differential Pressure Low Error
FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error
FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error
FAILURE CODE [CA2249] Common Rail Pressure Low Error 2
FAILURE CODE [CA2271] EGR Valve Position Sensor High Error
FAILURE CODE [CA2272] EGR Valve Position Sensor Low Error
FAILURE CODE [CA2288] Turbocharger Speed High Error 1
FAILURE CODE [CA2311] lMV Solenoid Error
FAILURE CODE [CA2349] EGR Valve Solenoid Open Circuit Error
FAILURE CODE [CA2353] EGR Valve Solenoid Short Circuit Error
FAILURE CODE [CA2357] EGR Valve Servo Error
FAILURE CODE [CA2381] KVGT Position Sensor High Error
FAILURE CODE [CA2382] KVGT Position Sensor Low Error
FAILURE CODE [CA2383] KVGT Solenoid Open Circuit Error
FAILURE CODE [CA2386] KVGT Solenoid Short Circuit Error
FAILURE CODE [CA2387] KVGT Servo Error
FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error
FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error
FAILURE CODE [CA2637] KDOC Face Plugging
FAILURE CODE [CA2639] Manual Stationary Regeneration Request
FAILURE CODE [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error
FAILURE CODE [CA2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable
FAILURE CODE [CA2976] AdBlue/DEF Pump Temperature Sensor Signal Error
FAILURE CODE [CA3133] KDPF Outlet Pressure Sensor High Error
FAILURE CODE [CA3134] KDPF Outlet Pressure Sensor Low Error
FAILURE CODE [CA3135] KDPF Outlet Pressure Sensor In Range Error
FAILURE CODE [CA3142] SCR Temperature Sensor High Error
FAILURE CODE [CA3143] SCR Temperature Sensor Low Error
FAILURE CODE [CA3144] SCR Temperature Sensor In Range Error
FAILURE CODE [CA3146] SCR Outlet Temperature Sensor High Error
FAILURE CODE [CA3147] SCR Outlet Temperature Sensor Low Error
FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range Error
FAILURE CODE [CA3151] SCR Catalyst Efficiency Low Error 2
FAILURE CODE [CA3165] SCR Outlet Temperature High Error
FAILURE CODE [CA3229] SCR Temperature High Error
FAILURE CODE [CA3231] SCR Temperature High Error - Non Regeneration
FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error
FAILURE CODE [CA3235] SCR Outlet Temperature High Error - Non Regeneration
FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error
FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error
FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error
FAILURE CODE [CA3251] KDOC Inlet Temperature High Error
FAILURE CODE [CA3253] KDOC Temperature Error - Non Regeneration
FAILURE CODE [CA3254] KDOC Outlet Temperature High Error 1
FAILURE CODE [CA3255] KDPF Temperature Error - Non Regeneration
FAILURE CODE [CA3256] KDPF Outlet Temperature High Error 1
FAILURE CODE [CA3311] KDOC Outlet Temperature High Error 2
FAILURE CODE [CA3312] KDPF Outlet Temperature High Error 2
FAILURE CODE [CA3313] KDOC Inlet Temperature Sensor Low Error
FAILURE CODE [CA3314] KDOC Inlet Temperature Sensor High Error
FAILURE CODE [CA3315] KDOC Inlet Temperature Sensor In Range Error
FAILURE CODE [CA3316] KDOC Outlet Temperature Sensor Low Error
FAILURE CODE [CA3317] KDOC Outlet Temperature Sensor High Error
FAILURE CODE [CA3318] KDOC Outlet Temperature Sensor In Range Error
FAILURE CODE [CA3319] KDPF Outlet Temperature Sensor High Error
FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Error
FAILURE CODE [CA3322] KDPF Outlet Temperature Sensor In Range Error
