Komatsu Hydraulic Excavator PC290LC-6K, PC290NLC-6K, PC290LC-7, PC290LC-8, PC290LC-10, PC290LC-11, PC290NLC-7, PC290NLC-8, PC290LL-11 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC290LC-6K, PC290NLC-6K, PC290LC-7, PC290LC-8, PC290LC-10, PC290LC-11, PC290NLC-7, PC290NLC-8, PC290LL-11, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC290LC-6K, PC290NLC-6K, PC290LC-7, PC290LC-8, PC290LC-10, PC290LC-11, PC290NLC-7, PC290NLC-8, PC290LL-11 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.
PRODUCT DETAILS:
Total Pages: 15,156 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
UEBM001601 - Hydraulic Excavator PC290LC, 290NLC-7K Shop Manual.pdf
EEBM001902 - Hydraulic Excavator PC290LC-6K, PC290NLC-6K Shop Manual.pdf
SEN05644-02 - Hydraulic Excavator PC290LC-10 Shop Manual.pdf
SEN06507-01 - Hydraulic Excavator PC290LC-11 Shop Manual.pdf
CEBM025103 - Hydraulic Excavator PC290LC-10 Shop Manual.pdf
CEBM028803 - HYDRAULIC EXCAVATOR PC290LC-11 Shop Manual.pdf
UEBM001600 - Hydraulic Excavator PC290LC-7, PC290NLC-7 Shop Manual.pdf
UEN00001-01 - Hydraulic Excavator PC290LC-8, PC290NLC-8 Shop Manual.pdf
CEBM031404 - Hydraulic LOG LOADER_ROAD BUILDER PC290LL-11 Shop Manual.pdf
EEAM010300 - Hydraulic Excavator PC290LC-6K, PC290NLC-6K Operation & Maintenance Manual.pdf
TEN00523-02 - Hydraulic Excavator PC290LC-10 Operation & Maintenance Manual.pdf
UEAM001603 - Hydraulic Excavator PC290LC-7K, PC290NLC-7K Operation & Maintenance Manual.pdf
UEAM004000 - Hydraulic Excavator PC290LC-6K, PC290NLC-6K Operation & Maintenance Manual.pdf
CEAM025303 - Hydraulic Excavator PC290LC-10 Operation & Maintenance Manual.pdf
MAIN SECTIONS
Shop Manual, PC290LC-11...0
00 INDEX AND FOREWORD...3
INDEX...4
ABBREVIATION LIST...1
FOREWORD, SAFETY, BASIC INFORMATION...6
HOW TO READ THE SHOP MANUAL...6
SAFETY NOTICE FOR OPERATION...8
PRECAUTIONS TO PREVENT FIRE...16
ACTIONS IF FIRE OCCURS...18
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS...19
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...20
PRECAUTIONS FOR DEF...21
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING...21
PRECAUTIONS FOR ADDING...21
PRECAUTIONS FOR STORING...21
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE...21
THE OTHER PRECAUTIONS...21
STORE AdBlue/DEF...22
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT...23
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS...25
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT...31
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT...33
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT...34
PRACTICAL USE OF KOMTRAX...35
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER...36
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER...36
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER...37
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER...38
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS...40
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR...44
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR...45
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL...47
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH...48
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE...50
HOW TO READ ELECTRICAL WIRE CODE...51
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD...55
STANDARD TIGHTENING TORQUE TABLE...58
CONVERSION TABLE...65
01 SPECIFICATIONS...71
CONTENTS...72
ABBREVIATION LIST...73
SPECIFICATIONS...78
SPECIFICATION DRAWING...78
SPECIFICATION DRAWING: PC290LC-11...78
WORKING RANGE DRAWINGS...79
WORKING RANGE: PC290LC-11...79
SPECIFICATIONS...80
SPECIFICATIONS: PC290LC-11...80
WEIGHT TABLE...83
WEIGHT TABLE: PC290LC-11...83
TABLE OF FUEL, COOLANT, AND LUBRICANTS...85
10 STRUCTURE AND FUNCTION...87
CONTENTS...88
ABBREVIATION LIST...91
UREA SCR SYSTEM...96
LAYOUT DRAWING OF UREA SCR SYSTEM...97
UREA SCR SYSTEM DIAGRAM...102
FUNCTION OF UREA SCR SYSTEM...103
FUNCTION OF AdBlue/DEF SYSTEM...103
INDUCEMENT STRATEGY...105
COMPONENT PARTS OF UREA SCR SYSTEM...111
AdBlue/DEF MIXING TUBE...111
STRUCTURE OF SCR ASSEMBLY...111
AdBlue/DEF TANK...114
AdBlue/DEF PUMP...116
AdBlue/DEF INJECTOR...117
AdBlue/DEF HOSE...118
AdBlue/DEF TANK HEATING VALVE...119
BOOT-UP SYSTEM...120
LAYOUT DRAWING OF BOOT-UP SYSTEM...120
SYSTEM OPERATING LAMP SYSTEM...122
SYSTEM OPERATING LAMP SYSTEM DIAGRAM...122
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM...122
BATTERY DISCONNECT SWITCH...123
FUNCTION OF BATTERY DISCONNECT SWITCH...123
ENGINE SYSTEM...124
LAYOUT DRAWING OF ENGINE SYSTEM...124
SPECIFICATIONS OF ENGINE SYSTEM...125
FUNCTION OF ENGINE SYSTEM...125
ENGINE CONTROL SYSTEM...126
ENGINE CONTROL SYSTEM DIAGRAM...126
FUNCTION OF ENGINE CONTROL SYSTEM...127
AUTO-DECELERATION SYSTEM...129
AUTO-DECELERATION SYSTEM DIAGRAM...129
FUNCTION OF AUTO-DECELERATION SYSTEM...129
OPERATION OF AUTO-DECELERATION SYSTEM...130
ENGINE AUTOMATIC WARM-UP SYSTEM...131
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM...131
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM...132
OVERHEAT PREVENTION SYSTEM...133
OVERHEAT PREVENTION SYSTEM DIAGRAM...133
FUNCTION OF OVERHEAT PREVENTION SYSTEM...134
TURBOCHARGER PROTECTION SYSTEM...136
TURBOCHARGER PROTECTION SYSTEM DIAGRAM...136
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM...137
AUTOMATIC IDLE STOP SYSTEM...138
AUTOMATIC IDLE STOP SYSTEM DIAGRAM...138
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM...138
COMPONENT PARTS OF ENGINE SYSTEM...141
KVGT...141
EGR SYSTEM...145
EGR VALVE...147
EGR COOLER...149
KCCV SYSTEM...151
KCCV VENTILATOR...153
KDPF...155
COOLING SYSTEM...159
LAYOUT DRAWING OF COOLING SYSTEM...159
SPECIFICATIONS OF COOLING SYSTEM...160
CONTROL SYSTEM...161
LAYOUT DRAWING OF CONTROL SYSTEM...161
MACHINE MONITOR SYSTEM...164
MACHINE MONITOR SYSTEM DIAGRAM...164
KOMTRAX SYSTEM...165
KOMTRAX SYSTEM DIAGRAM...165
FUNCTION OF KOMTRAX SYSTEM...165
COMPONENT PARTS OF CONTROL SYSTEM...166
MACHINE MONITOR...166
KOMTRAX TERMINAL...180
PUMP CONTROLLER...182
RESISTOR FOR PC-EPC VALVE...186
CAN TERMINATING RESISTOR...187
ENGINE CONTROLLER...188
FUEL CONTROL DIAL...195
HYDRAULIC SYSTEM...197
LAYOUT DRAWING OF HYDRAULIC SYSTEM...197
CLSS...203
STRUCTURE OF CLSS...203
OPERATION OF UNLOAD VALVE AND LS PRESSURE...205
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL...206
PRESSURE COMPENSATION CONTROL...219
ENGINE AND PUMP COMBINED CONTROL SYSTEM...221
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM...221
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM...222
PUMP AND VALVE CONTROL SYSTEM...227
PUMP AND VALVE CONTROL SYSTEM DIAGRAM...227
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM...228
COMPONENT PARTS OF HYDRAULIC SYSTEM...230
HYDRAULIC TANK...230
MAIN PUMP...232
CONTROL VALVE...258
WORK EQUIPMENT SYSTEM...317
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM...317
STRUCTURE OF VALVE CONTROL...322
PPC LEVERS...324
LH PPC LEVER (If Equipped)...324
RH PPC LEVER (If Equipped)...325
ONE-TOUCH POWER MAXIMIZING SYSTEM...326
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM...326
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM...327
PPC LOCK SYSTEM...328
PPC LOCK SYSTEM DIAGRAM...328
FUNCTION OF PPC LOCK SYSTEM...328
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM...329
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM...329
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM...329
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM...330
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT...331
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM...331
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT...332
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM...333
WORK EQUIPMENT AND SWING PPC VALVE...333
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)...339
2ND-LINE ATTACHMENT PPC VALVE...346
SOLENOID VALVE...348
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)...352
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)...354
PILOT CIRCUIT ACCUMULATOR...356
ATTACHMENT CIRCUIT ACCUMULATOR...357
SWING SYSTEM...358
LAYOUT DRAWING OF SWING SYSTEM...358
SWING CONTROL SYSTEM DIAGRAM...362
FUNCTION OF SWING CONTROL SYSTEM...362
COMPONENT PARTS OF SWING SYSTEM...366
SWING MOTOR...366
SWING MACHINERY...377
SWING CIRCLE...379
TRAVEL SYSTEM...380
LAYOUT DRAWING OF TRAVEL SYSTEM...380
TRAVEL CONTROL SYSTEM DIAGRAM...384
FUNCTION OF TRAVEL CONTROL SYSTEM...384
COMPONENT PARTS OF TRAVEL SYSTEM...386
TRAVEL MOTOR...386
FINAL DRIVE...398
TRAVEL PPC VALVE...400
CENTER SWIVEL JOINT...404
UNDERCARRIAGE AND FRAME...406
LAYOUT DRAWING OF UNDERCARRIAGE...406
SPECIFICATIONS OF UNDERCARRIAGE...407
WORK EQUIPMENT...408
STRUCTURE OF WORK EQUIPMENT...408
FUNCTION OF WORK EQUIPMENT...409
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM...410
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM...410
BUCKET CLEARANCE ADJUSTMENT SHIM...411
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM...411
CAB AND ITS ATTACHMENTS...412
ROPS CAB...412
STRUCTURE OF ROPS CAB...412
FUNCTION OF ROPS CAB...412
CAB MOUNT...413
STRUCTURE OF CAB MOUNT...413
FUNCTION OF CAB MOUNT...413
CAB TIPPING STOPPER...414
STRUCTURE OF CAB TIPPING STOPPER...414
FUNCTION OF CAB TIPPING STOPPER...414
20 STANDARD VALUE TABLE...415
CONTENTS...416
ABBREVIATION LIST...417
STANDARD VALUE TABLE FOR ENGINE...422
STANDARD VALUE TABLE FOR ENGINE: PC290LC-11...422
STANDARD VALUE TABLE FOR MACHINE...426
STANDARD VALUE TABLE FOR MACHINE: PC290LC-11...426
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE...439
STANDARD VALUE TABLE FOR ELECTRICAL...443
STANDARD VALUE TABLE FOR ELECTRICAL...443
30 TESTING AND ADJUSTING...453
CONTENTS...454
ABBREVIATION LIST...457
RELATED INFORMATION ON TESTING AND ADJUSTING...462
TOOLS FOR TESTING AND ADJUSTING...462
SKETCH OF TOOLS FOR TESTING AND ADJUSTING...468
ENGINE AND COOLING SYSTEM...470
TEST ENGINE SPEED...470
METHOD FOR TESTING ENGINE SPEED...470
TEST BOOST PRESSURE...473
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR...473
METHOD FOR TESTING BOOST PRESSURE...474
TEST EXHAUST GAS COLOR...475
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER...475
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER...476
TEST AND ADJUST VALVE CLEARANCE...478
METHOD FOR TESTING VALVE CLEARANCE...478
METHOD FOR ADJUSTING VALVE CLEARANCE...479
TEST COMPRESSION PRESSURE...480
METHOD FOR TESTING COMPRESSION PRESSURE...480
TEST BLOWBY PRESSURE...485
METHOD FOR TESTING BLOWBY PRESSURE...485
TEST ENGINE OIL PRESSURE...487
