Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC238USLC, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu Hydraulic Excavator PC238USLC-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: 2,841 pages
File Format: PDF
Language: English
SEN06635-04 – Komatsu Hydraulic Excavator PC238USLC-11 Shop Manual.pdf
MAIN SECTIONS
COVER…1
00 INDEX AND FOREWORD…3
INDEX…4
ABBREVIATION LIST…21
FOREWORD, SAFETY, BASIC INFORMATION…27
HOW TO READ THE SHOP MANUAL…27
SAFETY NOTICE FOR OPERATION…29
PRECAUTIONS TO PREVENT FIRE…37
ACTIONS IF FIRE OCCURS…39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS…40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS…41
PRECAUTIONS FOR DEF…42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING…42
PRECAUTIONS FOR ADDING…42
PRECAUTIONS FOR STORING…42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE…42
THE OTHER PRECAUTIONS…42
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT…43
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS…46
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT…53
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT…55
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT…56
PRACTICAL USE OF KOMTRAX…57
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER…58
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER…58
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER…59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER…60
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS…62
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR…66
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR…67
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL…69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH…70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE…72
HOW TO READ ELECTRICAL WIRE CODE…73
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD…77
STANDARD TIGHTENING TORQUE TABLE…80
CONVERSION TABLE…87
01 SPECIFICATIONS…93
CONTENTS…94
ABBREVIATION LIST…95
SPECIFICATIONS…101
SPECIFICATION DRAWING…101
SPECIFICATION DRAWING: PC238USLC-11…101
WORKING RANGE DRAWINGS…103
WORKING RANGE: PC238USLC-11…103
SPECIFICATIONS…104
SPECIFICATIONS: PC238USLC-11…104
WEIGHT TABLE…107
WEIGHT TABLE: PC238USLC-11…107
FUEL, COOLANT, LUBRICANTS (FOR NORTH AMERICA)…109
USE OF FUEL, COOLANT AND LUBRICANTS TO ACCORDING TO AMBIENT TEMPERATURE…109
10 STRUCTURE AND FUNCTION…111
CONTENTS…112
ABBREVIATION LIST…115
UREA SCR SYSTEM…121
LAYOUT DRAWING OF UREA SCR SYSTEM…121
UREA SCR SYSTEM DIAGRAM…126
FUNCTION OF UREA SCR SYSTEM…127
FUNCTION OF AdBlue/DEF SYSTEM…127
INDUCEMENT STRATEGY…129
COMPONENT PARTS OF UREA SCR SYSTEM…137
AdBlue/DEF MIXING TUBE…137
SCR ASSEMBLY…138
AdBlue/DEF TANK…140
AdBlue/DEF PUMP…142
AdBlue/DEF INJECTOR…143
AdBlue/DEF HOSE…144
AdBlue/DEF TANK HEATING VALVE…145
BOOT-UP SYSTEM…146
LAYOUT DRAWING OF BOOT-UP SYSTEM…146
SYSTEM OPERATING LAMP SYSTEM…148
SYSTEM OPERATING LAMP SYSTEM DIAGRAM…148
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM…148
BATTERY DISCONNECT SWITCH…149
FUNCTION OF BATTERY DISCONNECT SWITCH…149
ENGINE SYSTEM…150
LAYOUT DRAWING OF ENGINE SYSTEM…150
SPECIFICATIONS OF ENGINE SYSTEM…151
FUNCTION OF ENGINE SYSTEM…151
ENGINE CONTROL SYSTEM…152
ENGINE CONTROL SYSTEM DIAGRAM…152
FUNCTION OF ENGINE CONTROL SYSTEM…153
AUTO-DECELERATION SYSTEM…155
AUTO-DECELERATION SYSTEM DIAGRAM…155
FUNCTION OF AUTO-DECELERATION SYSTEM…155
OPERATION OF AUTO-DECELERATION SYSTEM…156
ENGINE AUTOMATIC WARM-UP SYSTEM…157
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM…157
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM…158
OVERHEAT PREVENTION SYSTEM…159
OVERHEAT PREVENTION SYSTEM DIAGRAM…159
FUNCTION OF OVERHEAT PREVENTION SYSTEM…160
TURBOCHARGER PROTECTION SYSTEM…162
TURBOCHARGER PROTECTION SYSTEM DIAGRAM…162
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM…163
AUTOMATIC IDLE STOP SYSTEM…164
AUTOMATIC IDLE STOP SYSTEM DIAGRAM…164
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM…164
COMPONENT PARTS OF ENGINE SYSTEM…167
VGT…167
EGR SYSTEM…172
EGR VALVE…174
EGR COOLER…176
KCCV SYSTEM…178
KCCV VENTILATOR…180
KDPF…182
COOLING SYSTEM…186
LAYOUT DRAWING OF COOLING SYSTEM…186
SPECIFICATIONS OF COOLING SYSTEM…187
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH…188
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH…188
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH…189
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH…190
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH…190
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH…190
COMPONENT PARTS OF COOLING SYSTEM…192
FAN CLUTCH…192
CONTROL SYSTEM…193
LAYOUT DRAWING OF CONTROL SYSTEM…193
MACHINE MONITOR SYSTEM…196
MACHINE MONITOR SYSTEM DIAGRAM…196
FUNCTION OF MACHINE MONITOR SYSTEM…196
KomVision SYSTEM…198
LAYOUT DRAWING OF KomVision SYSTEM…198
KomVision SYSTEM DIAGRAM…200
FUNCTION OF KomVision SYSTEM…200
KOMTRAX SYSTEM…202
KOMTRAX SYSTEM DIAGRAM…202
FUNCTION OF KOMTRAX SYSTEM…202
COMPONENT PARTS OF CONTROL SYSTEM…203
MACHINE MONITOR…203
KomVision CONTROLLER…222
KomVision CAMERA…226
KOMTRAX TERMINAL…227
PUMP CONTROLLER…229
RESISTOR FOR PC-EPC VALVE…234
CAN TERMINATING RESISTOR…235
ENGINE CONTROLLER…236
FUEL CONTROL DIAL…243
HYDRAULIC SYSTEM…245
LAYOUT DRAWING OF HYDRAULIC SYSTEM…245
CLSS…249
STRUCTURE OF CLSS…249
OPERATION OF UNLOAD VALVE AND LS PRESSURE…251
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL…252
PRESSURE COMPENSATION CONTROL…265
ENGINE AND PUMP COMBINED CONTROL SYSTEM…268
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM…268
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM…270
PUMP AND VALVE CONTROL SYSTEM…275
PUMP AND VALVE CONTROL SYSTEM DIAGRAM…275
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM…276
COMPONENT PARTS OF HYDRAULIC SYSTEM…278
HYDRAULIC TANK…278
MAIN PUMP…280
CONTROL VALVE…306
WORK EQUIPMENT SYSTEM…364
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM…364
ONE-TOUCH POWER MAXIMIZING SYSTEM…369
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM…369
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM…370
PPC LOCK SYSTEM…371
PPC LOCK SYSTEM DIAGRAM…371
FUNCTION OF PPC LOCK SYSTEM…371
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM…372
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM…372
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM…372
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM…373
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT…374
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM…374
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT…375
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM…376
WORK EQUIPMENT AND SWING PPC VALVE…376
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)…382
2ND-LINE ATTACHMENT PPC VALVE…387