FAILURE CODE [CA3419] MAF Sensor Supply Voltage High Error
FAILURE CODE [CA3421] MAF Sensor Supply Voltage Low Error
FAILURE CODE [CA3497] AdBlue/DEF Level Low Error 1
FAILURE CODE [CA3498] AdBlue/DEF Level Low Error 2
FAILURE CODE [CA3543] AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low)
FAILURE CODE [CA3545] SCR Outlet NOx Sensor Unstable Error
FAILURE CODE [CA3547] AdBlue/DEF Level Low Error 4
FAILURE CODE [CA3558] AdBlue/DEF Pump Voltage High Error
FAILURE CODE [CA3559] AdBlue/DEF Pump Voltage Low Error
FAILURE CODE [CA3562] AdBlue/DEF LineHeater Relay 1 Voltage High Error
FAILURE CODE [CA3563] AdBlue/DEF LineHeater Relay 1 Voltage Low Error
FAILURE CODE [CA3567] AdBlue/DEF Injector Open Circuit Error or Short Circuit Error
FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction
FAILURE CODE [CA3571] AdBlue/DEF Pump Pressure Sensor High Error
FAILURE CODE [CA3572] AdBlue/DEF Pump Pressure Sensor Low Error
FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Error
FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Error
FAILURE CODE [CA3577] AdBlue/DEF FCV Voltage High Error
FAILURE CODE [CA3578] AdBlue/DEF FCV Voltage Low Error
FAILURE CODE [CA3582] SCR Catalyst Efficiency Low Error 1
FAILURE CODE [CA3583] SCR Outlet NOx Sensor Heater Warming up Error
FAILURE CODE [CA3596] AdBlue/DEF Pump Pressure Unstable Error
FAILURE CODE [CA3649] Turbo Outlet NOx Sensor Heater Warming up Error
FAILURE CODE [CA3681] SCR Outlet NOx Sensor Power Voltage Error
FAILURE CODE [CA3682] Turbo Outlet NOx Sensor Power Voltage Error
FAILURE CODE [CA3713] AdBlue/DEF Line Heater 1 Voltage High Error
FAILURE CODE [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error
FAILURE CODE [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Error
FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error
FAILURE CODE [CA3741] Rail Press Valve Trip Error
FAILURE CODE [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error
FAILURE CODE [CA3751] SCR Catalyst Degradation Error
FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degradation Error
FAILURE CODE [CA3866] AdBlue/DEF Low Concentration Error 2
FAILURE CODE [CA3867] AdBlue/DEF Low Concentration Error 1
FAILURE CODE [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout Error
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error
FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error
FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error
FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Error
FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error
FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error
FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error
FAILURE CODE [CA4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error
FAILURE CODE [CA4152] SCR Temperature Sensor Datalink Timeout Error
FAILURE CODE [CA4155] AdBlue/DEF Pump Heater Relay Voltage High Error
FAILURE CODE [CA4156] AdBlue/DEF Pump Heater Relay Voltage Low Error
FAILURE CODE [CA4157] AdBlue/DEF FCV Malfunction
FAILURE CODE [CA4158] KDOC and KDPF Temperature Sensor Internal Circuit Error
FAILURE CODE [CA4159] SCR Temperature Sensor Internal Circuit Error
FAILURE CODE [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error
FAILURE CODE [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error
FAILURE CODE [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error