METHOD FOR TESTING ENGINE OIL PRESSURE...487
TEST EGR VALVE AND KVGT OIL PRESSURE...488
METHOD FOR TESTING EGR VALVE AND KVGT OIL PRESSURE...488
TEST FUEL PRESSURE...490
METHOD FOR TESTING FUEL PRESSURE...491
TEST FUEL DISCHARGE, RETURN AND LEAKAGE...496
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE...497
BLEEDING AIR FROM FUEL SYSTEM...502
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM...502
TEST FUEL CIRCUIT FOR LEAKAGE...503
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE...503
HANDLE CYLINDER CUT-OUT MODE OPERATION...505
HANDLE NO-INJECTION CRANKING OPERATION...506
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION...507
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT...507
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT...507
WRITING CORRECTION FOR ASH IN SOOT ACCUMULATION TO ENGINE CONTROLLER...509
METHOD FOR WRITING CORRECTION FOR ASH IN SOOT ACCUMULATION TO ENGINE CONTROLLER...509
TEST SCR RELATED FUNCTIONS...510
TEST AdBlue/DEF PUMP RAISED PRESSURE...513
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR...515
TEST AdBlue/DEF LINE HEATER RELAY 1...518
TEST AdBlue/DEF LINE HEATER RELAY 2...521
TEST AdBlue/DEF PUMP HEATER RELAY...523
TEST AdBlue/DEF TANK HEATER VALVE...526
TEST DENITRATION EFFICIENCY OF SCR...529
CLEAN AdBlue/DEF TANK...532
METHOD FOR CLEANING AdBlue/DEF TANK...532
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK...536
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK...536
POWER TRAIN...538
TEST SWING CIRCLE BEARING CLEARANCE...538
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE...538
UNDERCARRIAGE AND FRAME...539
TEST AND ADJUST TRACK TENSION...539
METHOD FOR TESTING TRACK TENSION...539
METHOD FOR ADJUSTING TRACK TENSION...539
HYDRAULIC SYSTEM...541
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM...541
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT...541
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS...542
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS...543
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS...549
TEST OIL PRESSURE OF CONTROL CIRCUIT...552
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT...552
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT...554
TEST PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)...554
TEST PC-EPC VALVE OUTLET PRESSURE...555
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT...556
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT...557
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY MACHINE MONITOR...557
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE BY TESTING TOOL...558
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)...561
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE...562
METHOD FOR ADJUSTING LS VALVE...563
TEST OUTLET PRESSURE OF SOLENOID VALVE...564
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE...564
OPERATING CONDITION OF SOLENOID VALVE...565
TEST PPC VALVE OUTLET PRESSURE...568
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE...568
ADJUST WORK EQUIPMENT AND SWING PPC VALVES...570
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES...570
TEST PUMP SWASH PLATE SENSOR...571
METHOD FOR TESTING PUMP SWASH PLATE SENSOR...571
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT...572
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER...572
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER...572
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE...573
TEST OIL LEAKAGE...574
TEST OIL LEAKAGE OF BOOM CYLINDER...574
TEST OIL LEAKAGE OF ARM CYLINDER...574
TEST OIL LEAKAGE OF BUCKET CYLINDER...575
METHOD FOR TESTING OIL LEAKAGE OF SWING MOTOR...575
METHOD FOR TESTING OIL LEAKAGE OF TRAVEL MOTOR...575
BLEED AIR FROM HYDRAULIC CIRCUIT...577
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT...578
CAB AND ITS ATTACHMENTS...580
TEST CAB TIPPING STOPPER...580
METHOD FOR TESTING CAB TIPPING STOPPER...580
METHOD FOR ADJUSTING MIRRORS...581
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A)...581
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A)...582
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B)...583
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B)...584
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C)...585
ELECTRICAL SYSTEM...587
SET AND OPERATE MACHINE MONITOR...587
OPERATOR MODE...590
SERVICE MODE...595
METHOD FOR STARTING UP KOMTRAX TERMINAL...662
ADJUST REARVIEW CAMERA ANGLE...667
METHOD FOR ADJUSTING REARVIEW CAMERA ANGLE...667
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER...670
HANDLE BATTERY DISCONNECT SWITCH...671
TEST DIODES...672
METHOD FOR TESTING DIODE USING DIGITAL TESTER...672
METHOD FOR TESTING DIODE USING ANALOG TESTER...672
Pm CLINIC...673
Pm CLINIC SERVICE...673
Pm CLINIC CHECK SHEET...674
40 TROUBLESHOOTING...685
CONTENTS...686
ABBREVIATION LIST...696
RELATED INFORMATION ON TROUBLESHOOTING...701
GENERAL TROUBLESHOOTING POINTS...701
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM...702
SEQUENCE OF EVENTS IN TROUBLESHOOTING...714
CHECKS BEFORE TROUBLESHOOTING...716
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING...718
WALK-AROUND CHECK...718
TESTING IN ACCORDANCE WITH TESTING PROCEDURE...720
CHECK FUEL LEVEL AND TYPE...720
CHECK IMPURE INGREDIENT IN FUEL...720
CHECK FUEL PREFILTER...721
WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT...721
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE...722
CHECK MAIN FILTER...723
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN)...725
CHECK COOLANT LEVEL (RESERVOIR TANK)...726
CHECK CLOGGING OF AIR CLEANER...726
OUTER ELEMENT - CLEAN...727
ELEMENTS - REPLACE...729
CHECK HYDRAULIC OIL LEVEL...730
CHECK HYDRAULIC OIL STRAINER...731
CHECK HYDRAULIC FILTER...732
CHECK OIL LEVEL IN SWING MACHINERY CASE...733
CHECK OIL LEVEL IN DAMPER CASE...734
CHECK OIL LEVEL IN FINAL DRIVE CASE...734
BLEED AIR FROM FUEL SYSTEM...735
BLEED AIR FROM HYDRAULIC SYSTEM...735
ELECTRICAL EQUIPMENT - CHECK METHOD...735
ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION...743
PROCEDURE FOR TESTING AND TROUBLESHOOTING...753
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS...756
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...760
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM...762
CONNECTOR LIST AND LAYOUT...765
CONNECTOR CONTACT IDENTIFICATION...778
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE...818
FUSE LOCATION TABLE...824
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)...826
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])...830
FAILURE CODES TABLE...832
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)...849
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit...849
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit...850
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit...851
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit...853
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit...855
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit...856
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit...857
FAILURE CODE [879EMC] Ventilation Damper Malfunction...859
FAILURE CODE [879FMC] Air Mix Damper Malfunction...860
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range...861
FAILURE CODE [989L00] Engine Controller Lock Caution 1...863
FAILURE CODE [989M00] Engine Controller Lock Caution 2...864
FAILURE CODE [989N00] Engine Controller Lock Caution 3...865
FAILURE CODE [A1U0N3] HC Desorb Request 1...866
FAILURE CODE [A1U0N4] HC Desorb Request 2...868
FAILURE CODE [A900FR] Abrupt Engine Stop by Auto Idling Stop 3...870
FAILURE CODE [A900N6] Abrupt Engine Stop by Auto Idling Stop 1...871
FAILURE CODE [A900NY] Abrupt Engine Stop by Auto Idling Stop 2...872
FAILURE CODE [AA10NX] Air Cleaner Clogging...873
FAILURE CODE [AB00KE] Charge Voltage Low...875
FAILURE CODE [AQ10N3] Manual Stationary Regeneration Request (KDOC Face Plugging)...878
FAILURE CODE [AS00N3] Manual Stationary Regeneration Request (SCR)...880
!!! new_index = 901
!!! num_start = 1
!!! num_style = Arabic
FAILURE CODE [AS00R2] Warning 2 (SCR Device Abnormality)...2
FAILURE CODE [AS00R3] Inducement 1 (SCR Device Abnormality)...3
FAILURE CODE [AS00R4] Inducement 2 (SCR Device Abnormality)...4
FAILURE CODE [AS00R5] Inducement 3 (SCR Device Abnormality)...5
FAILURE CODE [AS00R6] Temporary Recovery of Inducement...6
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Error 5...7
FAILURE CODE [AS10KM] AdBlue/DEF Injector Overheat Warning...8
FAILURE CODE [AS10NR] AdBlue/DEF Injector High Temperature Warning...9
FAILURE CODE [AS10NT] AdBlue/DEF Injector Overheat Caution...10
FAILURE CODE [B@BAZG] Engine Oil Pressure Low...11
FAILURE CODE [B@BAZK] Eng Oil Level Low...12
FAILURE CODE [B@BCNS] Eng Water Overheat...14
FAILURE CODE [B@BCZK] Eng Water Level Low...15
FAILURE CODE [B@HANS] Hyd Oil Overheat...17
FAILURE CODE [CA115] Engine NE and Backup Speed Sensor Error...18
FAILURE CODE [CA122] Charge Air Pressure Sensor High Error...19
FAILURE CODE [CA123] Charge Air Pressure Sensor Low Error...21
FAILURE CODE [CA131] Throttle Sensor High Error...23
FAILURE CODE [CA132] Throttle Sensor Low Error...25
FAILURE CODE [CA144] Coolant Temperature Sensor High Error...27
FAILURE CODE [CA145] Coolant Temperature Sensor Low Error...29
FAILURE CODE [CA153] Charge Air Temperature Sensor High Error...31
FAILURE CODE [CA154] Charge Air Temperature Sensor Low Error...34
FAILURE CODE [CA187] Sensor 2 Supply Voltage Low Error...36
FAILURE CODE [CA221] Ambient Pressure Sensor High Error...38
FAILURE CODE [CA222] Ambient Pressure Sensor Low Error...40
FAILURE CODE [CA227] Sensor 2 Supply Voltage High Error...42
FAILURE CODE [CA234] Engine Overspeed...43
FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error...44
FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Error...46
FAILURE CODE [CA249] Ambient Air Temp Sensor High Error...48
FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error...50
FAILURE CODE [CA271] IMV or PCV 1 Short Circuit Error...52
FAILURE CODE [CA272] IMV or PCV 1 Open Circuit Error...54
FAILURE CODE [CA322] Injector #1 (L#1) Open Circuit Error or Short Circuit Error...56
FAILURE CODE [CA323] Injector #5 (L#5) Open Circuit Error or Short Circuit Error...58
FAILURE CODE [CA324] Injector #3 (L#3) Open Circuit Error or Short Circuit Error...60
FAILURE CODE [CA325] Injector #6 (L#6) Open Circuit Error or Short Circuit Error...62
FAILURE CODE [CA331] Injector #2 (L#2) Open Circuit Error or Short Circuit Error...64