SOLENOID VALVE…389
BOOM ANGLE POTENTIOMETER…393
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)…394
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)…396
PILOT CIRCUIT ACCUMULATOR…398
ATTACHMENT CIRCUIT ACCUMULATOR…399
SWING SYSTEM…400
LAYOUT DRAWING OF SWING SYSTEM…400
SWING CONTROL SYSTEM DIAGRAM…404
FUNCTION OF SWING CONTROL SYSTEM…404
COMPONENT PARTS OF SWING SYSTEM…408
SWING MOTOR…408
SWING MACHINERY…420
SWING CIRCLE…422
TRAVEL SYSTEM…423
LAYOUT DRAWING OF TRAVEL SYSTEM…423
TRAVEL CONTROL SYSTEM DIAGRAM…427
FUNCTION OF TRAVEL CONTROL SYSTEM…428
COMPONENT PARTS OF TRAVEL SYSTEM…429
TRAVEL MOTOR…429
FINAL DRIVE…442
TRAVEL PPC VALVE…444
CENTER SWIVEL JOINT…448
UNDERCARRIAGE AND FRAME…450
LAYOUT DRAWING OF UNDERCARRIAGE…450
SPECIFICATIONS OF UNDERCARRIAGE…451
WORK EQUIPMENT…452
STRUCTURE OF WORK EQUIPMENT…452
FUNCTION OF WORK EQUIPMENT…453
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM…454
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM…454
BUCKET CLEARANCE ADJUSTMENT SHIM…455
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM…455
CAB AND ITS ATTACHMENTS…456
ROPS CAB…456
STRUCTURE OF ROPS CAB…456
FUNCTION OF ROPS CAB…456
CAB MOUNT…457
STRUCTURE OF CAB MOUNT…457
FUNCTION OF CAB MOUNT…457
CAB TIPPING STOPPER…458
STRUCTURE OF CAB TIPPING STOPPER…458
FUNCTION OF CAB TIPPING STOPPER…458
TAKE WIRING HARNESS OUT OF CAB…459
20 STANDARD VALUE TABLE…461
CONTENTS…462
ABBREVIATION LIST…463
STANDARD VALUE TABLE FOR ENGINE…469
STANDARD VALUE TABLE FOR ENGINE: PC238USLC-11…469
STANDARD VALUE TABLE FOR MACHINE…474
Japanese Only…474
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE…488
30 TESTING AND ADJUSTING…493
CONTENTS…494
ABBREVIATION LIST…497
RELATED INFORMATION ON TESTING AND ADJUSTING…503
TOOLS FOR TESTING AND ADJUSTING…503
SKETCH OF TOOLS FOR TESTING AND ADJUSTING…509
ENGINE AND COOLING SYSTEM…510
TEST ENGINE SPEED…510
METHOD FOR TESTING ENGINE SPEED…510
TEST BOOST PRESSURE…513
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR…513
METHOD FOR TESTING BOOST PRESSURE…514
TEST EXHAUST GAS COLOR…516
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER…516
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER…517
TEST AND ADJUST VALVE CLEARANCE…519
METHOD FOR TESTING VALVE CLEARANCE…519
METHOD FOR ADJUSTING VALVE CLEARANCE…520
TEST COMPRESSION PRESSURE…521
METHOD FOR TESTING COMPRESSION PRESSURE…521
TEST BLOWBY PRESSURE…526
METHOD FOR TESTING BLOWBY PRESSURE…526
TEST ENGINE OIL PRESSURE…528
METHOD FOR TESTING ENGINE OIL PRESSURE…528
TEST EGR VALVE AND VGT OIL PRESSURE…529
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE…529
TEST FUEL PRESSURE…531
METHOD FOR TESTING FUEL PRESSURE…532
TEST FUEL DISCHARGE, RETURN AND LEAKAGE…537
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE…538
BLEEDING AIR FROM FUEL SYSTEM…544
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM…544
TEST FUEL CIRCUIT FOR LEAKAGE…545
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE…545
HANDLE CYLINDER CUT-OUT MODE OPERATION…547
HANDLE NO-INJECTION CRANKING OPERATION…548
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION…549
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT…549
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT…549
TEST COOLING FAN SPEED…551
METHOD FOR TESTING COOLING FAN SPEED…551
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER…552
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER…552
TEST SCR RELATED FUNCTIONS…553
TEST AdBlue/DEF PUMP RAISED PRESSURE…557
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR…560
TEST AdBlue/DEF LINE HEATER RELAY 1…564
TEST AdBlue/DEF LINE HEATER RELAY 2…568
TEST AdBlue/DEF PUMP HEATER RELAY…571
TEST AdBlue/DEF TANK HEATER VALVE…574
TEST DENITRATION EFFICIENCY OF SCR…577
CLEAN AdBlue/DEF TANK…581
METHOD FOR CLEANING AdBlue/DEF TANK…581
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK…585
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK…585
POWER TRAIN…587
TEST SWING CIRCLE BEARING CLEARANCE…587
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE…587
UNDERCARRIAGE AND FRAME…588
TEST AND ADJUST TRACK TENSION…588
METHOD FOR TESTING TRACK TENSION…588
METHOD FOR ADJUSTING TRACK TENSION…588
HYDRAULIC SYSTEM…590
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM…590
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK…590
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT…590
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT…594
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT…595
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS…596
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS…597
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS…605
TEST OIL PRESSURE OF CONTROL CIRCUIT…607
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT…607
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT…609
METHOD FOR TESTING PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)…609
METHOD FOR TESTING PC-EPC VALVE OUTLET PRESSURE…610
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT…611
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT…613
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR…613
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE…615
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)…616
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE…617
METHOD FOR ADJUSTING LS VALVE…618
TEST OUTLET PRESSURE OF SOLENOID VALVE…619
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE…619
OPERATING CONDITION OF SOLENOID VALVE…620
TEST PPC VALVE OUTLET PRESSURE…623
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE…623
ADJUST WORK EQUIPMENT AND SWING PPC VALVES…626
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES…626
TEST PUMP SWASH PLATE SENSOR…627
METHOD FOR TESTING PUMP SWASH PLATE SENSOR…627
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT…628
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER…628
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER…629
METHOD FOR TESTING OF THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM LOCK VALVE…629
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE…629
TEST OIL LEAKAGE…631
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER…631
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER…631
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER…632
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR…632
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR…633
BLEED AIR FROM HYDRAULIC CIRCUIT…634
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT…636
WORK EQUIPMENT…638
ADJUST BOOM ANGLE POTENTIOMETER…638
METHOD FOR ADJUSTING BOOM ANGLE POTENTIOMETER…638
CAB AND ITS ATTACHMENTS…639
TEST CAB TIPPING STOPPER…639
METHOD FOR TESTING CAB TIPPING STOPPER…639
METHOD FOR ADJUSTING MIRRORS…640