FAILURE CODE [CA4164] SCR Temperature Sensor ECU Voltage High Error
FAILURE CODE [CA4165] SCR Temperature Sensor ECU Voltage Low Error
FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Temperature Error
FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error
FAILURE CODE [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error
FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error
FAILURE CODE [CA4249] AdBlue/DEF Pump Temperature Sensor 1 In Range Error
FAILURE CODE [CA4251] AdBlue/DEF Pump Temperature Sensor 2 In Range Error
FAILURE CODE [CA4259] KDOC and KDPF Temperature Sensor Power Interrupt Error
FAILURE CODE [CA4261] SCR Temperature Sensor Power Interrupt Error
FAILURE CODE [CA4277] AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error
FAILURE CODE [CA4459] AdBlue/DEF LineHeater Relay 2 Voltage High Error
FAILURE CODE [CA4461] AdBlue/DEF LineHeater Relay 2 Voltage Low Error
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error
FAILURE CODE [CA4731] AdBlue/DEF Temperature Sensor Transmission Data Error
FAILURE CODE [CA4732] AdBlue/DEF Level Sensor Transmission Data Error
FAILURE CODE [CA4739] AdBlue/DEF Level Sensor Internal Circuit Error
FAILURE CODE [CA4768] Fuel in AdBlue/DEF Tank Error
FAILURE CODE [CA4769] AdBlue/DEF Level Measurement Impossible
FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error
FAILURE CODE [CA4952] System Operating Lamp Short Circuit (Engine Controller)
FAILURE CODE [CA5115] AdBlue/DEF Line Heater 1 Voltage Low Error
FAILURE CODE [CA5179] Engine Room Temperature Sensor High Error
FAILURE CODE [CA5181] Engine Room Temperature Sensor Low Error
FAILURE CODE [CA5383] Ash Accumulation High Error
FAILURE CODE [D110KB] Battery Relay Output Short Circuit
FAILURE CODE [D19JKZ] Personal Code Relay Open Circuit or Short Circuit
FAILURE CODE [D811MC] KOMTRAX Malfunction
FAILURE CODE [D862KA] GPS Antenna Open Circuit
FAILURE CODE [D8ALKA] System Operating Lamp Open Circuit (KOMTRAX)
FAILURE CODE [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX)
FAILURE CODE [D8AQKR] CAN 2 Defective Communication (KOMTRAX)
FAILURE CODE [DA20MC] Pump Controller Malfunction
FAILURE CODE [DA22KK] Pump Controller Solenoid Power Voltage Low Error
FAILURE CODE [DA25KP] 5V Sensor 1 Power Voltage Low Error
FAILURE CODE [DA29KQ] Model Selection Signal Mismatch (Pump Controller)
FAILURE CODE [DA2LKA] System Operating Lamp Open Circuit (Pump Controller)
FAILURE CODE [DA2LKB] System Operating Lamp Short Circuit (Pump Controller)
FAILURE CODE [DA2QKR] Controller Area Network 2 Defective Communication (Pump Controller)
FAILURE CODE [DA2RKR] Controller Area Network 1 Defective Communication (Pump Controller)
FAILURE CODE [DAF0MB] Monitor ROM Abnormality
FAILURE CODE [DAF0MC] Monitor Malfunction
FAILURE CODE [DAF8KB] Camera Power Supply Short Circuit
FAILURE CODE [DAF9KQ] Model Selection Signal Mismatch (Monitor)
FAILURE CODE [DAFGMC] GPS Module Malfunction
FAILURE CODE [DAFLKA] System Operating Lamp Open Circuit (Monitor)
FAILURE CODE [DAFLKB] System Operating Lamp Short Circuit (Monitor)
FAILURE CODE [DAFQKR] CAN 2 Defective Communication (Monitor)
FAILURE CODE [DAZ9KQ] Model Selection Signal Mismatch (A/C)
FAILURE CODE [DAZQKR] CAN 2 Defective Communication (A/C ECU)
FAILURE CODE [DB2QKR] CAN 2 Defective Communication (Engine Controller)
FAILURE CODE [DB2RKR] CAN 1 Defective Communication (Engine Controller)