FAILURE CODE [CA332] Injector #4 (L#4) Open Circuit Error or Short Circuit Error...66
FAILURE CODE [CA343] Engine Controller Internal Failure...68
FAILURE CODE [CA351] Injectors Drive Circuit Error...69
FAILURE CODE [CA352] Sensor 1 Supply Voltage Low Error...70
FAILURE CODE [CA356] MAF Sensor High Error...73
FAILURE CODE [CA357] MAF Sensor Low Error...75
FAILURE CODE [CA386] Sensor 1 Supply Voltage High Error...77
FAILURE CODE [CA428] Water in Fuel Sensor High Error...78
FAILURE CODE [CA429] Water in Fuel Sensor Low Error...80
FAILURE CODE [CA435] Engine Oil Pressure SW Error...82
FAILURE CODE [CA441] Battery Voltage Low Error...84
FAILURE CODE [CA442] Battery Voltage High Error...86
FAILURE CODE [CA449] Common Rail Pressure High Error 2...87
FAILURE CODE [CA451] Common Rail Pressure Sensor High Error...88
FAILURE CODE [CA452] Common Rail Pressure Sensor Low Error...90
FAILURE CODE [CA488] Charge Air Temperature High Torque Derate...92
FAILURE CODE [CA515] Common Rail Pressure Sensor Supply Voltage High Error...93
FAILURE CODE [CA516] Common Rail Pressure Sensor Supply Voltage Low Error...95
FAILURE CODE [CA553] Common Rail Pressure High Error 1...97
FAILURE CODE [CA555] Crankcase Pressure High Error 1...98
FAILURE CODE [CA556] Crankcase Pressure High Error 2...99
FAILURE CODE [CA559] Common Rail Pressure Low Error 1...100
FAILURE CODE [CA595] Turbocharger Speed High Error 2...103
FAILURE CODE [CA687] Turbocharger Speed Low Error...104
FAILURE CODE [CA689] Engine NE Speed Sensor Error...106
FAILURE CODE [CA691] Intake Air Temperature Sensor High Error...109
FAILURE CODE [CA692] Intake Air Temperature Sensor Low Error...111
FAILURE CODE [CA697] Engine Controller Internal Temperature Sensor High Error...113
FAILURE CODE [CA698] Engine Controller Internal Temperature Sensor Low Error...114
FAILURE CODE [CA731] Engine Backup Speed Sensor Phase Error...115
FAILURE CODE [CA778] Engine Backup Speed Sensor Error...117
FAILURE CODE [CA1117] Engine Controller Partial Data Lost Error...122
FAILURE CODE [CA1664] KDOC Abnormality...123
FAILURE CODE [CA1669] AdBlue/DEF Level Sensor Voltage High Error...125
FAILURE CODE [CA1673] AdBlue/DEF Level Low Error 3...126
FAILURE CODE [CA1677] AdBlue/DEF Temperature Sensor Low Error...127
FAILURE CODE [CA1678] AdBlue/DEF Temperature Sensor High Error...128
FAILURE CODE [CA1682] AdBlue/DEF Pump Priming Error...129
FAILURE CODE [CA1683] AdBlue/DEF Tank Heating Valve Voltage High Error...131
FAILURE CODE [CA1684] AdBlue/DEF Tank Heating Valve Voltage Low Error...133
FAILURE CODE [CA1686] AdBlue/DEF Quality Sensor Voltage High Error...135
FAILURE CODE [CA1691] Defective Regeneration...136
FAILURE CODE [CA1694] SCR Outlet NOx Sensor In Range Error...139
FAILURE CODE [CA1695] Sensor 5 Supply Voltage High Error...142
FAILURE CODE [CA1696] Sensor 5 Supply Voltage Low Error...143
FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error...145
FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Error...148
FAILURE CODE [CA1714] AdBlue/DEF Quality Sensor Out of Calibration Error...150
FAILURE CODE [CA1715] AdBlue/DEF Quality Sensor Internal Circuit Error...151
FAILURE CODE [CA1776] Sensor Supply Relay Voltage High Error...152
FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error...155
FAILURE CODE [CA1843] Crankcase Pressure Sensor High Error...158
FAILURE CODE [CA1844] Crankcase Pressure Sensor Low Error...160
!!! new_index = 1061
!!! num_start = 1
!!! num_style = Arabic
FAILURE CODE [CA1879] KDPF Differential Pressure Sensor High Error...3
FAILURE CODE [CA1881] KDPF Differential Pressure Sensor Low Error...5
FAILURE CODE [CA1883] KDPF Differential Pressure Sensor In Range Error...7
FAILURE CODE [CA1885] Turbo Outlet NOx Sensor Circuit Error...10
FAILURE CODE [CA1887] SCR Outlet NOx Sensor Circuit Error...12
FAILURE CODE [CA1921] KDPF Soot Accumulation High Error 1...14
FAILURE CODE [CA1922] KDPF Soot Accumulation High Error 2...17
FAILURE CODE [CA1942] Crankcase Pressure Sensor In Range Error...22
FAILURE CODE [CA1993] KDPF Differential Pressure Low Error...23
FAILURE CODE [CA2185] Throttle Sensor Supply Voltage High Error...26
FAILURE CODE [CA2186] Throttle Sensor Supply Voltage Low Error...27
FAILURE CODE [CA2249] Common Rail Pressure Low Error 2...29
FAILURE CODE [CA2271] EGR Valve Position Sensor High Error...30
FAILURE CODE [CA2272] EGR Valve Position Sensor Low Error...33
FAILURE CODE [CA2288] Turbocharger Speed High Error 1...36
FAILURE CODE [CA2311] lMV Solenoid Error...37
FAILURE CODE [CA2349] EGR Valve Solenoid Open Circuit Error...38
FAILURE CODE [CA2353] EGR Valve Solenoid Short Circuit Error...41
FAILURE CODE [CA2357] EGR Valve Servo Error...43
FAILURE CODE [CA2381] KVGT Position Sensor High Error...44
FAILURE CODE [CA2382] KVGT Position Sensor Low Error...47
FAILURE CODE [CA2383] KVGT Solenoid Open Circuit Error...50
FAILURE CODE [CA2386] KVGT Solenoid Short Circuit Error...53
FAILURE CODE [CA2387] KVGT Servo Error...55
FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error...56
FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error...59
FAILURE CODE [CA2637] KDOC Face Plugging...62
FAILURE CODE [CA2639] Manual Stationary Regeneration Request...64
FAILURE CODE [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error...67
FAILURE CODE [CA2777] Manual Stationary Regeneration Request but KDPF Regeneration Disable...73
FAILURE CODE [CA2976] AdBlue/DEF Pump Temperature Sensor Signal Error...76
FAILURE CODE [CA3133] KDPF Outlet Pressure Sensor High Error...78
FAILURE CODE [CA3134] KDPF Outlet Pressure Sensor Low Error...81
FAILURE CODE [CA3135] KDPF Outlet Pressure Sensor In Range Error...83
FAILURE CODE [CA3142] SCR Temperature Sensor High Error...86
FAILURE CODE [CA3143] SCR Temperature Sensor Low Error...87
FAILURE CODE [CA3144] SCR Temperature Sensor In Range Error...88
FAILURE CODE [CA3146] SCR Outlet Temperature Sensor High Error...90
FAILURE CODE [CA3147] SCR Outlet Temperature Sensor Low Error...91
FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range Error...92
FAILURE CODE [CA3151] SCR Catalyst Efficiency Low Error 2...94
FAILURE CODE [CA3165] SCR Outlet Temperature High Error...100
FAILURE CODE [CA3229] SCR Temperature High Error...102
FAILURE CODE [CA3231] SCR Temperature High Error - Non Regeneration...104
FAILURE CODE [CA3232] Turbo Outlet NOx Sensor Datalink Timeout Error...106
FAILURE CODE [CA3235] SCR Outlet Temperature High Error - Non Regeneration...110
FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error...112
FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error...115
FAILURE CODE [CA3242] AdBlue/DEF Tank Heating Error...118
FAILURE CODE [CA3251] KDOC Inlet Temperature High Error...121
FAILURE CODE [CA3253] KDOC Temperature Error - Non Regeneration...123
FAILURE CODE [CA3254] KDOC Outlet Temperature High Error 1...126
FAILURE CODE [CA3255] KDPF Temperature Error - Non Regeneration...129
FAILURE CODE [CA3256] KDPF Outlet Temperature High Error 1...133
FAILURE CODE [CA3311] KDOC Outlet Temperature High Error 2...135
FAILURE CODE [CA3312] KDPF Outlet Temperature High Error 2...137
FAILURE CODE [CA3313] KDOC Inlet Temperature Sensor Low Error...140
FAILURE CODE [CA3314] KDOC Inlet Temperature Sensor High Error...142
FAILURE CODE [CA3315] KDOC Inlet Temperature Sensor In Range Error...143
FAILURE CODE [CA3316] KDOC Outlet Temperature Sensor Low Error...145
FAILURE CODE [CA3317] KDOC Outlet Temperature Sensor High Error...147
FAILURE CODE [CA3318] KDOC Outlet Temperature Sensor In Range Error...148
FAILURE CODE [CA3319] KDPF Outlet Temperature Sensor High Error...150
FAILURE CODE [CA3321] KDPF Outlet Temperature Sensor Low Error...151
FAILURE CODE [CA3322] KDPF Outlet Temperature Sensor In Range Error...153
FAILURE CODE [CA3419] MAF Sensor Supply Voltage High Error...155
FAILURE CODE [CA3421] MAF Sensor Supply Voltage Low Error...157
FAILURE CODE [CA3497] AdBlue/DEF Level Low Error 1...159
FAILURE CODE [CA3498] AdBlue/DEF Level Low Error 2...160
FAILURE CODE [CA3543] AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low)...161
FAILURE CODE [CA3545] SCR Outlet NOx Sensor Unstable Error...167
FAILURE CODE [CA3547] AdBlue/DEF Level Low Error 4...169
FAILURE CODE [CA3558] AdBlue/DEF Pump Voltage High Error...170
FAILURE CODE [CA3559] AdBlue/DEF Pump Voltage Low Error...172
FAILURE CODE [CA3562] AdBlue/DEF LineHeater Relay 1 Voltage High Error...174
FAILURE CODE [CA3563] AdBlue/DEF LineHeater Relay 1 Voltage Low Error...176
FAILURE CODE [CA3567] AdBlue/DEF Injector Open Circuit Error or Short Circuit Error...179
FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction...182
FAILURE CODE [CA3571] AdBlue/DEF Pump Pressure Sensor High Error...186
FAILURE CODE [CA3572] AdBlue/DEF Pump Pressure Sensor Low Error...188
FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Error...190
FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Error...192
FAILURE CODE [CA3577] AdBlue/DEF FCV Voltage High Error...194
FAILURE CODE [CA3578] AdBlue/DEF FCV Voltage Low Error...196
FAILURE CODE [CA3582] SCR Catalyst Efficiency Low Error 1...198
FAILURE CODE [CA3583] SCR Outlet NOx Sensor Heater Warming up Error...204
FAILURE CODE [CA3596] AdBlue/DEF Pump Pressure Unstable Error...206
FAILURE CODE [CA3649] Turbo Outlet NOx Sensor Heater Warming up Error...208
FAILURE CODE [CA3681] SCR Outlet NOx Sensor Power Voltage Error...210
FAILURE CODE [CA3682] Turbo Outlet NOx Sensor Power Voltage Error...215
FAILURE CODE [CA3713] AdBlue/DEF Line Heater 1 Voltage High Error...221
FAILURE CODE [CA3717] SCR Outlet NOx Sensor Voltage Mismatch Error...224
FAILURE CODE [CA3718] Turbo Outlet NOx Sensor Voltage Mismatch Error...225
FAILURE CODE [CA3725] Turbo Outlet NOx Sensor Unstable Error...226
FAILURE CODE [CA3741] Rail Press Valve Trip Error...229
FAILURE CODE [CA3748] Turbo Outlet NOx Sensor Stuck In Range Error...230
FAILURE CODE [CA3751] SCR Catalyst Degradation Error...232
FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degradation Error...234
FAILURE CODE [CA3866] AdBlue/DEF Low Concentration Error 2...236
FAILURE CODE [CA3867] AdBlue/DEF Low Concentration Error 1...239
FAILURE CODE [CA3868] AdBlue/DEF Tank Sensor Datalink Timeout Error...242
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error...246
FAILURE CODE [CA3911] SCR NH3 Sensor Datalink Timeout Error...248
FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warming up Error...252
FAILURE CODE [CA3932] SCR NH3 Sensor Heater Voltage High Error...254