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A)…640
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A)…641
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B)…642
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B)…643
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (C)…644
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (C)…644
PROCEDURE FOR ADJUSTING MACHINE REAR MIRROR (D)…646
ELECTRICAL SYSTEM…647
SET AND OPERATE MACHINE MONITOR…647
OPERATOR MODE…651
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN…651
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN…651
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)…652
CHECKING FUNCTION OF SERVICE METER…652
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD…652
SERVICE MODE…655
METHOD FOR OPERATING SERVICE MODE…655
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION…657
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION…664
ABNORMALITY RECORD MENU…676
METHOD FOR CONFIRMING MAINTENANCE RECORD…680
METHOD FOR OPERATING MAINTENANCE MODE SETTING…681
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING…685
DEFAULT MENU…687
DIAGNOSTIC TESTS MENU…694
ADJUSTMENT MENU…704
METHOD FOR PERFORMING NO-INJECTION CRANKING…724
KOMTRAX SETTINGS MENU…726
METHOD FOR DISPLAYING SERVICE MESSAGE…728
METHOD FOR STARTING UP KOMTRAX TERMINAL…730
ADJUST REARVIEW CAMERA ANGLE…735
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE…735
ADJUST KomVision CAMERA ANGLE…737
METHOD FOR ADJUSTING KomVision CAMERA ANGLE…738
ADJUST KomVision RELATED ITEMS…740
SETTING OF KomVision (MAIN SETTING)…741
SETTING OF KomVision (CAMERA SETTING)…744
SETTING OF KomVision (CAMERA CALIBRATION)…746
KomVision screen – Check 12 m visibility…758
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER…761
HANDLE BATTERY DISCONNECT SWITCH…762
TEST DIODES…763
METHOD FOR TESTING DIODE USING DIGITAL TESTER…763
METHOD FOR TESTING DIODE USING ANALOG TESTER…763
Pm CLINIC…764
Pm CLINIC SERVICE…764
Pm CLINIC CHECK SHEET: PC238USLC-11…766
40 TROUBLESHOOTING…775
CONTENTS…776
ABBREVIATION LIST…787
RELATED INFORMATION ON TROUBLESHOOTING…793
GENERAL TROUBLESHOOTING POINTS…793
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM…794
SEQUENCE OF EVENTS IN TROUBLESHOOTING…806
CHECKS BEFORE TROUBLESHOOTING…808
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING…810
WALK-AROUND CHECK…810
TESTING IN ACCORDANCE WITH TESTING PROCEDURE…812
CHECK FUEL LEVEL AND TYPE…812
CHECK IMPURE INGREDIENT IN FUEL…812
CHECK FUEL PREFILTER…813
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT…813
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE…814
CHECK MAIN FILTER…815
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN)…817
CHECK COOLANT LEVEL (RESERVOIR TANK)…818
CHECK CLOGGING OF AIR CLEANER…818
OUTER ELEMENT – CLEAN…819
ELEMENTS – REPLACE…821
CHECK HYDRAULIC OIL LEVEL…822
CHECK HYDRAULIC OIL STRAINER…823
CHECK HYDRAULIC FILTER…824
CHECK OIL LEVEL IN SWING MACHINERY CASE…825
CHECK OIL LEVEL IN DAMPER CASE…826
CHECK OIL LEVEL IN FINAL DRIVE CASE…826
BLEED AIR FROM FUEL SYSTEM…827
BLEED AIR FROM HYDRAULIC SYSTEM…827
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod…827
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM…833
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR…833
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER…833
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER…834
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL…834
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH SPECIAL LOCK…835
PROCEDURE FOR TESTING AND TROUBLESHOOTING…840
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS…843
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE…847
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM…849
CONNECTORS LIST AND LAYOUT…852
CONNECTOR CONTACT IDENTIFICATION…866
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE…906
FUSE LOCATION TABLE…912
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)…914
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])…918
FAILURE CODES TABLE…920
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)…937
FAILURE CODE [879AKA]…937
FAILURE CODE [879AKB]…938
FAILURE CODE [879BKA]…939
FAILURE CODE [879BKB]…941
FAILURE CODE [879CKA]…943
FAILURE CODE [879CKB]…944
FAILURE CODE [879DKZ]…945
FAILURE CODE [879EMC]…947
FAILURE CODE [879FMC]…948
FAILURE CODE [879GKX]…949
FAILURE CODE [989L00]…951
FAILURE CODE [989M00]…952
FAILURE CODE [989N00]…953
FAILURE CODE [A1U0N3]…954
FAILURE CODE [A1U0N4]…956
FAILURE CODE [A900FR]…958
FAILURE CODE [A900N6]…959
FAILURE CODE [A900NY]…960
FAILURE CODE [AA10NX]…961
FAILURE CODE [AB00KE]…963
FAILURE CODE [AQ10N3]…965
FAILURE CODE [AS00N3]…967
FAILURE CODE [AS00R2]…969
FAILURE CODE [AS00R3]…970
FAILURE CODE [AS00R4]…971
FAILURE CODE [AS00R5]…972
FAILURE CODE [AS00R6]…973
FAILURE CODE [AS00ZK]…974
FAILURE CODE [AS10KM]…975
FAILURE CODE [AS10NR]…976
FAILURE CODE [AS10NT]…977
FAILURE CODE [B@BAZG]…978
FAILURE CODE [B@BAZK]…980
FAILURE CODE [B@BCNS]…982
FAILURE CODE [B@BCQA]…984
FAILURE CODE [B@BCZK]…986
FAILURE CODE [B@HANS]…988
FAILURE CODE [CA115]…990
FAILURE CODE [CA122]…995
FAILURE CODE [CA123]…998
FAILURE CODE [CA131]…1000
FAILURE CODE [CA132]…1002
FAILURE CODE [CA144]…1004
FAILURE CODE [CA145]…1006
FAILURE CODE [CA153]…1008
FAILURE CODE [CA154]…1010
FAILURE CODE [CA187]…1012
FAILURE CODE [CA221]…1014
FAILURE CODE [CA222]…1016
FAILURE CODE [CA227]…1018
FAILURE CODE [CA234]…1019
FAILURE CODE [CA238]…1020
FAILURE CODE [CA239]…1021
FAILURE CODE [CA249]…1022
FAILURE CODE [CA256]…1024
FAILURE CODE [CA271]…1026
FAILURE CODE [CA272]…1028
FAILURE CODE [CA322]…1030
FAILURE CODE [CA323]…1032
FAILURE CODE [CA324]…1034
FAILURE CODE [CA325]…1036
FAILURE CODE [CA331]…1038
FAILURE CODE [CA332]…1040
FAILURE CODE [CA343]…1042
FAILURE CODE [CA351]…1044
FAILURE CODE [CA352]…1046
FAILURE CODE [CA356]…1048
FAILURE CODE [CA357]…1050
FAILURE CODE [CA386]…1052
FAILURE CODE [CA428]…1054
FAILURE CODE [CA429]…1056
FAILURE CODE [CA435]…1058
FAILURE CODE [CA441]…1060
FAILURE CODE [CA442]…1062
FAILURE CODE [CA449]…1063
FAILURE CODE [CA451]…1064
FAILURE CODE [CA452]…1066
FAILURE CODE [CA488]…1068
FAILURE CODE [CA515]…1071
FAILURE CODE [CA516]…1073
FAILURE CODE [CA553]…1075
FAILURE CODE [CA555]…1076
FAILURE CODE [CA556]…1078
FAILURE CODE [CA559]…1080
FAILURE CODE [CA595]…1083
FAILURE CODE [CA687]…1085
FAILURE CODE [CA689]…1087
FAILURE CODE [CA691]…1090
FAILURE CODE [CA692]…1092
FAILURE CODE [CA697]…1094
FAILURE CODE [CA698]…1095
FAILURE CODE [CA731]…1096
FAILURE CODE [CA778]…1098
FAILURE CODE [CA1117]…1103
FAILURE CODE [CA1664]…1104
FAILURE CODE [CA1669]…1107
FAILURE CODE [CA1673]…1108
FAILURE CODE [CA1677]…1109
FAILURE CODE [CA1678]…1110
FAILURE CODE [CA1682]…1111
FAILURE CODE [CA1683]…1115