FAILURE CODE [DDNRKA] W/E Lever Lock SW Open Circuit
FAILURE CODE [DDNRKY] W/E Lever Lock SW Short Circuit
FAILURE CODE [DDNS00] Lock Lever Auto Lock Release SW On
FAILURE CODE [DGH2KA] Hydraulic Oil Temperature Sensor Open Circuit
FAILURE CODE [DGH2KB] Hydraulic Oil Temperature Sensor Ground Fault
FAILURE CODE [DHA4KA] Air Cleaner Clog Sensor Open Circuit
FAILURE CODE [DHAAMA] KDPF Differential Pressure Sensor Frozen
FAILURE CODE [DHACMA] KDPF Outlet Pressure Sensor Frozen
FAILURE CODE [DHPAMA] Front Pump Pressure Sensor Defective Function
FAILURE CODE [DHPBMA] Rear Pump Pressure Sensor Defective Function
FAILURE CODE [DHS3MA] Arm IN PPC Pressure Sensor Defective Function
FAILURE CODE [DHS4MA] Bucket CURL PPC Pressure Sensor Defective Function
FAILURE CODE [DHS8MA] Boom RAISE PPC Pressure Sensor Defective Function
FAILURE CODE [DHS9MA] Boom LOWER PPC Pressure Sensor Defective Function
FAILURE CODE [DHSAMA] Swing Right PPC Pressure Sensor Defective Function
FAILURE CODE [DHSBMA] Swing Left PPC Pressure Sensor Defective Function
FAILURE CODE [DHSCMA] Arm OUT PPC Pressure Sensor Defective Function
FAILURE CODE [DHSDMA] Bucket DUMP PPC Pressure Sensor Defective Function
FAILURE CODE [DHSFMA] Travel Forward Left PPC Pressure Sensor Defective Function
FAILURE CODE [DHSGMA] Travel Forward Right PPC Pressure Sensor Defective Function
FAILURE CODE [DHSHMA] Travel Reverse Left PPC Pressure Sensor Defective Function
FAILURE CODE [DHSJMA] Travel Reverse Right PPC Pressure Sensor Defective Function
FAILURE CODE [DKR0MA] Front Pump Swash Plate Sensor Defective Function
FAILURE CODE [DKR1MA] Rear Pump Swash Plate Sensor Defective Function
FAILURE CODE [DKULKA] PPC Lock Relay Open Circuit
FAILURE CODE [DKULKB] PPC Lock Relay Short Circuit
FAILURE CODE [DKULKY] PPC Lock Relay Hot Short Circuit
FAILURE CODE [DR21KX] Camera 2 Picture Reverse Drive Input Out of Range
FAILURE CODE [DR31KX] Camera 3 Picture Reverse Drive Input Out of Range
FAILURE CODE [DV20KB] Travel Alarm Short Circuit
FAILURE CODE [DW43KA] Travel Speed Solenoid Open Circuit
FAILURE CODE [DW43KB] Travel Speed Solenoid Short Circuit
FAILURE CODE [DW43KY] Travel Speed Solenoid Hot Short Circuit
FAILURE CODE [DW45KA]Swing Parking Brake Solenoid Open Circuit
FAILURE CODE [DW45KB] Swing Parking Brake Solenoid Short Circuit
FAILURE CODE [DW45KY] Swing Parking Brake Solenoid Hot Short Circuit
FAILURE CODE [DW4CKY] PPC Lock Solenoid Hot Short Circuit
FAILURE CODE [DW91KA] Travel Junction Solenoid Open Circuit
FAILURE CODE [DW91KB] Travel Junction Solenoid Short Circuit
FAILURE CODE [DW91KY] Travel Junction Solenoid Hot Short Circuit
FAILURE CODE [DWA2KA] Attachment Single or 2-Way Change Solenoid Open Circuit
FAILURE CODE [DWA2KB] Attachment Single or 2-Way Change Solenoid Short Circuit
FAILURE CODE [DWA2KY] Attachment Single or 2-Way Change Solenoid Hot Short Circuit
FAILURE CODE [DWK0KA] 2-Stage Relief Solenoid Open Circuit
FAILURE CODE [DWK0KB] 2-Stage Relief Solenoid Open Circuit
FAILURE CODE [DWK0KY] 2-Stage Relief Solenoid Hot Short Circuit
FAILURE CODE [DWK2KA] Variable Back Pressure Solenoid Open Circuit
FAILURE CODE [DWK2KB] Variable Back Pressure Solenoid Short Circuit
FAILURE CODE [DWK2KY] Variable Back Pressure Solenoid Hot Short Circuit
FAILURE CODE [DWK8KA] Swing Pressure Cutoff Solenoid Open Circuit
FAILURE CODE [DWK8KB] Swing Pressure Cutoff Solenoid Short Circuit