FAILURE CODE [CA3933] SCR NH3 Sensor Heater Voltage Low Error...256
FAILURE CODE [CA3934] SCR NH3 Sensor Power Interrupt Error...258
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error...261
FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error...263
FAILURE CODE [CA4151] KDOC and KDPF Temperature Sensor Datalink Timeout Error...265
FAILURE CODE [CA4152] SCR Temperature Sensor Datalink Timeout Error...269
FAILURE CODE [CA4155] AdBlue/DEF Pump Heater Relay Voltage High Error...273
FAILURE CODE [CA4156] AdBlue/DEF Pump Heater Relay Voltage Low Error...276
FAILURE CODE [CA4157] AdBlue/DEF FCV Malfunction...279
FAILURE CODE [CA4158] KDOC and KDPF Temperature Sensor Internal Circuit Error...281
FAILURE CODE [CA4159] SCR Temperature Sensor Internal Circuit Error...282
FAILURE CODE [CA4161] KDOC and KDPF Temperature Sensor ECU Voltage High Error...283
FAILURE CODE [CA4162] KDOC and KDPF Temperature Sensor ECU Voltage Low Error...286
FAILURE CODE [CA4163] KDOC and KDPF Temperature Sensor ECU Over Temperature Error...289
FAILURE CODE [CA4164] SCR Temperature Sensor ECU Voltage High Error...291
FAILURE CODE [CA4165] SCR Temperature Sensor ECU Voltage Low Error...293
FAILURE CODE [CA4166] SCR Temperature Sensor ECU High Temperature Error...295
FAILURE CODE [CA4168] AdBlue/DEF Pump Heater ON Stuck Error...297
FAILURE CODE [CA4169] AdBlue/DEF Pump Heater OFF Stuck Error...300
FAILURE CODE [CA4171] AdBlue/DEF Pump Thawing Error...302
FAILURE CODE [CA4249] AdBlue/DEF Pump Temperature Sensor 1 In Range Error...305
FAILURE CODE [CA4251] AdBlue/DEF Pump Temperature Sensor 2 In Range Error...307
FAILURE CODE [CA4259] KDOC and KDPF Temperature Sensor Power Interrupt Error...309
FAILURE CODE [CA4261] SCR Temperature Sensor Power Interrupt Error...312
FAILURE CODE [CA4277] AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error...315
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Response Error...318
FAILURE CODE [CA4459] AdBlue/DEF LineHeater Relay 2 Voltage High Error...321
FAILURE CODE [CA4461] AdBlue/DEF LineHeater Relay 2 Voltage Low Error...324
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Error...327
FAILURE CODE [CA4731] AdBlue/DEF Temperature Sensor Transmission Data Error...331
FAILURE CODE [CA4732] AdBlue/DEF Level Sensor Transmission Data Error...332
FAILURE CODE [CA4739] AdBlue/DEF Level Sensor Internal Circuit Error...333
FAILURE CODE [CA4768] Fuel in AdBlue/DEF Tank Error...334
FAILURE CODE [CA4769] AdBlue/DEF Level Measurement Impossible...336
FAILURE CODE [CA4842] AdBlue/DEF High Concentration Error...339
FAILURE CODE [CA4952] System Operating Lamp Short Circuit (Engine Controller)...342
FAILURE CODE [CA5115] AdBlue/DEF Line Heater 1 Voltage Low Error...344
FAILURE CODE [CA5179] Engine Room Temperature Sensor High Error...347
FAILURE CODE [CA5181] Engine Room Temperature Sensor Low Error...349
FAILURE CODE [CA5383] Ash Accumulation High Error...351
FAILURE CODE [D110KB] Battery Relay Output Short Circuit...353
FAILURE CODE [D19JKZ] Personal Code Relay Open Circuit or Short Circuit...355
FAILURE CODE [D811MC] KOMTRAX Malfunction...358
FAILURE CODE [D862KA] GPS Antenna Open Circuit...359
FAILURE CODE [D8ALKA] System Operating Lamp Open Circuit (KOMTRAX)...360
FAILURE CODE [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX)...362
FAILURE CODE [D8AQKR] CAN 2 Defective Communication (KOMTRAX)...364
FAILURE CODE [DA20MC] Pump Controller Malfunction...366
FAILURE CODE [DA22KK] Pump Controller Solenoid Power Voltage Low Error...367
FAILURE CODE [DA25KP] 5V Sensor 1 Power Voltage Low Error...370
FAILURE CODE [DA29KQ] Model Selection Signal Mismatch (Pump Controller)...373
FAILURE CODE [DA2LKA] System Operating Lamp Open Circuit (Pump Controller)...375
FAILURE CODE [DA2LKB] System Operating Lamp Short Circuit (Pump Controller)...377
FAILURE CODE [DA2QKR] Controller Area Network 2 Defective Communication (Pump Controller)...379
FAILURE CODE [DA2RKR] Controller Area Network 1 Defective Communication (Pump Controller)...382
FAILURE CODE [DAF0MB] Monitor ROM Abnormality...383
FAILURE CODE [DAF0MC] Monitor Malfunction...384
FAILURE CODE [DAF8KB] Camera Power Supply Short Circuit...385
FAILURE CODE [DAF9KQ] Model Selection Signal Mismatch (Monitor)...387
FAILURE CODE [DAFGMC] GPS Module Malfunction...388
FAILURE CODE [DAFLKA] System Operating Lamp Open Circuit (Monitor)...389
FAILURE CODE [DAFLKB] System Operating Lamp Short Circuit (Monitor)...391
FAILURE CODE [DAFQKR] CAN 2 Defective Communication (Monitor)...393
FAILURE CODE [DAZ9KQ] Model Selection Signal Mismatch (A/C)...394
FAILURE CODE [DAZQKR] CAN 2 Defective Communication (A/C ECU)...395
FAILURE CODE [DB2QKR] CAN 2 Defective Communication (Engine Controller)...400
FAILURE CODE [DB2RKR] CAN 1 Defective Communication (Engine Controller)...405
FAILURE CODE [DDNRKA] W/E Lever Lock SW Open Circuit...410
FAILURE CODE [DDNRKY] W/E Lever Lock SW Short Circuit...412
FAILURE CODE [DDNS00] Lock Lever Auto Lock Release SW On...414
FAILURE CODE [DGH2KA] Hydraulic Oil Temperature Sensor Open Circuit...416
FAILURE CODE [DGH2KB] Hydraulic Oil Temperature Sensor Ground Fault...418
FAILURE CODE [DHA4KA] Air Cleaner Clog Sensor Open Circuit...420
FAILURE CODE [DHAAMA] KDPF Differential Pressure Sensor Frozen...422
FAILURE CODE [DHACMA] KDPF Outlet Pressure Sensor Frozen...424
FAILURE CODE [DHPAMA] Front Pump Pressure Sensor Defective Function...426
FAILURE CODE [DHPBMA] Rear Pump Pressure Sensor Defective Function...429
FAILURE CODE [DHS3MA] Arm IN PPC Pressure Sensor Defective Function...432
FAILURE CODE [DHS4MA] Bucket CURL PPC Pressure Sensor Defective Function...435
FAILURE CODE [DHS8MA] Boom RAISE PPC Pressure Sensor Defective Function...438
FAILURE CODE [DHS9MA] Boom LOWER PPC Pressure Sensor Defective Function...441
FAILURE CODE [DHSAMA] Swing Right PPC Pressure Sensor Defective Function...444
FAILURE CODE [DHSBMA] Swing Left PPC Pressure Sensor Defective Function...447
FAILURE CODE [DHSCMA] Arm OUT PPC Pressure Sensor Defective Function...450
FAILURE CODE [DHSDMA] Bucket DUMP PPC Pressure Sensor Defective Function...453
FAILURE CODE [DHSFMA] Travel Forward Left PPC Pressure Sensor Defective Function...456
FAILURE CODE [DHSGMA] Travel Forward Right PPC Pressure Sensor Defective Function...459
FAILURE CODE [DHSHMA] Travel Reverse Left PPC Pressure Sensor Defective Function...462
FAILURE CODE [DHSJMA] Travel Reverse Right PPC Pressure Sensor Defective Function...465
FAILURE CODE [DKR0MA] Front Pump Swash Plate Sensor Defective Function...468
FAILURE CODE [DKR1MA] Rear Pump Swash Plate Sensor Defective Function...471
FAILURE CODE [DKULKA] PPC Lock Relay Open Circuit...474
FAILURE CODE [DKULKB] PPC Lock Relay Short Circuit...476
FAILURE CODE [DKULKY] PPC Lock Relay Hot Short Circuit...478
FAILURE CODE [DR21KX] Camera 2 Picture Reverse Drive Input Out of Range...480
FAILURE CODE [DR31KX] Camera 3 Picture Reverse Drive Input Out of Range...482
FAILURE CODE [DV20KB] Travel Alarm Short Circuit...484
FAILURE CODE [DW43KA] Travel Speed Solenoid Open Circuit...486
FAILURE CODE [DW43KB] Travel Speed Solenoid Short Circuit...488
FAILURE CODE [DW43KY] Travel Speed Solenoid Hot Short Circuit...490
FAILURE CODE [DW45KA]Swing Parking Brake Solenoid Open Circuit...492
FAILURE CODE [DW45KB] Swing Parking Brake Solenoid Short Circuit...495
FAILURE CODE [DW45KY] Swing Parking Brake Solenoid Hot Short Circuit...498
FAILURE CODE [DW4CKY] PPC Lock Solenoid Hot Short Circuit...500
FAILURE CODE [DW91KA] Travel Junction Solenoid Open Circuit...502
FAILURE CODE [DW91KB] Travel Junction Solenoid Short Circuit...504
FAILURE CODE [DW91KY] Travel Junction Solenoid Hot Short Circuit...506
FAILURE CODE [DWA2KA] Attachment Single or 2-Way Change Solenoid Open Circuit...508
FAILURE CODE [DWA2KB] Attachment Single or 2-Way Change Solenoid Short Circuit...510
FAILURE CODE [DWA2KY] Attachment Single or 2-Way Change Solenoid Hot Short Circuit...512
FAILURE CODE [DWK0KA] 2-Stage Relief Solenoid Open Circuit...514
FAILURE CODE [DWK0KB] 2-Stage Relief Solenoid Open Circuit...516
FAILURE CODE [DWK0KY] 2-Stage Relief Solenoid Hot Short Circuit...518
FAILURE CODE [DWK2KA] Variable Back Pressure Solenoid Open Circuit...520
FAILURE CODE [DWK2KB] Variable Back Pressure Solenoid Short Circuit...522
FAILURE CODE [DWK2KY] Variable Back Pressure Solenoid Hot Short Circuit...524
FAILURE CODE [DWK8KA] Swing Pressure Cutoff Solenoid Open Circuit...526
FAILURE CODE [DWK8KB] Swing Pressure Cutoff Solenoid Short Circuit...528
FAILURE CODE [DWK8KY] Swing Pressure Cutoff Solenoid Hot Short Circuit...530
FAILURE CODE [DXA8KA] Front Pump PC-EPC Solenoid Open Circuit...532
FAILURE CODE [DXA8KB] Front Pump PC-EPC Solenoid Short Circuit...534
FAILURE CODE [DXA9KA] Rear Pump PC-EPC Solenoid Open Circuit...536
FAILURE CODE [DXA9KB] Rear Pump PC-EPC Solenoid Short Circuit...538
FAILURE CODE [DXE0KA] LS-EPC Solenoid Open Circuit...540
FAILURE CODE [DXE0KB] LS-EPC Solenoid Short Circuit...541
FAILURE CODE [DXE4KA] Attachment Flow Regulating EPC Solenoid Open Circuit...543
FAILURE CODE [DXE4KB] Attachment Flow Regulating EPC Solenoid Short Circuit...545
FAILURE CODE [DXE4KY] Attachment Flow EPC Hot Short Circuit...547
FAILURE CODE [DXE5KA] Merge-divider Main Solenoid Open Circuit...549
FAILURE CODE [DXE5KB] Merge-divider Main Solenoid Short Circuit...551
FAILURE CODE [DXE6KA] Merge-divider LS Solenoid Open Circuit...553
FAILURE CODE [DXE6KB] Merge-divider LS Solenoid Short Circuit...555
FAILURE CODE [DXE7KA] Attachment Flow Regulating EPC 2 Solenoid Open Circuit...557
FAILURE CODE [DXE7KB] Attachment Flow Regulating EPC 2 Solenoid Short Circuit...559
FAILURE CODE [DXE7KY] Attachment Flow Regulating EPC 2 Hot Short Circuit...561
FAILURE CODE [DXE8KA] Attachment Flow Regulating EPC 3 Solenoid Open Circuit...563
FAILURE CODE [DXE8KB] Attachment Flow Regulating EPC 3 Solenoid Short Circuit...565
FAILURE CODE [DXE8KY] Attachment Flow Regulating EPC 3 Hot Short Circuit...567
FAILURE CODE [DXE9KA] Attachment Flow Regulating EPC 4 Solenoid Open Circuit...569
FAILURE CODE [DXE9KB] Attachment Flow Regulating EPC 4 Solenoid Short Circuit...571
FAILURE CODE [DXE9KY] Attachment Flow Regulating EPC 4 Hot Short Circuit...573
FAILURE CODE [DXEAKA] Attachment Flow Regulating EPC 5 Solenoid Open Circuit...575
FAILURE CODE [DXEAKB] Attachment Flow Regulating EPC 5 Solenoid Short Circuit...577
FAILURE CODE [DXEAKY] Attachment Flow Regulating EPC 5 Hot Short Circuit...579
FAILURE CODE [DY20KA]Wiper Motor Open Circuit...581