FAILURE CODE [CA1684]…1117
FAILURE CODE [CA1686]…1119
FAILURE CODE [CA1691]…1120
FAILURE CODE [CA1694]…1123
FAILURE CODE [CA1695]…1125
FAILURE CODE [CA1696]…1127
FAILURE CODE [CA1712]…1129
FAILURE CODE [CA1713]…1132
FAILURE CODE [CA1714]…1135
FAILURE CODE [CA1715]…1136
FAILURE CODE [CA1776]…1137
FAILURE CODE [CA1777]…1140
FAILURE CODE [CA1843]…1143
FAILURE CODE [CA1844]…1145
FAILURE CODE [CA1879]…1147
FAILURE CODE [CA1881]…1149
FAILURE CODE [CA1883]…1151
FAILURE CODE [CA1885]…1156
FAILURE CODE [CA1887]…1158
FAILURE CODE [CA1921]…1160
FAILURE CODE [CA1922]…1163
FAILURE CODE [CA1942]…1168
FAILURE CODE [CA1993]…1170
FAILURE CODE [CA2185]…1173
FAILURE CODE [CA2186]…1174
FAILURE CODE [CA2249]…1176
FAILURE CODE [CA2271]…1179
FAILURE CODE [CA2272]…1181
FAILURE CODE [CA2288]…1183
FAILURE CODE [CA2311]…1185
FAILURE CODE [CA2349]…1187
FAILURE CODE [CA2353]…1189
FAILURE CODE [CA2357]…1191
FAILURE CODE [CA2381]…1194
FAILURE CODE [CA2382]…1196
FAILURE CODE [CA2383]…1199
FAILURE CODE [CA2386]…1201
FAILURE CODE [CA2387]…1203
FAILURE CODE [CA2555]…1206
FAILURE CODE [CA2556]…1208
FAILURE CODE [CA2637]…1210
FAILURE CODE [CA2639]…1212
FAILURE CODE [CA2771]…1214
FAILURE CODE [CA2777]…1219
FAILURE CODE [CA2976]…1222
FAILURE CODE [CA3133]…1224
FAILURE CODE [CA3134]…1226
FAILURE CODE [CA3135]…1228
FAILURE CODE [CA3142]…1231
FAILURE CODE [CA3143]…1232
FAILURE CODE [CA3144]…1233
FAILURE CODE [CA3146]…1236
FAILURE CODE [CA3147]…1237
FAILURE CODE [CA3148]…1238
FAILURE CODE [CA3151]…1241
FAILURE CODE [CA3165]…1248
FAILURE CODE [CA3229]…1250
FAILURE CODE [CA3231]…1253
FAILURE CODE [CA3232]…1256
FAILURE CODE [CA3235]…1261
FAILURE CODE [CA3239]…1264
FAILURE CODE [CA3241]…1267
FAILURE CODE [CA3242]…1269
FAILURE CODE [CA3251]…1272
FAILURE CODE [CA3253]…1274
FAILURE CODE [CA3254]…1278
FAILURE CODE [CA3255]…1282
FAILURE CODE [CA3256]…1285
FAILURE CODE [CA3311]…1288
FAILURE CODE [CA3312]…1291
FAILURE CODE [CA3313]…1294
FAILURE CODE [CA3314]…1295
FAILURE CODE [CA3315]…1296
FAILURE CODE [CA3316]…1298
FAILURE CODE [CA3317]…1299
FAILURE CODE [CA3318]…1300
FAILURE CODE [CA3319]…1303
FAILURE CODE [CA3321]…1305
FAILURE CODE [CA3322]…1307
FAILURE CODE [CA3419]…1310
FAILURE CODE [CA3421]…1312
FAILURE CODE [CA3497]…1314
FAILURE CODE [CA3498]…1315
FAILURE CODE [CA3543]…1316
FAILURE CODE [CA3545]…1322
FAILURE CODE [CA3547]…1324
FAILURE CODE [CA3558]…1325
FAILURE CODE [CA3559]…1327
FAILURE CODE [CA3562]…1329
FAILURE CODE [CA3563]…1331
FAILURE CODE [CA3567]…1334
FAILURE CODE [CA3568]…1337
FAILURE CODE [CA3571]…1342
FAILURE CODE [CA3572]…1344
FAILURE CODE [CA3574]…1346
FAILURE CODE [CA3575]…1349
FAILURE CODE [CA3577]…1351
FAILURE CODE [CA3578]…1353
FAILURE CODE [CA3582]…1355
FAILURE CODE [CA3583]…1364
FAILURE CODE [CA3596]…1366
FAILURE CODE [CA3649]…1370
FAILURE CODE [CA3681]…1373
FAILURE CODE [CA3682]…1378
FAILURE CODE [CA3713]…1383
FAILURE CODE [CA3717]…1386
FAILURE CODE [CA3718]…1387
FAILURE CODE [CA3725]…1388
FAILURE CODE [CA3741]…1391
FAILURE CODE [CA3748]…1392
FAILURE CODE [CA3751]…1395
FAILURE CODE [CA3755]…1397
FAILURE CODE [CA3866]…1399
FAILURE CODE [CA3867]…1403
FAILURE CODE [CA3868]…1406
FAILURE CODE [CA3899]…1411
FAILURE CODE [CA3911]…1413
FAILURE CODE [CA3912]…1418
FAILURE CODE [CA3932]…1420
FAILURE CODE [CA3933]…1422
FAILURE CODE [CA3934]…1424
FAILURE CODE [CA3935]…1427
FAILURE CODE [CA3936]…1429
FAILURE CODE [CA4151]…1431
FAILURE CODE [CA4152]…1437
FAILURE CODE [CA4155]…1442
FAILURE CODE [CA4156]…1444
FAILURE CODE [CA4157]…1447
FAILURE CODE [CA4158]…1449
FAILURE CODE [CA4159]…1450
FAILURE CODE [CA4161]…1451
FAILURE CODE [CA4162]…1454
FAILURE CODE [CA4163]…1457
FAILURE CODE [CA4164]…1458
FAILURE CODE [CA4165]…1460
FAILURE CODE [CA4166]…1462
FAILURE CODE [CA4168]…1464
FAILURE CODE [CA4169]…1468
FAILURE CODE [CA4171]…1472
FAILURE CODE [CA4249]…1476
FAILURE CODE [CA4251]…1480
FAILURE CODE [CA4259]…1484
FAILURE CODE [CA4261]…1487
FAILURE CODE [CA4277]…1490
FAILURE CODE [CA4281]…1492
FAILURE CODE [CA4459]…1495
FAILURE CODE [CA4461]…1497
FAILURE CODE [CA4658]…1500
FAILURE CODE [CA4731]…1503
FAILURE CODE [CA4732]…1504
FAILURE CODE [CA4739]…1505
FAILURE CODE [CA4768]…1506
FAILURE CODE [CA4769]…1508
FAILURE CODE [CA4842]…1511
FAILURE CODE [CA4952]…1514
FAILURE CODE [CA5115]…1516
FAILURE CODE [CA5179]…1519
FAILURE CODE [CA5181]…1521
FAILURE CODE [CA5383]…1523
FAILURE CODE [D110KB]…1525
FAILURE CODE [D19JKZ]…1527
FAILURE CODE [D811MC]…1530
FAILURE CODE [D862KA]…1531
FAILURE CODE [D8ALKA]…1532
FAILURE CODE [D8ALKB]…1534
FAILURE CODE [D8AQKR]…1536
FAILURE CODE [DA20MC]…1540
FAILURE CODE [DA22KK]…1541
FAILURE CODE [DA25KP]…1544
FAILURE CODE [DA29KQ]…1547
FAILURE CODE [DA2LKA]…1550
FAILURE CODE [DA2LKB]…1552
FAILURE CODE [DA2QKR]…1554
FAILURE CODE [DA2RKR]…1559
FAILURE CODE [DAF0KM]…1564
FAILURE CODE [DAF0MB]…1565
FAILURE CODE [DAF0MC]…1566
FAILURE CODE [DAF8KB]…1567
FAILURE CODE [DAF9KQ]…1569
FAILURE CODE [DAFGMC]…1570
FAILURE CODE [DAFLKA]…1571
FAILURE CODE [DAFLKB]…1573
FAILURE CODE [DAFQKR]…1575
FAILURE CODE [DAZ9KQ]…1579
FAILURE CODE [DAZQKR]…1580
FAILURE CODE [DB2QKR]…1584
FAILURE CODE [DB2RKR]…1589
FAILURE CODE [DBP0KM]…1595
FAILURE CODE [DBP0KT]…1596
FAILURE CODE [DBPQKR]…1597
FAILURE CODE [DDNRKA]…1602
FAILURE CODE [DDNRKY]…1604
FAILURE CODE [DDNS00]…1606
FAILURE CODE [DFB1KZ]…1608
FAILURE CODE [DFB2KZ]…1610
FAILURE CODE [DFB3L8]…1612
FAILURE CODE [DFB4L8]…1614
FAILURE CODE [DFB5KZ]…1616
FAILURE CODE [DFB6KZ]…1618
FAILURE CODE [DGH2KA]…1620
FAILURE CODE [DGH2KB]…1622
FAILURE CODE [DHA4KA]…1624
FAILURE CODE [DHAAMA]…1626
FAILURE CODE [DHACMA]…1628
FAILURE CODE [DHPAMA]…1630
FAILURE CODE [DHPBMA]…1632
FAILURE CODE [DHS3MA]…1634
FAILURE CODE [DHS4MA]…1636
FAILURE CODE [DHS8MA]…1638
FAILURE CODE [DHS9MA]…1640
FAILURE CODE [DHSAMA]…1642
FAILURE CODE [DHSBMA]…1644
FAILURE CODE [DHSCMA]…1646
FAILURE CODE [DHSDMA]…1648
FAILURE CODE [DHSFMA]…1650
FAILURE CODE [DHSGMA]…1652
FAILURE CODE [DHSHMA]…1654
FAILURE CODE [DHSJMA]…1656
FAILURE CODE [DKR0MA]…1658
FAILURE CODE [DKR1MA]…1661
FAILURE CODE [DKULKA]…1664
FAILURE CODE [DKULKB]…1666
FAILURE CODE [DKULKY]…1668
FAILURE CODE [DLM5KA]…1670
FAILURE CODE [DLM5MB]…1672
FAILURE CODE [DR10KA]…1675
FAILURE CODE [DR21KX]…1678
FAILURE CODE [DR31KX]…1680
FAILURE CODE [DUMBKA]…1682
FAILURE CODE [DUMBKB]…1684
FAILURE CODE [DV20KB]…1686
FAILURE CODE [DW43KA]…1688
FAILURE CODE [DW43KB]…1690
FAILURE CODE [DW43KY]…1692
FAILURE CODE [DW45KA]…1694
FAILURE CODE [DW45KB]…1697
FAILURE CODE [DW45KY]…1700
FAILURE CODE [DW4CKY]…1702
FAILURE CODE [DW4GKA]…1704
FAILURE CODE [DW91KA]…1706
FAILURE CODE [DW91KB]…1708
FAILURE CODE [DW91KY]…1710
FAILURE CODE [DWA2KA]…1712
FAILURE CODE [DWA2KB]…1714
FAILURE CODE [DWA2KY]…1716
FAILURE CODE [DWK0KA]…1718
FAILURE CODE [DWK0KB]…1720
FAILURE CODE [DWK0KY]…1722
FAILURE CODE [DWK2KA]…1724
FAILURE CODE [DWK2KB]…1726