FAILURE CODE [DWK8KY] Swing Pressure Cutoff Solenoid Hot Short Circuit
FAILURE CODE [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit
FAILURE CODE [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit
FAILURE CODE [DXA9KA] Rear Pump PC-EPC Solenoid Open Circuit
FAILURE CODE [DXA9KB] Rear Pump PC-EPC Solenoid Short Circuit
FAILURE CODE [DXE0KA] LS-EPC Solenoid Open Circuit
FAILURE CODE [DXE0KB] LS-EPC Solenoid Short Circuit
FAILURE CODE [DXE4KA] Attachment Flow Regulating EPC Solenoid Open Circuit
FAILURE CODE [DXE4KB] Attachment Flow Regulating EPC Solenoid Short Circuit
FAILURE CODE [DXE4KY] Attachment Flow EPC Hot Short Circuit
FAILURE CODE [DXE5KA] Merge-divider Main Solenoid Open Circuit
FAILURE CODE [DXE5KB] Merge-divider Main Solenoid Short Circuit
FAILURE CODE [DXE6KA] Merge-divider LS Solenoid Open Circuit
FAILURE CODE [DXE6KB] Merge-divider LS Solenoid Short Circuit
FAILURE CODE [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid Open Circuit
FAILURE CODE [DXE7KB] Attachment Flow Regulating EPC 2 Solenoid Short Circuit
FAILURE CODE [DXE7KY] Attachment Flow Regulating EPC 2 Hot Short Circuit
FAILURE CODE [DXE8KA] Attachment Flow Regulating EPC 3 Solenoid Open Circuit
FAILURE CODE [DXE8KB] Attachment Flow Regulating EPC 3 Solenoid Short Circuit
FAILURE CODE [DXE8KY] Attachment Flow Regulating EPC 3 Hot Short Circuit
FAILURE CODE [DXE9KA] Attachment Flow Regulating EPC 4 Solenoid Open Circuit
FAILURE CODE [DXE9KB] Attachment Flow Regulating EPC 4 Solenoid Short Circuit
FAILURE CODE [DXE9KY] Attachment Flow Regulating EPC 4 Hot Short Circuit
FAILURE CODE [DXEAKA] Attachment Flow Regulating EPC 5 Solenoid Open Circuit
FAILURE CODE [DXEAKB] Attachment Flow Regulating EPC 5 Solenoid Short Circuit
FAILURE CODE [DXEAKY] Attachment Flow Regulating EPC 1 Hot Short Circuit
FAILURE CODE [DY20KA]Wiper Motor Open Circuit
FAILURE CODE [DY20MA] Wiper Motor Defective Function
FAILURE CODE [DY2CKB] Washer Motor Short Circuit
FAILURE CODE [DY2DKB] Wiper Motor (Normal Rotation) Short Circuit
FAILURE CODE [DY2EKB] Wiper Motor (Reverse Rotation) Short Circuit
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED
E-24 FUNCTION SWITCH DOES NOT OPERATE
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE
E-32 ALARM BUZZER CANNOT BE CANCELED
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION
E-34 SERVICE MODE CANNOT BE SELECTED
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED
E-41 ALARM DOES NOT SOUND DURING TRAVEL
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED
E-43 HORN DOES NOT SOUND
E-44 HORN DOES NOT STOP SOUNDING
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS
FAILURE MODE AND CAUSE TABLE
H-1 All of work equipments, swing and travel operation lack speed or power.
H-2 Engine speed lowers significantly or engine stalls
H-3 Any of work equipment, swing and travel does not work
H-4 Unusual sound is heard from around hydraulic pump
H-5 Fine control performance or response is poor
H-6 Speed or power of boom is low
H-7 Speed or power of arm is low
H-8 Speed or power of bucket is low
H-9 Work equipment does not move in single operation
H-10 Hydraulic drift of boom is large
H-11 Hydraulic drift of arm is large
H-12 Hydraulic drift of bucket is large
H-13 Other work equipment moves when one of work equipment is relieved
H-14 In combined operation of work equipment , equipment having heavier load moves slower.