FAILURE CODE [DY20MA] Wiper Motor Defective Function...583
FAILURE CODE [DY2CKB] Washer Motor Short Circuit...585
FAILURE CODE [DY2DKB] Wiper Motor (Normal Rotation) Short Circuit...588
FAILURE CODE [DY2EKB] Wiper Motor (Reverse Rotation) Short Circuit...590
FAILURE CODE [DFB1KZ] Service Lever Potentio 1 Abnormality...592
FAILURE CODE [DFB2KZ] Service Lever Potentio 2 Abnormality...594
FAILURE CODE [DFB5KZ] Service Lever Sub Potentio 1 Abnormality...596
FAILURE CODE [DFB6KZ] Service Lever Sub Potentio 2 Abnormality...598
FAILURE CODE [DFB3L8] Service Lever 1 Potentio Error...600
FAILURE CODE [DFB4L8] Service Lever 2 Potentio Error...601
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...603
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)...603
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK...609
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK...612
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP...614
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING...616
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW...619
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW...620
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING...621
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING...622
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING...623
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...624
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...625
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...626
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...627
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...628
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...629
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM...630
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL...632
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM...633
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE...634
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM...635
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE...637
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED...638
E-24 FUNCTION SWITCH DOES NOT OPERATE...639
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)...640
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF...641
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER...642
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED...643
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED...644
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE...645
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE...646
E-32 ALARM BUZZER CANNOT BE CANCELED...648
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION...649
E-34 SERVICE MODE CANNOT BE SELECTED...650
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE...651
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK...654
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING...656
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE...659
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR...661
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED...664
E-41 ALARM DOES NOT SOUND DURING TRAVEL...665
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED...667
E-43 HORN DOES NOT SOUND...668
E-44 HORN DOES NOT STOP SOUNDING...671
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF...673
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE...674
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE...676
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...677
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...678
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...679
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...680
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...681
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...682
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...683
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...684
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...685
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED...687
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY...688
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)...689
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)...689
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS...690
FAILURE MODE AND CAUSE TABLE...692
H-1 ANY OF WORK EQUIPMENT, SWING AND TRAVEL DOES NOT WORK...701
H-2 ALL OF WORK EQUIPMENTS, SWING AND TRAVEL OPERATION LACK SPEED OR POWER...702
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR...705
H-4 UNUSUAL SOUND IS HEARD FROM AROUND HYDRAULIC PUMP...706
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS...707
H-6 SPEED OR POWER OF BOOM IS LOW...709
H-7 SPEED OR POWER OF ARM IS LOW...713
H-8 SPEED OR POWER OF BUCKET IS LOW...718
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION...721
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE...722
H-11 HYDRAULIC DRIFT OF ARM IS LARGE...724
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE...726
H-13 OTHER WORK EQUIPMENT MOVES WHEN ONE OF WORK EQUIPMENT IS RELIEVED...727
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE...728
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT WORK...729
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED...730
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CONTROLLED...731
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT , EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER...732
H-19 TRAVEL SPEED DROPS LARGELY IN COMBINED OPERATION OF SWING AND TRAVE...733
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW...734
H-21 MACHINE DOES NOT TRAVEL STRAIGHT...735
H-22 MACHINE IS HARD TO STEER OR TRAVEL POWER IS LOW...737
H-23 TRAVEL SPEED IS LOW...740
H-24 ONE OF TRACKS DOES NOT RUN...742
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO LOW OR HIGH...743
H-26 UPPER STRUCTURE DOES NOT SWING IN BOTH RIGHT AND LEFT DIRECTIONS...744
H-27 UPPER STRUCTURE SWING IN ONLY ONE DIRECTION...745
H-28 SWING ACCELERATION OR SWING SPEED OF UPPER STRUCTURE IS LOW IN BOTH RIGHT AND LEFT DIRECTIONS...746
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN ONLY ONE DIRECTION...747
H-30 OVERRUN OF UPPER STRUCTURE IS LARGE IN BOTH RIGHT AND LEFT DIRECTIONS...748
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWING IN ONLY ONE DIRECTION...749
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING...750
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING...751
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)...752
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)...753
TROUBLESHOOTING OF ENGINE (S-MODE)...754
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)...754
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION...755
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT...756
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)...757
S-4 ENGINE STARTABILITY IS POOR...759
S-5 ENGINE DOES NOT PICK UP SMOOTHLY...761
S-6 ENGINE STOPS DURING OPERATION...763
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE...765
S-8 ENGINE LACKS POWER...766
S-9 KDPF GETS CLOGGED IN A SHORT TIME...768
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE...770
S-11 OIL BECOMES CONTAMINATED QUICKLY...771
S-12 FUEL CONSUMPTION IS EXCESSIVE...772
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)...773
S-14 OIL PRESSURE DROPS...774
S-15 FUEL MIXES INTO ENGINE OIL...776
S-16 WATER MIXES INTO ENGINE OIL (MILKY)...777
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)...778
S-18 UNUSUAL NOISE IS HEARD...779
S-19 VIBRATION IS EXCESSIVE...780
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT...781
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY...782
S-22 ACTIVE REGENERATION TAKES TIME...784
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION...785
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE...786
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)...788
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)...789
50 DISASSEMBLY AND ASSEMBLY...791
CONTENTS...792
ABBREVIATION LIST...797
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY...802
HOW TO READ THIS MANUAL...802
COATING MATERIALS LIST...804
SPECIAL TOOLS LIST...809
SKETCHES OF SPECIAL TOOLS...821
ENGINE AND COOLING SYSTEM...827
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY...827
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY...827
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY...830
REMOVE AND INSTALL INJECTOR ASSEMBLY...834
METHOD FOR REMOVING INJECTOR ASSEMBLY...834
METHOD FOR INSTALLING INJECTOR ASSEMBLY...839
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY...847
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY...848
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY...857
REMOVE AND INSTALL EGR VALVE ASSEMBLY...873
METHOD FOR REMOVING EGR VALVE ASSEMBLY...873
METHOD FOR INSTALLING EGR VALVE ASSEMBLY...874
REMOVE AND INSTALL EGR COOLER ASSEMBLY...877
METHOD FOR REMOVING EGR COOLER ASSEMBLY...877
METHOD FOR INSTALLING EGR COOLER ASSEMBLY...880
REMOVE AND INSTALL STARTER ASSEMBLY...885
METHOD FOR REMOVING STARTER ASSEMBLY...885
METHOD FOR INSTALLING STARTER ASSEMBLY...887
REMOVE AND INSTALL ALTERNATOR BELT...889
METHOD FOR REMOVING ALTERNATOR BELT...889
METHOD FOR INSTALLING ALTERNATOR BELT...891
REMOVE AND INSTALL RADIATOR ASSEMBLY...893
METHOD FOR REMOVING RADIATOR ASSEMBLY...893
METHOD FOR INSTALLING RADIATOR ASSEMBLY...895
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY...897
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY...897
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY...900
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY...903
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY...903
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY...904
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY...906
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY...907
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY...915
REMOVE AND INSTALL ENGINE FRONT OIL SEAL...926
METHOD FOR REMOVING ENGINE FRONT OIL SEAL...926
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL...929
REMOVE AND INSTALL ENGINE REAR OIL SEAL...933
METHOD FOR REMOVING ENGINE REAR OIL SEAL...933
METHOD FOR INSTALLING ENGINE REAR OIL SEAL...934
REMOVE AND INSTALL FUEL COOLER ASSEMBLY...937
METHOD FOR REMOVING FUEL COOLER ASSEMBLY...937
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY...938
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY...939