FAILURE CODE [DWK2KY]…1728
FAILURE CODE [DWK8KA]…1730
FAILURE CODE [DWK8KB]…1732
FAILURE CODE [DWK8KY]…1734
FAILURE CODE [DWN5KY]…1736
FAILURE CODE [DXA8KA]…1738
FAILURE CODE [DXA8KB]…1740
FAILURE CODE [DXA9KA]…1742
FAILURE CODE [DXA9KB]…1744
FAILURE CODE [DXE0KA]…1746
FAILURE CODE [DXE0KB]…1748
FAILURE CODE [DXE4KA]…1750
FAILURE CODE [DXE4KB]…1752
FAILURE CODE [DXE4KY]…1754
FAILURE CODE [DXE5KA]…1756
FAILURE CODE [DXE5KB]…1758
FAILURE CODE [DXE6KA]…1760
FAILURE CODE [DXE6KB]…1762
FAILURE CODE [DXE7KA]…1764
FAILURE CODE [DXE7KB]…1766
FAILURE CODE [DXE7KY]…1768
FAILURE CODE [DXE8KA]…1770
FAILURE CODE [DXE8KB]…1772
FAILURE CODE [DXE8KY]…1774
FAILURE CODE [DXE9KA]…1776
FAILURE CODE [DXE9KB]…1778
FAILURE CODE [DXE9KY]…1780
FAILURE CODE [DXEAKA]…1782
FAILURE CODE [DXEAKB]…1784
FAILURE CODE [DXEAKY]…1786
FAILURE CODE [DY20KA]…1788
FAILURE CODE [DY20MA]…1790
FAILURE CODE [DY2CKB]…1792
FAILURE CODE [DY2DKB]…1794
FAILURE CODE [DY2EKB]…1796
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…1798
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)…1798
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK…1804
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK…1807
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP…1809
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING…1811
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW…1814
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW…1815
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING…1816
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING…1817
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING…1818
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…1819
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…1820
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…1821
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…1822
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…1823
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING…1824
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM…1825
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL…1827
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM…1828
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE…1829
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM…1830
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE…1832
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED…1833
E-24 FUNCTION SWITCH DOES NOT OPERATE…1834
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)…1835
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF…1836
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER…1837
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED…1838
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED…1839
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE…1840
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE…1841
E-32 ALARM BUZZER CANNOT BE CANCELED…1843
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION…1844
E-34 SERVICE MODE CANNOT BE SELECTED…1845
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE…1846
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK…1849
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING…1851
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE…1854
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR…1856
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED…1858
E-41 ALARM DOES NOT SOUND DURING TRAVEL…1859
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED…1861
E-43 HORN DOES NOT SOUND…1862
E-44 HORN DOES NOT STOP SOUNDING…1865
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF…1867
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE…1868
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE…1870
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…1871
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…1872
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…1873
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…1874
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…1875
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…1876
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…1877
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…1878
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION…1879
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED…1881
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY…1883
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)…1884
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)…1884
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS…1885
FAILURE MODE AND CAUSE TABLE…1887
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK…1899
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER…1900
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR…1902
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP…1903
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS…1904
H-6 SPEED OR POWER OF BOOM IS LOW…1906
H-7 ARM SPEED OR POWER IS LOW…1911
H-8 BUCKET SPEED OR POWER IS LOW…1916
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION…1919
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE…1920
H-11 HYDRAULIC DRIFT OF ARM IS LARGE…1922
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE…1924
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES…1925
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE…1926
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE…1927
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED…1928
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED…1929
H-18 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER…1930
H-19 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY…1931
H-20 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW…1932
H-21 MACHINE DOES NOT TRAVEL STRAIGHT…1933
H-22 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW…1935
H-23 TRAVEL SPEED IS LOW…1938
H-24 ONE OF TRACKS DOES NOT RUN…1940
H-25 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST…1941
H-26 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT…1942
H-27 SWINGS ONLY IN ONE DIRECTION…1943
H-28 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)…1944
H-29 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION…1945
H-30 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)…1946
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)…1947
H-32 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING…1948
H-33 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING…1949
H-34 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)…1950
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)…1951
H-36 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY)…1952
H-37 UNUSUAL NOISE IS HEARD FROM AROUND FAN…1953
TROUBLESHOOTING OF ENGINE (S-MODE)…1954