H-15 Time lag of work equipment is large
H-16 Machine does not travel straight
H-17 Machine is hard to steer or travel power is low
H-18 Travel speed is low
H-19 One of tracks does not run
H-20 Travel speed does not change, or travel speed is too low or high
H-21 Upper structure does not swing in both right and left directions
H-22 Upper structure does not swing in only one direction
H-23 Swing acceleration or swing speed of upper structure is low in both right and left directions
H-24 Swing acceleration or swing speed is low in only one direction
H-25 Overrun of upper structure is large in both right and left directions
H-26 Upper structure overruns excessively when it stops swing in only one direction
H-27 Shock is large when upper structure stops swinging
H-28 Large unusual noise is heard when upper structure stops swinging
H-29 Swing drift on a slope is large (while swing parking brake is applied)
H-30 Swing drift on a slope is large (while swing parking brake is released)
H-31 Travel speed drops largely in combined operation of swing and trave
H-32 In combined operation of swing and boom RAISE, boom rising speed is low
H-33 One-touch power maximizing function does not work
H-34 Attachment circuit cannot be changed
H-35 Oil flow in attachment circuit cannot be controlled
TROUBLESHOOTING OF ENGINE (S-MODE)
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)
S-4 ENGINE STARTABILITY IS POOR
S-5 ENGINE DOES NOT PICK UP SMOOTHLY
S-6 ENGINE STOPS DURING OPERATION
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE
S-8 ENGINE LACKS POWER
S-9 KDPF GETS CLOGGED IN A SHORT TIME
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE
S-11 OIL BECOMES CONTAMINATED QUICKLY
S-12 FUEL CONSUMPTION IS EXCESSIVE
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)
S-14 OIL PRESSURE DROPS
S-15 FUEL MIXES INTO ENGINE OIL
S-16 WATER MIXES INTO ENGINE OIL (MILKY)
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)
S-18 UNUSUAL NOISE IS HEARD
S-19 VIBRATION IS EXCESSIVE
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY
S-22 ACTIVE REGENERATION TAKES TIME
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)

50 DISASSEMBLY AND ASSEMBLY
CONTENTS
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
COATING MATERIALS LIST
SPECIAL TOOLS LIST
SKETCHES OF SPECIAL TOOLS
ENGINE AND COOLING SYSTEM
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY
REMOVE AND INSTALL INJECTOR ASSEMBLY
METHOD FOR REMOVING INJECTOR ASSEMBLY
METHOD FOR INSTALLING INJECTOR ASSEMBLY
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY
REMOVE AND INSTALL EGR VALVE ASSEMBLY
METHOD FOR REMOVING EGR VALVE ASSEMBLY
METHOD FOR INSTALLING EGR VALVE ASSEMBLY
REMOVE AND INSTALL EGR COOLER ASSEMBLY
METHOD FOR REMOVING EGR COOLER ASSEMBLY
METHOD FOR INSTALLING EGR COOLER ASSEMBLY
REMOVE AND INSTALL STARTER ASSEMBLY
METHOD FOR REMOVING STARTER ASSEMBLY
METHOD FOR INSTALLING STARTER ASSEMBLY
REMOVE AND INSTALL ALTERNATOR BELT
METHOD FOR REMOVING ALTERNATOR BELT
METHOD FOR INSTALLING ALTERNATOR BELT
REMOVE AND INSTALL RADIATOR ASSEMBLY
METHOD FOR REMOVING RADIATOR ASSEMBLY
METHOD FOR INSTALLING RADIATOR ASSEMBLY
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY
REMOVE AND INSTALL ENGINE FRONT OIL SEAL
METHOD FOR REMOVING ENGINE FRONT OIL SEAL
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL
REMOVE AND INSTALL ENGINE REAR OIL SEAL
METHOD FOR REMOVING ENGINE REAR OIL SEAL
METHOD FOR INSTALLING ENGINE REAR OIL SEAL
REMOVE AND INSTALL FUEL COOLER ASSEMBLY