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY...939
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY...941
REMOVE AND INSTALL FUEL TANK ASSEMBLY...947
METHOD FOR REMOVING FUEL TANK ASSEMBLY...947
METHOD FOR INSTALLING FUEL TANK ASSEMBLY...951
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY...955
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY...955
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY...960
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...966
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...966
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...971
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR...977
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR...977
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR...977
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER...979
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER...979
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER...979
REMOVE AND INSTALL KDPF ASSEMBLY...980
METHOD FOR REMOVING KDPF ASSEMBLY...980
METHOD FOR INSTALLING KDPF ASSEMBLY...982
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY...984
METHOD FOR DISASSEMBLING KDPF ASSEMBLY...985
METHOD FOR ASSEMBLING KDPF ASSEMBLY...988
REMOVE AND INSTALL SCR ASSEMBLY...993
METHOD FOR REMOVING SCR ASSEMBLY...993
METHOD FOR INSTALLING SCR ASSEMBLY...995
REMOVE AND INSTALL KDPF, SCR ASSEMBLY...997
METHOD FOR REMOVING KDPF, SCR ASSEMBLY...997
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY...1003
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET...1009
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET...1009
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET...1016
REMOVE AND INSTALL KCCV ASSEMBLY...1024
METHOD FOR REMOVING KCCV ASSEMBLY...1024
METHOD FOR INSTALLING KCCV ASSEMBLY...1026
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE...1031
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE...1031
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE...1036
REMOVE AND INSTALL AdBlue/DEF INJECTOR...1041
METHOD FOR REMOVING AdBlue/DEF INJECTOR...1041
METHOD FOR INSTALLING AdBlue/DEF INJECTOR...1043
REMOVE AND INSTALL AdBlue/DEF PUMP...1045
METHOD FOR REMOVING AdBlue/DEF PUMP...1045
METHOD FOR INSTALLING AdBlue/DEF PUMP...1047
REMOVE AND INSTALL AdBlue/DEF HOSE...1050
METHOD FOR REMOVING AdBlue/DEF HOSE...1050
METHOD FOR INSTALLING AdBlue/DEF HOSE...1057
REMOVE AND INSTALL AIR CLEANER ASSEMBLY...1063
METHOD FOR REMOVING AIR CLEANER ASSEMBLY...1063
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY...1064
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY...1066
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY...1066
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY...1068
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...1071
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY...1071
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY...1072
POWER TRAIN...1073
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...1073
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...1073
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...1074
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY...1075
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY...1075
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY...1079
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY...1088
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY...1088
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY...1090
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY...1094
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY...1094
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY...1098
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY...1105
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY...1105
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY...1105
UNDERCARRIAGE AND FRAME...1107
SEPARATION AND CONNECTION OF TRACK ASSEMBLY...1107
METHOD FOR SEPARATING TRACK ASSEMBLY...1107
METHOD FOR INSTALLING TRACK ASSEMBLY...1109
REMOVE AND INSTALL SPROCKET...1112
METHOD FOR REMOVING SPROCKET...1112
METHOD FOR INSTALLING SPROCKET...1112
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY...1114
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY...1114
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY...1115
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY...1116
METHOD FOR DISASSEMBLING IDLER ASSEMBLY...1116
METHOD FOR ASSEMBLING IDLER ASSEMBLY...1117
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY...1121
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY...1122
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY...1123
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY...1124
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY...1125
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY...1126
DISASSEMBLE AND ASSEMBLE CARRIER ROLLER ASSEMBLY...1128
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY...1128
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY...1129
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY...1132
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY...1132
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY...1134
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY...1136
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY...1136
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY...1139
HYDRAULIC SYSTEM...1143
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY...1143
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY...1143
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY...1145
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY...1148
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY...1149
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY...1150
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY...1151
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY...1151
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY...1153
REMOVE AND INSTALL MAIN PUMP ASSEMBLY...1156
METHOD FOR REMOVING MAIN PUMP ASSEMBLY...1156
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY...1159
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY...1162
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY...1162
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY...1167
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY...1174
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING...1174
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY...1176
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY...1180
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY...1180
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY...1180
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY...1182
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY...1182
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY...1183
WORK EQUIPMENT...1185
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY...1185
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY...1185
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY...1189
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY...1195
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY...1195
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY...1198
CAB AND ITS ATTACHMENTS...1204
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY...1204
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY...1204
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY...1209
REMOVE AND INSTALL OPERATOR'S CAB GLASS (ADHERED GLASS)...1216
METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY...1218
METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY...1218
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY...1228
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY...1228
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY...1231
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY...1237
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY...1237
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY...1244
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY...1251
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY...1251
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY...1256
REMOVE AND INSTALL OPERATOR'S SEAT...1262
METHOD FOR REMOVING OPERATOR'S SEAT...1262
METHOD FOR INSTALLING OPERATOR'S SEAT...1264
REMOVE AND INSTALL SEAT BELT...1267
METHOD FOR REMOVING SEAT BELT...1267
METHOD FOR INSTALLING SEAT BELT...1268
REMOVE AND INSTALL FRONT WIPER ASSEMBLY...1269
METHOD FOR REMOVING FRONT WIPER ASSEMBLY...1269
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY...1274
ELECTRICAL SYSTEM...1282
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...1282
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY...1282
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY...1283
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY...1285
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY...1285
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY...1289
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY...1294
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY...1294
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY...1297
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR...1301
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR...1301
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR...1302
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR...1303
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR...1303
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR...1303
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR...1305
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR...1305
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR...1306
REMOVE AND INSTALL SCR TEMPERATURE SENSOR...1307
METHOD FOR REMOVING SCR TEMPERATURE SENSOR...1307
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR...1309
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY...1311
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY...1311
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY...1314
60 MAINTENANCE STANDARD...1317
CONTENTS...1318
ABBREVIATION LIST...1319
ENGINE AND COOLING SYSTEM...1324
MAINTENANCE STANDARD OF ENGINE MOUNT...1324
MAINTENANCE STANDARD OF COOLING SYSTEM...1325
POWER TRAIN...1326
MAINTENANCE STANDARD OF SWING CIRCLE...1326
MAINTENANCE STANDARD OF SWING MACHINERY...1327
MAINTENANCE STANDARD OF FINAL DRIVE...1329