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)…1954
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION…1955
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT…1956
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)…1957
S-4 ENGINE STARTABILITY IS POOR…1959
S-5 ENGINE DOES NOT PICK UP SMOOTHLY…1961
S-6 ENGINE STOPS DURING OPERATION…1963
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE…1965
S-8 ENGINE LACKS POWER…1966
S-9 KDPF GETS CLOGGED IN A SHORT TIME…1968
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE…1970
S-11 OIL BECOMES CONTAMINATED QUICKLY…1971
S-12 FUEL CONSUMPTION IS EXCESSIVE…1972
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)…1973
S-14 OIL PRESSURE DROPS…1974
S-15 FUEL MIXES INTO ENGINE OIL…1976
S-16 WATER MIXES INTO ENGINE OIL (MILKY)…1977
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)…1978
S-18 UNUSUAL NOISE IS HEARD…1979
S-19 VIBRATION IS EXCESSIVE…1980
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT…1981
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY…1982
S-22 ACTIVE REGENERATION TAKES TIME…1984
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION…1985
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE…1986
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)…1988
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)…1989
50 DISASSEMBLY AND ASSEMBLY…1991
CONTENTS…1992
ABBREVIATION LIST…1997
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY…2003
HOW TO READ THIS MANUAL…2003
COATING MATERIALS LIST…2005
SPECIAL TOOLS LIST…2009
SKETCHES OF SPECIAL TOOLS…2028
ENGINE AND COOLING SYSTEM…2034
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY…2034
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY…2034
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY…2037
REMOVE AND INSTALL INJECTOR ASSEMBLY…2040
METHOD FOR REMOVING INJECTOR ASSEMBLY…2041
METHOD FOR INSTALLING INJECTOR ASSEMBLY…2046
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY…2056
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY…2057
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY…2066
REMOVE AND INSTALL EGR VALVE ASSEMBLY…2082
METHOD FOR REMOVING EGR VALVE ASSEMBLY…2082
METHOD FOR INSTALLING EGR VALVE ASSEMBLY…2083
REMOVE AND INSTALL EGR COOLER ASSEMBLY…2085
METHOD FOR REMOVING EGR COOLER ASSEMBLY…2085
METHOD FOR INSTALLING EGR COOLER ASSEMBLY…2088
REMOVE AND INSTALL STARTER ASSEMBLY…2092
METHOD FOR REMOVING STARTER ASSEMBLY…2092
METHOD FOR INSTALLING STARTER ASSEMBLY…2094
REMOVE AND INSTALL ALTERNATOR BELT…2097
METHOD FOR REMOVING ALTERNATOR BELT…2097
METHOD FOR INSTALLING ALTERNATOR BELT…2100
REMOVE AND INSTALL RADIATOR ASSEMBLY…2103
METHOD FOR REMOVING RADIATOR ASSEMBLY…2103
METHOD FOR INSTALLING RADIATOR ASSEMBLY…2106
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY…2110
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY…2110
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY…2117
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY…2124
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY…2124
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY…2126
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY…2128
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY…2128
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY…2133
REMOVE AND INSTALL ENGINE ASSEMBLY…2138
METHOD FOR REMOVING ENGINE ASSEMBLY…2138
METHOD FOR INSTALLING ENGINE ASSEMBLY…2148
REMOVE AND INSTALL ENGINE FRONT OIL SEAL…2160
METHOD FOR REMOVING ENGINE FRONT OIL SEAL…2160
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL…2165
REMOVE AND INSTALL ENGINE REAR OIL SEAL…2170
METHOD FOR REMOVING ENGINE REAR OIL SEAL…2170
METHOD FOR INSTALLING ENGINE REAR OIL SEAL…2171
REMOVE AND INSTALL FUEL COOLER ASSEMBLY…2174
METHOD FOR REMOVING FUEL COOLER ASSEMBLY…2174
METHOD FOR INSTALLING FUEL COOLER ASSEMBLY…2176
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY…2178
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY…2178
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY…2179
REMOVE AND INSTALL FUEL TANK ASSEMBLY…2181
METHOD FOR REMOVING FUEL TANK ASSEMBLY…2181
METHOD FOR INSTALLING FUEL TANK ASSEMBLY…2187
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY…2194
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY…2195
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY…2202
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…2208
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…2209
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY…2216
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR…2221
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR…2221
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR…2222
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER…2224
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER…2224
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER…2224
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER…2225
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER…2225
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER…2227
REMOVE AND INSTALL KDPF ASSEMBLY…2229
METHOD FOR REMOVING KDPF ASSEMBLY…2230
METHOD FOR INSTALLING KDPF ASSEMBLY…2233
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY…2237
METHOD FOR DISASSEMBLING KDPF ASSEMBLY…2237
METHOD FOR ASSEMBLING KDPF ASSEMBLY…2241
REMOVE AND INSTALL SCR ASSEMBLY…2246
METHOD FOR REMOVING SCR ASSEMBLY…2246
METHOD FOR INSTALLING SCR ASSEMBLY…2247
REMOVE AND INSTALL KDPF, SCR ASSEMBLY…2250
METHOD FOR REMOVING KDPF, SCR ASSEMBLY…2250
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY…2260
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET…2270
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET…2270
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET…2271
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY…2273
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY…2273
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY…2275
REMOVE AND INSTALL KCCV ASSEMBLY…2277
METHOD FOR REMOVING KCCV ASSEMBLY…2277
METHOD FOR INSTALLING KCCV ASSEMBLY…2278
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE…2279
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE…2279
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE…2285
REMOVE AND INSTALL AdBlue/DEF INJECTOR…2290
METHOD FOR REMOVING AdBlue/DEF INJECTOR…2290
METHOD FOR INSTALLING AdBlue/DEF INJECTOR…2294
REMOVE AND INSTALL AdBlue/DEF PUMP…2299
METHOD FOR REMOVING AdBlue/DEF PUMP…2299
METHOD FOR INSTALLING AdBlue/DEF PUMP…2303
REMOVE AND INSTALL AdBlue/DEF HOSE…2307
METHOD FOR REMOVING AdBlue/DEF HOSE…2308
METHOD FOR INSTALLING AdBlue/DEF HOSE…2317
REMOVE AND INSTALL AIR CLEANER ASSEMBLY…2328
METHOD FOR REMOVING AIR CLEANER ASSEMBLY…2328
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY…2330