METHOD FOR REMOVING FUEL COOLER ASSEMBLY
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY
REMOVE AND INSTALL FUEL TANK ASSEMBLY
METHOD FOR REMOVING FUEL TANK ASSEMBLY
METHOD FOR INSTALLING FUEL TANK ASSEMBLY
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR
REMOVE AND INSTALL AdBlue/DEF STRAINER
METHOD FOR REMOVING AdBlue/DEF STRAINER
METHOD FOR INSTALLING AdBlue/DEF STRAINER
REMOVE AND INSTALL KDPF ASSEMBLY
METHOD FOR REMOVING KDPF ASSEMBLY
METHOD FOR INSTALLING KDPF ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY
METHOD FOR DISASSEMBLING KDPF ASSEMBLY
METHOD FOR ASSEMBLING KDPF ASSEMBLY
REMOVE AND INSTALL SCR ASSEMBLY
METHOD FOR REMOVING SCR ASSEMBLY
METHOD FOR INSTALLING SCR ASSEMBLY
REMOVE AND INSTALL KDPF, SCR ASSEMBLY
METHOD FOR REMOVING KDPF, SCR ASSEMBLY
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET
REMOVE AND INSTALL KCCV ASSEMBLY
METHOD FOR REMOVING KCCV ASSEMBLY
METHOD FOR INSTALLING KCCV ASSEMBLY
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE
REMOVE AND INSTALL AdBlue/DEF INJECTOR
METHOD FOR REMOVING AdBlue/DEF INJECTOR
METHOD FOR INSTALLING AdBlue/DEF INJECTOR
REMOVE AND INSTALL AdBlue/DEF PUMP
METHOD FOR REMOVING AdBlue/DEF PUMP
METHOD FOR INSTALLING AdBlue/DEF PUMP
REMOVE AND INSTALL AdBlue/DEF HOSE
METHOD FOR REMOVING AdBlue/DEF HOSE
METHOD FOR INSTALLING AdBlue/DEF HOSE
REMOVE AND INSTALL AIR CLEANER ASSEMBLY
METHOD FOR REMOVING AIR CLEANER ASSEMBLY
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY
POWER TRAIN
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY
UNDERCARRIAGE AND FRAME
SEPARATION AND CONNECTION OF TRACK ASSEMBLY
METHOD FOR SEPARATING TRACK ASSEMBLY
METHOD FOR INSTALLING TRACK ASSEMBLY
REMOVE AND INSTALL SPROCKET
METHOD FOR REMOVING SPROCKET
METHOD FOR INSTALLING SPROCKET
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY
METHOD FOR DISASSEMBLING IDLER ASSEMBLY
METHOD FOR ASSEMBLING IDLER ASSEMBLY
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY
HYDRAULIC SYSTEM
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY
REMOVE AND INSTALL MAIN PUMP ASSEMBLY
METHOD FOR REMOVING MAIN PUMP ASSEMBLY
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY
WORK EQUIPMENT
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY
CAB AND ITS ATTACHMENTS
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY
REMOVE AND INSTALL OPERATOR'S SEAT
METHOD FOR REMOVING OPERATOR'S SEAT
METHOD FOR INSTALLING OPERATOR'S SEAT
REMOVE AND INSTALL SEAT BELT
METHOD FOR REMOVING SEAT BELT
METHOD FOR INSTALLING SEAT BELT
REMOVE AND INSTALL FRONT WIPER ASSEMBLY
METHOD FOR REMOVING FRONT WIPER ASSEMBLY
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY
ELECTRICAL SYSTEM
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR
REMOVE AND INSTALL SCR TEMPERATURE SENSOR
METHOD FOR REMOVING SCR TEMPERATURE SENSOR
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY

60 MAINTENANCE STANDARD
CONTENTS
ENGINE AND COOLING SYSTEM
MAINTENANCE STANDARD OF ENGINE MOUNT
MAINTENANCE STANDARD OF COOLING SYSTEM
POWER TRAIN
MAINTENANCE STANDARD OF SWING CIRCLE
MAINTENANCE STANDARD OF SWING MACHINERY
MAINTENANCE STANDARD OF FINAL DRIVE
MAINTENANCE STANDARD OF SPROCKET
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING
UNDERCARRIAGE AND FRAME
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION
MAINTENANCE STANDARD OF IDLER
MAINTENANCE STANDARD OF TRACK ROLLER
MAINTENANCE STANDARD OF CARRIER ROLLER
MAINTENANCE STANDARD OF TRACK SHOE
MAINTENANCE STANDARD OF TRIPLE SHOE