MAINTENANCE STANDARD OF SPROCKET...1331
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING...1332
UNDERCARRIAGE AND FRAME...1334
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION...1334
MAINTENANCE STANDARD OF IDLER...1336
MAINTENANCE STANDARD OF TRACK ROLLER...1338
MAINTENANCE STANDARD OF CARRIER ROLLER...1340
MAINTENANCE STANDARD OF TRACK SHOE...1341
MAINTENANCE STANDARD OF TRIPLE SHOE...1344
HYDRAULIC SYSTEM...1345
MAINTENANCE STANDARD OF HYDRAULIC TANK...1345
MAINTENANCE STANDARD OF MAIN PUMP...1346
MAINTENANCE STANDARD OF LS-EPC VALVE...1347
MAINTENANCE STANDARD OF PC-EPC VALVE...1348
MAINTENANCE STANDARD OF SWING MOTOR...1349
MAINTENANCE STANDARD OF TRAVEL MOTOR...1352
MAINTENANCE STANDARD OF CONTROL VALVE...1355
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE...1365
MAINTENANCE STANDARD OF TRAVEL PPC VALVE...1368
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)...1371
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE...1372
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE...1374
MAINTENANCE STANDARD OF SOLENOID VALVE...1376
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)...1377
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)...1378
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT...1379
WORK EQUIPMENT...1380
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE...1380
DIMENSION OF ARM...1385
DIMENSIONS OF BUCKET...1387
MAINTENANCE STANDARD OF BOOM CYLINDER...1389
MAINTENANCE STANDARD OF ARM CYLINDER...1390
MAINTENANCE STANDARD OF BUCKET CYLINDER...1391
80 APPENDIX...1393
CONTENTS...1394
ABBREVIATION LIST...1396
AIR CONDITIONER SYSTEM...1401
PRECAUTIONS FOR REFRIGERANT...1401
AIR CONDITIONER COMPONENT...1402
SPECIFICATIONS OF AIR CONDITIONER...1404
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE...1405
OUTLINE OF REFRIGERATION CYCLE...1406
COMPONENT PARTS OF AIR CONDITIONER SYSTEM...1408
AIR CONDITIONER UNIT...1408
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT...1408
FUNCTION OF AIR CONDITIONER UNIT...1410
COMPONENT PARTS OF AIR CONDITIONER UNIT...1412
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT...1413
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT...1413
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT...1413
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT...1413
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...1414
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...1414
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...1414
FUNCTION OF DUAL PRESSURE SWITCH...1415
AIR CONDITIONER CONTROLLER...1416
STRUCTURE OF AIR CONDITIONER CONTROLLER...1416
COMPRESSOR...1417
STRUCTURE OF COMPRESSOR...1417
SPECIFICATIONS OF COMPRESSOR...1417
FUNCTION OF COMPRESSOR...1418
CONDENSER...1419
STRUCTURE OF CONDENSER...1419
SPECIFICATIONS OF CONDENSER...1419
FUNCTION OF CONDENSER...1419
SENSORS FOR AIR CONDITIONER SYSTEM...1421
STRUCTURE OF SUNLIGHT SENSOR...1421
FUNCTION OF SUNLIGHT SENSOR...1421
STRUCTURE OF AMBIENT TEMPERATURE SENSOR...1421
FUNCTION OF AMBIENT TEMPERATURE SENSOR...1421
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER...1423
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER...1425
AIR CONDITIONER SYSTEM DIAGRAM...1427
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER...1428
FUNCTION OF AIR CONDITIONER CONTROLLER...1429
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS...1430
TESTING AIR LEAKAGE (DUCT)...1434
METHOD FOR TESTING AIR LEAKAGE (DUCT)...1434
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION...1436
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR...1437
TEST VENT (MODE) CHANGEOVER...1438
METHOD FOR TESTING VENT (MODE) CHANGEOVER...1438
TESTING FRESH/RECIRC AIR CHANGEOVER...1440
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER...1440
TEST SUNLIGHT SENSOR...1441
METHOD FOR TESTING SUNLIGHT SENSOR...1441
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT...1442
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT...1442
TEST RELAYS...1443
METHOD FOR TESTING RELAYS...1443
AIR CONDITIONER TROUBLESHOOTING CHART 1...1444
AIR CONDITIONER TROUBLESHOOTING CHART 2...1445
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...1448
FAILURE CODE [879AKA] A/C Recirculation Air Temperature Sensor Open Circuit...1450
FAILURE CODE [879AKB] A/C Recirculation Air Temperature Sensor Short Circuit...1451
FAILURE CODE [879BKA] A/C Fresh Air Temperature Sensor Open Circuit...1452
FAILURE CODE [879BKB] A/C Fresh Air Temperature Sensor Short Circuit...1454
FAILURE CODE [879CKA] Ventilating Sensor Open Circuit...1456
FAILURE CODE [879CKB] Ventilating Sensor Short Circuit...1457
FAILURE CODE [879DKZ] Sunlight Sensor Open Circuit or Short Circuit...1458
FAILURE CODE [879EMC] Ventilation Damper Malfunction...1460
FAILURE CODE [879FMC] Air Mix Damper Malfunction...1461
FAILURE CODE [879GKX] Refrigerant Pressure Input Signal Out of Range...1462
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)...1464
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)...1466
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)...1469
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER...1471
TROUBLESHOOTING USING GAUGE PRESSURE...1473
CONNECTION OF SERVICE TOOL...1476
METHOD FOR CONNECTING SERVICE TOOL...1476
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS...1478
HANDLE COMPRESSOR OIL...1480
METHOD FOR REPLACING DESICCANT...1482
90 CIRCUIT DIAGRAMS...1485
CONTENTS...1486
ABBREVIATION LIST...1487
HYDRAULIC CIRCUIT DIAGRAM...1492
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM...1492
HYDRAULIC CIRCUIT DIAGRAM (1/2)...1496
HYDRAULIC CIRCUIT DIAGRAM (2/2)...1497
ELECTRICAL CIRCUIT DIAGRAM...1498
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM...1498
ELECTRICAL CIRCUIT DIAGRAM (1/7)...1502
ELECTRICAL CIRCUIT DIAGRAM (2/7)...1503
ELECTRICAL CIRCUIT DIAGRAM (3/7)...1504
ELECTRICAL CIRCUIT DIAGRAM (4/7)...1505
ELECTRICAL CIRCUIT DIAGRAM (5/7)...1506
ELECTRICAL CIRCUIT DIAGRAM (6/7)...1507
ELECTRICAL CIRCUIT DIAGRAM (7/7)...1508
INDEX...1509
CEAM025303.pdf...0
CEAM025303_PC290LC-10 S/N A25001 and UP...1
INTRODUCTION...3
FORWARD...4
SAFETY INFORMATION...5
Safety labels...6
INTRODUCTION...7
Directions of Machine...7
Visibilty from Operator?s Seat...7
Structure to Protect the Operator...7
Breaking-in The New Machine...8
Product Information...9
Product Identification Number (Pin)/Machine Serial No. Plate...9
EPA* Regulations, Engine Number Plate...9
Service Meter Location...10
Your Machine Serial Numbers And Distributor...10
Engine Acronyms...10
TABLE OF CONTENTS...11
SAFETY...21
SAFETY LABELS...22
Location Of Safety Labels...22
Safety Labels...23
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE...32
Precautions Before Starting Operation...32
Ensuring Safe Operation...32
Understanding The Machine...32
Preparations For Safe Operation...32
Precautions Regarding Safety-related Equipment...32
Inspecting Machine...32
Clothing And Personal Protective Items...32
Keep Machine Clean...33
Keep Operator's Compartment Clean...33
Fire Extinguisher And First Aid Kit...33
Safety Equipment...33
If Problems Are Found...33
Fire Prevention And Explosion Prevention...34
Action If Fire Occurs...35
Handrails and Steps...36
Mounting And Dismounting...36
No Persons On Attachments...36
Leaving Operator's Seat With Lock...37
Emergency Exit From Operator's Cab...37
Do Not Get Caught In Work Equipment...38
Precautions Related To Protective Structures...38
Falling Objects, Flying Objects And Intruding Objects Prevention...38
Unauthorized Modification...39
Precautions Related To Attachments And Options...39
Precautions Related To Cab Glass...39
Precautions When Running Engine Inside Building...39
Safety At Jobsite...40
Working On Loose Ground...40
Distance To High Voltage Cables...40
Ensure Good Visibility...41
Signalman's Signal And Signs...41
Asbestos Dust Hazard Prevention...42
SAFETY MACHINE OPERATION...43
Starting Engine...43
Checks Before Starting Engine...43
Safety Rules For Starting Engine...44
Starting Engine In Cold Weather...44
Starting Engine With Booster Cables...44
Operation...45
Checks Before Operation...45
Safety Rules For Changing Machine Directions...45
Safety Rules For Traveling...46
Traveling On Slopes...47
Operations On Slopes...48
Prohibited Operations...49
Operations On Snow Or Frozen Surfaces...51
Parking Machine...51
TRANSPORTATION...52
Loading and Unloading...52
Shipping the Machine...52
TOWING...53
Safety Rules For Towing...53
LIFTING OBJECTS WITH BUCKET...54
Safety Rules For Lifting Objects...54
SAFETY MAINTENANCE INFORMATION...55
Warning Tag...55
Keep Work Place Clean And Tidy...55
Select Suitable Place For Inspection And Maintenance...55
Only Authorized Personnel...55
Appoint Leader When Working With Others...55
Stop Engine Before Carrying Out Maintenance...56
Precautions When Working At High Places...56
Two Workers For Maintenance When Engine Is Running...57
Attachments...57
Work On Machine...58
Work Under The Machine...58
Proper Tools...58
Battery Disconnect Switch...59
Removing Battery Terminals...59
Welding...59
Battery...59
Battery Hazard Prevention...59
When Using Hammer...60
Precautions With High-temperature Coolant...60
Precautions With High-temperature Oil...61
Safety Rules For High-pressure Oil...61
Precaution For High Fuel Pressure...61
Safety Handling High-pressure Hoses or Piping...61
Precaution For High Voltage...62
Noise...62
Safety First When Using High-pressure Grease To Adjust Track Tension...62
Do Not Disassemble Recoil Springs...63
Accumulator...63
Handling Gas Spring...63
Precautions when using...63
Precautions when discarding...64
Compressed Air...64
Air Conditioner Maintenance...64
Waste Materials...64
Select Window Washer Fluid...64
Personnel...64
Periodic Replacement Of Safety Critical Parts...65
OPERATION...67
MACHINE VIEW ILLUSTRATIONS...68
Overall Machine View...68
General View of Cab...70
CONTROLS AND GAUGES...71
Machine Monitor...72
EXPLANATION OF COMPONENTS...73
Machine Monitor...73
Basic Operation of Machine Monitor...74
Warning Display...79
Meter Display...89
Gauges and Meter...96
Monitor Switches Portion...99
Handling Function Switches...109
User Menu Selector Switch...113
User Menu...114
Machine Settings...125
Maintenance Screen Setting...130
Monitor Setting...132
Screen Adjustment...132
Screen Adjustment (Camera)...133
Clock Adjustment...133
Time...135
SWITCHES...140
Starting Switch...140
Fuel Control Dial...141
Cigarette Lighter...141
Swing Lock Switch...141
Lamp Switch...142
Horn Switch...142