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY…2334
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY…2334
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY…2336
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY…2340
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY…2340
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY…2341
POWER TRAIN…2342
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…2342
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…2342
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY…2343
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY…2344
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY…2345
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY…2348
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY…2356
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY…2356
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY…2357
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY…2360
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY…2360
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY…2364
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY…2371
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY…2371
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY…2371
UNDERCARRIAGE AND FRAME…2373
SEPARATION AND CONNECTION OF TRACK ASSEMBLY…2373
METHOD FOR SEPARATING TRACK ASSEMBLY…2373
METHOD FOR INSTALLING TRACK ASSEMBLY…2374
REMOVE AND INSTALL SPROCKET…2377
METHOD FOR REMOVING SPROCKET…2377
METHOD FOR INSTALLING SPROCKET…2378
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY…2379
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY…2379
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY…2380
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY…2381
METHOD FOR DISASSEMBLING IDLER ASSEMBLY…2381
METHOD FOR ASSEMBLING IDLER ASSEMBLY…2382
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY…2386
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY…2386
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY…2387
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY…2389
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY…2389
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY…2390
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY…2392
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY…2392
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY…2394
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY…2397
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY…2397
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY…2402
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY FOR MAINTENANCE…2407
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY FOR MAINTENANCE…2407
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY FOR MAINTENANCE…2411
HYDRAULIC SYSTEM…2416
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY…2416
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY…2416
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY…2418
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY…2420
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY…2420
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY…2421
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY…2423
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY…2423
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY…2432
REMOVE AND INSTALL MAIN PUMP ASSEMBLY…2440
METHOD FOR REMOVING MAIN PUMP ASSEMBLY…2440
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY…2445
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY…2450
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY…2451
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY…2465
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY…2478
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING…2478
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY…2479
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY…2484
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY…2484
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY…2485
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY…2487
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY…2487
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY…2488
WORK EQUIPMENT…2490
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY…2490
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY…2490
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY…2493
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY…2496
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY…2497
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY…2499
CAB AND ITS ATTACHMENTS…2505
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY…2505
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY…2505
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY…2510
REMOVE AND INSTALL OPERATOR'S CAB DOOR…2515
METHOD FOR INSTALLING OPERATOR'S CAB DOOR…2516
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)…2520
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)…2521
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)…2522
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY…2533
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY…2533
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY…2535
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY…2541
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY…2541
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY…2547
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY…2553
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY…2553
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY…2558
REMOVE AND INSTALL OPERATOR'S SEAT…2563
METHOD FOR REMOVING OPERATOR'S SEAT…2563
METHOD FOR INSTALLING OPERATOR'S SEAT…2563
REMOVE AND INSTALL SEAT BELT…2565
METHOD FOR REMOVING SEAT BELT…2565
METHOD FOR INSTALLING SEAT BELT…2566
REMOVE AND INSTALL FRONT WIPER ASSEMBLY…2567
METHOD FOR REMOVING FRONT WIPER ASSEMBLY…2567
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY…2572
ELECTRICAL SYSTEM…2581
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY…2581
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY…2581
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY…2583
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY…2585
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY…2585
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY…2587
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY…2590
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY…2590
METHOD FOR INSTALLING KomVision CONTROLLER…2591
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY…2593
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY…2593
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY…2596