MAINTENANCE STANDARD OF SWAMP SHOE
MAINTENANCE STANDARD OF ROAD LINER
HYDRAULIC SYSTEM
MAINTENANCE STANDARD OF HYDRAULIC TANK
MAINTENANCE STANDARD OF MAIN PUMP
MAINTENANCE STANDARD OF PC-EPC VALVE
MAINTENANCE STANDARD OF SWING MOTOR
MAINTENANCE STANDARD OF TRAVEL MOTOR
MAINTENANCE STANDARD OF CONTROL VALVE
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE
MAINTENANCE STANDARD OF TRAVEL PPC VALVE
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)
MAINTENANCE STANDARD OF EPC VALVE
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE
MAINTENANCE STANDARD OF SOLENOID VALVE
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT
WORK EQUIPMENT
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE
DIMENSION OF ARM
DIMENSIONS OF BUCKET
MAINTENANCE STANDARD OF BOOM CYLINDER
MAINTENANCE STANDARD OF BOOM CYLINDER (FOR LARGE DIAMETER PISTON)
MAINTENANCE STANDARD OF ARM CYLINDER
MAINTENANCE STANDARD OF BUCKET CYLINDER

80 APPENDIX
CONTENTS
AIR CONDITIONER SYSTEM
PRECAUTIONS FOR REFRIGERANT
AIR CONDITIONER COMPONENT
SPECIFICATIONS OF AIR CONDITIONER
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE
OUTLINE OF REFRIGERATION CYCLE
COMPONENT PARTS OF AIR CONDITIONER SYSTEM
AIR CONDITIONER UNIT
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT
FUNCTION OF AIR CONDITIONER UNIT
COMPONENT PARTS OF AIR CONDITIONER UNIT
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT
FUNCTION OF DUAL PRESSURE SWITCH
AIR CONDITIONER CONTROLLER
STRUCTURE OF AIR CONDITIONER CONTROLLER
COMPRESSOR
STRUCTURE OF COMPRESSOR
SPECIFICATIONS OF COMPRESSOR
FUNCTION OF COMPRESSOR
CONDENSER
STRUCTURE OF CONDENSER
SPECIFICATIONS OF CONDENSER
FUNCTION OF CONDENSER
SENSORS FOR AIR CONDITIONER SYSTEM
STRUCTURE OF SUNLIGHT SENSOR
FUNCTION OF SUNLIGHT SENSOR
STRUCTURE OF AMBIENT TEMPERATURE SENSOR
FUNCTION OF AMBIENT TEMPERATURE SENSOR
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER
AIR CONDITIONER SYSTEM DIAGRAM
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER
FUNCTION OF AIR CONDITIONER CONTROLLER
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS
TESTING AIR LEAKAGE (DUCT)
METHOD FOR TESTING AIR LEAKAGE (DUCT)
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR
TEST VENT (MODE) CHANGEOVER
METHOD FOR TESTING VENT (MODE) CHANGEOVER
TESTING FRESH/RECIRC AIR CHANGEOVER
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER
TEST SUNLIGHT SENSOR
METHOD FOR TESTING SUNLIGHT SENSOR
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT
TEST RELAYS
METHOD FOR TESTING RELAYS
AIR CONDITIONER TROUBLESHOOTING CHART 1
AIR CONDITIONER TROUBLESHOOTING CHART 2
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit
FAILURE CODE [879EMC] Ventilation Damper Malfunction
FAILURE CODE [879FMC] Air Mix Damper Malfunction
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)
A-2 TROUBLESHOOTING OF COMPRESSOR SYSTEM (AIR IS NOT COOLED)
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER
TROUBLESHOOTING USING GAUGE PRESSURE
CONNECTION OF SERVICE TOOL
METHOD FOR CONNECTING SERVICE TOOL
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS
HANDLE COMPRESSOR OIL
METHOD FOR REPLACING DESICCANT

90 CIRCUIT DIAGRAMS
CONTENTS
HYDRAULIC CIRCUIT DIAGRAM
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM (1/7)
ELECTRICAL CIRCUIT DIAGRAM (2/7)
ELECTRICAL CIRCUIT DIAGRAM (3/7)
ELECTRICAL CIRCUIT DIAGRAM (4/7)
ELECTRICAL CIRCUIT DIAGRAM (5/7)
ELECTRICAL CIRCUIT DIAGRAM (6/7)
ELECTRICAL CIRCUIT DIAGRAM (7/7)

INDEX
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