One Touch Power Max. Switch...142
Room Lamp Switch...142
Emergency Pump Drive Switch...143
Swing Brake Cancel Switch...143
Ceiling Window Wiper Switch...144
Seat Heater Switch...144
Engine Shutdown Secondary Switch...145
CONTROL LEVERS AND PEDALS...146
Lock Lever...146
Travel Levers...147
Work Equipment Control Lever...148
SUN ROOF...150
WINDSHIELD...150
EMERGENCY ESCAPE HAMMER...156
DOOR LOCK...157
CAB DOOR HINGE...157
ENGINE HOOD...158
When Opening (Normal Case: Intermediate Lock Position)...158
When Closing (Normal Case: Intermediate Lock Position)...160
CAPS AND COVERS WITH LOCK...162
Open and Close Caps with Lock...162
Opening the Cap...162
Locking the Cap...162
Open and Close Covers with Lock...163
Opening the Cover (Locked Cover)...163
Locking the Cover...163
Lock and Unlock Engine Hood...163
Opening the Hood (Locked Hood)...163
Locking the Hood...163
Lock and Unlock Cab Door...164
Opening the Door (Locked Door)...164
Locking the Door...164
DRINK BOX...165
MAGAZINE BOX...165
CUP HOLDER...165
ASHTRAY...166
AIR CONDITIONER CONTROLS...167
Air Conditioner Control Panel...167
Method of Operation...172
Automatic Operation...172
Stopping Automatic Operation...173
Manual Operation...173
Stop Manual Operation...175
Operation with Cold Air to Face and Warm Air to Feet...175
Defroster Operation...177
Rules for Using Air Conditioner...179
Air Conditioner Maintenance...179
RADIO...180
Control Panel...180
Operation Method...182
Frequency Adjustment...182
Frequency Adjustment (Auto Presetting)...182
Preset Call...182
Preset Memory...182
Sound Adjustment (Balance)...182
Sound Adjustment (Treble)...183
Sound Adjustment (Bass)...183
Time Adjustment...183
AUXILIARY ELECTRIC POWER...184
24 V Power Source...184
12 V Power Source...184
FUSE...185
FUSIBLE LINK...186
TOOL BOX...186
GREASE GUN HOLDER...186
FIRE EXTINGUISHER...186
BATTERY DISCONNECT SWITCH...187
SYSTEM OPERATING LAMP...188
HANDLING KOMATSU DIESEL PARTICULATE FILTER (KDPF)...189
Operation Procedure of Manual Stationary Regeneration...192
Komatsu Diesel Particulate Filter (KDPF) Regeneration Disable Procedure...194
While Regeneration is not being Performed: Setting for Regeneration Disable...195
While Regeneration is being Performed: Stopping Regeneration...197
Komatsu Diesel Particulate Filter (KDPF) Regeneration Disable Cancel Procedure...198
Handling Komatsu Closed Crankcase Ventilation (KCCV)...198
HANDLING MACHINES EQUIPPED WITH KOMTRAX...199
Basic Precautions...200
MACHINE OPERATIONS AND CONTROLS...201
Before Starting Engine...201
Walk-around Checks...201
Checks Before Starting...203
Adjustment...212
Seat Belt Inspection...221
Seat Belt...222
Operations Before Starting Engine...223
STARTING ENGINE...225
Turbo Protect Function...228
AFTER STARTING ENGINE...229
Engine Warm Up...231
Hydraulic System Warm-Up...233
Operation After Completion Of Warming-Up Operation...240
STOPPING THE ENGINE...242
MACHINE OPERATION...243
Preparations for Moving the Machine...243
Moving Machine Forward...244
Moving Machine Backward...245
Stopping Machine...246
STEERING THE MACHINE...247
Steering...247
Steering the Machine when Stopped...247
Changing Direction of the Machine...248
Counter-rotation Turn (Spin Turn)...248
SWINGING...249
WORK EQUIPMENT CONTROLS AND OPERATIONS...250
WORKING MODE...252
Working Mode Switch...252
One-Touch Power Max. Switch...254
PROHIBITED OPERATIONS...255
GENERAL OPERATION INFORMATION...258
Traveling...258
High Speed Travel...258
Permissible Water Depth...259
TRAVELING ON SLOPES...260
ESCAPE FROM MUD...262
Track on One Side Stuck...262
Tracks on Both Sides Stuck...262
RECOMMENDED APPLICATIONS...263
Backhoe Work...263
Shovel Work...263
Ditching Work...263
Loading Work...264
BUCKET REPLACEMENT AND INVERSION...265
Replacement...265
Inversion...267
PARKING MACHINE...269
MACHINE INSPECTION AFTER DAILY WORK...271
LOCKING...271
TRANSPORTATION...271
Transportation Procedure...271
Loading And Unloading With Trailer...272
Loading...273
Securing Machine...276
Stowing Radio Antenna...278
Rearview Mirrors...278
Remove and Install Handrail...280
Unloading...281
LIFTING MACHINE...283
Standard Specification Machines...283
Machines with Lifting Hook...285
COLD WEATHER OPERATION...286
Cold Weather Operation Information...286
Fuel and Lubricants...286
Coolant...286
Battery...287
AFTER DAILY WORK COMPLETION...288
AFTER COLD WEATHER SEASON...288
LONG TERM STORAGE...289
Before Storage...289
During Storage...289
After Storage...290
Starting Machine After Long-term Storage...290
TROUBLES AND ACTIONS...291
Running Out Of Fuel...291
Phenomena That Are Not Failures...291
Towing The Machine...292
Lightweight Towing Hole...293
Severe Job Condition...293
Discharged Battery...294
Battery Removal and Installation...294
Battery Charges...295
Starting Engine with Booster Cables...296
OTHER TROUBLE...298
Electrical System...298
Chassis...299
Engine...300
Electronic Control System...302
Point of Contact to Telephone when Error Occurs...302
MAINTENANCE...303
MAINTENANCE INFORMATION...304
OUTLINE OF SERVICE...306
Handling Oil, Fuel, Coolant, And Performing Oil Clinic...306
Oil...306
Fuel...307
Coolant And Water For Dilution...307
Grease...308
Carrying Out KOWA (Komatsu Oil Wear Analysis)...308
Storing Oil And Fuel...309
Filters...309
Electric System Maintenance...309
WEAR PARTS...310
Wear Parts List...310
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...311
Lubrication Chart...311
Fuel, Coolant, and Lubricants to Match the Ambient Temperature...313
KDPF (Komatsu Diesel Particulate Filter)...313
Recommended Brands, Recommended Quality For Products Other Than Komatsu Genuine Oil...314
TORQUE SPECIFICATIONS...315
Torque List...315
Torque Of Bolts...315
Torque Of Hose Nuts...316
Torque Of Split Flange Bolts...316
Torque For Flared Nuts...317
Torque For O-ring Boss Piping Joints...317
Torque For O-ring Boss Plugs...318
Torque For Hoses (Taper Seal Type And Face Seal Type)...318
SAFETY CRITICAL PARTS...320
Safety Critical Parts List...321
MAINTENANCE SCHEDULE...322
Maintenance Schedule Table...322
Maintenance Interval For Hydraulic Breaker...324
MAINTENANCE PROCEDURE...325
Initial 10 Hours Maintenance...325
Initial 250 Hours Maintenance (Only After The First 250 Hours)...325
Initial 500 Hours Maintenance (Only After The First 500 Hours)...325
When Required...326
Check, Clean And Replace Air Cleaner Element...326
Clean Inside Of Cooling System...333
Check And Tighten Track Shoe Bolts...338
Check And Adjust Track Tension...339
Replace Bucket Teeth (Vertical Pin Type)...341
Replace Bucket Teeth (Horizontal Pin Type)...344
Replace Bucket Side Cutter, Shroud...346
Adjust Bucket Clearance...347
Check Window Washer Fluid Level, Add Fluid...348
Check And Maintenance Air Conditioner...349
Wash Washable Floor...350
Method of Setting Machine at Angle...352
Check Gas Spring...353
Bleeding Air From Hydraulic System...354
Check Before Starting...356
Every 100 Hours Maintenance...357
Lubricating...357
Every 250 Hours Maintenance...358
Check Level Of Battery Electrolyte...358
Check Air Conditioner Compressor Belt Tension, Adjust...360
Every 500 Hours Maintenance...362
Lubricating...362
Change Oil In Engine Oil Pan...364
Replace Engine Oil Filter Cartridge...364
Replace Fuel Pre-filter Cartridge...366
Check Swing Pinion Grease Level, Add Grease...368
Clean And Inspect Radiator Fins, Oil Cooler Fins, Aftercooler Fins, Fuel Cooler Fins, And Condenser Fins...369
Clean Air Conditioner Fresh/Recirc Filters...371
Replace Breather Element In Hydraulic Tank...373
Check Oil Level In Swing Machinery Case, Add Oil...374
Check Oil Level In Final Drive Case, Add Oil...375
Every 1000 Hours Maintenance...376
Replace Hydraulic Oil Filter Element...376
Change Oil In Swing Machinery Case...377
Check Oil Level In Damper Case, Add Oil...378
Replace Fuel Main Filter Cartridge...379
Check All Tightening Points Of Engine Exhaust Pipe Clamps...382
Check Fan Belt Tension And Replace Fan Belt...382
Check Nitrogen Gas Charge Pressure In Accumulator (For Breaker)...382
Every 2000 Hours Maintenance...383
Change Oil In Final Drive Case...383
Clean Hydraulic Tank Strainer...384
Checking Charge Pressure Of Nitrogen Gas In Accumulator (For Control Circuit)...385
Check Alternator...388
Check Engine Valve Clearance, Adjust...388
Replace Komatsu Closed Crankcase Ventilation (KCCV) Filter Element...389
Every 4000 Hours Maintenance...392
Check Water Pump...392
Check Vibration Damper...392
Check Starting Motor...392
Replace Accumulator (For Control Circuit)...393
Check For Looseness Of High-pressure Piping Clamp, Hardening Of Rubber...394
Check For Missing Fuel Spray Prevention Cap, Hardening Of Rubber...394
Check Operating Condition Of Compressor...395
Every 4500 Hours Maintenance...396
Clean Komatsu Diesel Particulate Filter (KDPF)...396
Replace Komatsu Closed Crankcase Ventilation (KCCV) Hose...396
Every 5000 Hours Maintenance...397
Change Oil In Hydraulic Tank...397
Every 8000 Hours Maintenance...398
Replace Fuel Spray Prevention Cap...398
Replace High-pressure Piping Clamp...398
SPECIFICATIONS...399
SPECIFICATIONS...400
OPTIONS, ATTACHMENTS...403
GENERAL PRECAUTIONS FOR SAFETY...404
Precautions When Selecting...404
Read The Operation and Maintenance Manual Thoroughly...404
Precautions When Removing Or Installing...404
Precautions When Using...404
BUCKET WITH HOOK...406
Hook Condition...406
Prohibited Operations...406
CHANGING DIRECTION OF THE MACHINE...407
Straight Travel (Option)...408
CHANGING MACHINE CONTROL PATTERN...409
Control Pattern Change Procedure...409
MACHINE READY FOR ATTACHMENT...411
Locations...411
Stop Valve...411
Selector Valve...412
Attachment Control Pedal...412
Lock Pin...412
Breaker Circuit Additional Oil Filter...413
Accumulator...414
HYDRAULIC CIRCUIT...415
Switching Hydraulic Circuit...415
Switching Between Breaker and General Attachment...415
Hydraulic Circuit Connection...416
Oil Flow Path...417
Replace Additional Breaker Filter Element...418
Replace Additional Breaker Pilot Filter Element...421
ATTACHMENT REMOVAL AND INSTALLATION...424
Attachment Removal...424
Attachment Installation...426
ATTACHMENT OPERATIONS...428
When Using Breaker...428
When Using General Attachment Such as Crusher...431
LONG TERM STORAGE...432
Specifications...432
Attachment Guide...433
Attachment Combinations...433
TRACK SHOES SELECTION...434
BUCKET TEETH SELECTION...435
Selection Guide for Horizontal or Vertical Pin Type Tooth...435
RECOMMENDED ATTACHMENT OPERATIONS...436
Hydraulic Breaker...436
Prohibited Works...438