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR…2599
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR…2599
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR…2600
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR…2602
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR…2602
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR…2604
REMOVE AND INSTALL SCR TEMPERATURE SENSOR…2606
METHOD FOR REMOVING SCR TEMPERATURE SENSOR…2606
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR…2609
REMOVE AND INSTALL KomVision CAMERA…2612
METHOD FOR REMOVING KomVision CAMERA…2612
METHOD FOR INSTALLING KomVision CAMERA…2614
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY…2617
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY…2617
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY…2619
60 MAINTENANCE STANDARD…2621
CONTENTS…2622
ABBREVIATION LIST…2623
ENGINE AND COOLING SYSTEM…2629
MAINTENANCE STANDARD OF ENGINE MOUNT…2629
MAINTENANCE STANDARD OF COOLING SYSTEM…2630
POWER TRAIN…2632
MAINTENANCE STANDARD OF SWING CIRCLE…2632
MAINTENANCE STANDARD OF SWING MACHINERY…2633
MAINTENANCE STANDARD OF FINAL DRIVE…2635
MAINTENANCE STANDARD OF SPROCKET…2637
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING…2638
UNDERCARRIAGE AND FRAME…2640
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION…2640
MAINTENANCE STANDARD OF IDLER…2642
MAINTENANCE STANDARD OF TRACK ROLLER…2644
MAINTENANCE STANDARD OF CARRIER ROLLER…2646
MAINTENANCE STANDARD OF TRACK SHOE…2647
MAINTENANCE STANDARD OF TRIPLE SHOE…2650
MAINTENANCE STANDARD OF ROAD LINER…2651
MAINTENANCE STANDARD OF FLAT SHOE…2652
HYDRAULIC SYSTEM…2653
MAINTENANCE STANDARD OF HYDRAULIC TANK…2653
MAINTENANCE STANDARD OF MAIN PUMP…2654
MAINTENANCE STANDARD OF LS-EPC VALVE…2655
MAINTENANCE STANDARD OF PC-EPC VALVE…2656
MAINTENANCE STANDARD OF SWING MOTOR…2657
MAINTENANCE STANDARD OF TRAVEL MOTOR…2660
MAINTENANCE STANDARD OF CONTROL VALVE…2663
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE…2673
MAINTENANCE STANDARD OF TRAVEL PPC VALVE…2676
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)…2679
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE…2681
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE…2682
MAINTENANCE STANDARD OF SOLENOID VALVE…2684
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE)…2685
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE)…2686
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT…2687
WORK EQUIPMENT…2688
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE…2688
DIMENSION OF ARM…2693
DIMENSIONS OF BUCKET…2695
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON)…2697
MAINTENANCE STANDARD OF ARM CYLINDER…2698
MAINTENANCE STANDARD OF BUCKET CYLINDER…2699
80 APPENDIX…2701
CONTENTS…2702
ABBREVIATION LIST…2704
AIR CONDITIONER SYSTEM…2710
PRECAUTIONS FOR REFRIGERANT…2710
AIR CONDITIONER COMPONENT…2711
SPECIFICATIONS OF AIR CONDITIONER…2713
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE…2714
OUTLINE OF REFRIGERATION CYCLE…2715
COMPONENT PARTS OF AIR CONDITIONER SYSTEM…2717
AIR CONDITIONER UNIT…2717
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT…2717
FUNCTION OF AIR CONDITIONER UNIT…2719
COMPONENT PARTS OF AIR CONDITIONER UNIT…2720
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT…2720
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT…2720
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT…2720
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT…2720
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…2721
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…2721
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT…2721
FUNCTION OF DUAL PRESSURE SWITCH…2722
AIR CONDITIONER CONTROLLER…2723
STRUCTURE OF AIR CONDITIONER CONTROLLER…2723
COMPRESSOR…2724
STRUCTURE OF COMPRESSOR…2724
SPECIFICATIONS OF COMPRESSOR…2724
FUNCTION OF COMPRESSOR…2724
CONDENSER…2725
STRUCTURE OF CONDENSER…2725
SPECIFICATIONS OF CONDENSER…2725
FUNCTION OF CONDENSER…2725
SENSORS FOR AIR CONDITIONER SYSTEM…2727
STRUCTURE OF SUNLIGHT SENSOR…2727
FUNCTION OF SUNLIGHT SENSOR…2727
STRUCTURE OF AMBIENT TEMPERATURE SENSOR…2727
FUNCTION OF AMBIENT TEMPERATURE SENSOR…2727
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER…2729
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER…2731
AIR CONDITIONER SYSTEM DIAGRAM…2733
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER…2734
FUNCTION OF AIR CONDITIONER CONTROLLER…2735
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS…2736
TESTING AIR LEAKAGE (DUCT)…2745
METHOD FOR TESTING AIR LEAKAGE (DUCT)…2745
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION…2747
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR…2748
TEST VENT (MODE) CHANGEOVER…2749
METHOD FOR TESTING VENT (MODE) CHANGEOVER…2749
TESTING FRESH/RECIRC AIR CHANGEOVER…2750
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER…2750
TEST SUNLIGHT SENSOR…2751
METHOD FOR TESTING SUNLIGHT SENSOR…2751
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT…2752
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT…2752
TEST RELAYS…2754
METHOD FOR TESTING RELAYS…2754
AIR CONDITIONER TROUBLESHOOTING CHART 1…2755
AIR CONDITIONER TROUBLESHOOTING CHART 2…2756
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE…2759
FAILURE CODE [879AKA]…2761
FAILURE CODE [879AKB]…2762
FAILURE CODE [879BKA]…2763
FAILURE CODE [879BKB]…2765
FAILURE CODE [879CKA]…2767
FAILURE CODE [879CKB]…2768
FAILURE CODE [879DKZ]…2769
FAILURE CODE [879EMC]…2771
FAILURE CODE [879FMC]…2772
FAILURE CODE [879GKX]…2773
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)…2775
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)…2777
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)…2780
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER…2782
TROUBLESHOOTING USING GAUGE PRESSURE…2784
CONNECTION OF SERVICE TOOL…2786
METHOD FOR CONNECTING SERVICE TOOL…2786
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS…2788
HANDLE COMPRESSOR OIL…2790
METHOD FOR REPLACING DESICCANT…2792
90 CIRCUIT DIAGRAMS…2795
CONTENTS…2796
ABBREVIATION LIST…2797
HYDRAULIC CIRCUIT DIAGRAM…2803
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM…2803
HYDRAULIC CIRCUIT DIAGRAM (1/2)…2807
HYDRAULIC CIRCUIT DIAGRAM (2/2)…2808
ELECTRICAL CIRCUIT DIAGRAM…2809
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM…2809
ELECTRICAL CIRCUIT DIAGRAM (1/9)…2813
ELECTRICAL CIRCUIT DIAGRAM (2/9)…2814
ELECTRICAL CIRCUIT DIAGRAM (3/9)…2815
ELECTRICAL CIRCUIT DIAGRAM (4/9)…2816
ELECTRICAL CIRCUIT DIAGRAM (5/9)…2817
ELECTRICAL CIRCUIT DIAGRAM (6/9)…2818
ELECTRICAL CIRCUIT DIAGRAM (7/9)…2819
ELECTRICAL CIRCUIT DIAGRAM (8/9)…2820
ELECTRICAL CIRCUIT DIAGRAM (9/9)…2821
INDEX…2822
Komatsu Hydraulic Excavator PC238USLC Repair Service Manuals
