Komatsu PC240LC-10 - Workshop Manual / Repair Manual - Wiring Schematics

KOMATSU PC240LC-10 - WORKSHOP, SERVICE, REPAIR MANUAL - WIRING SCHEMATICS

- English Workshop Manual and Wiring Schematics, for Komatsu PC240LC-10.
 

INDEX:

00 - FOREWORD
- GENERAL
- HOW TO READ THE SHOP MANUAL
- Volumes
- Distribution And Updating
- Filing Method
- Revised Edition Mark
- Revisions
- Symbols
- HOISTING INSTRUCTIONS
- Hoisting
- Making Signs
- Precautions
- Selecting Wire Ropes
- HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
- Points to Remember When Handling Electric Equipment
- Points to Remember When Handling Hydraulic Equipment
- PUSH PULL COUPLER
- Type 1
- Type 2
- Type 3
- EXPLANATION OF MAINTENANCE STANDARD TERMS
- HANDLING OF FUEL SYSTEM DEVICES
- HANDLING OF INTAKE SYSTEM PARTS
- STANDARD TIGHTENING TORQUE
- Bolts And Nuts
- Tightening Torque Of Hose Nuts
- Tightening Torque Of Split Flange Bolts
- Tightening Torque For Flared Nuts
- Tightening Torques for Split Flanged Bolts
- Tightening Torques For O-ring Boss Piping Joints
- Table Of Tightening Torques For O-ring Boss Plugs
- Tightening Torque For Hoses (Taper Seal Type And Face Seal Type)
- ELECTRIC WIRE CODE
- Classification By Thickness
- Classification By Color And Code
- How To Read Electric Wire Code
- PRECAUTIONS FOR OPERATIONS
- Precautions when Carrying Out Removal Work
- Precautions when Carrying Out Installation Work
- Precautions when Completing the Operation
- CONVERSION TABLES
- Method Of Using The Conversion Table
- COATING MATERIALS
- LIST OF ABBREVIATIONS
- List of Abbreviations Used in the Shop Manual
- List of Abbreviations Used in the Circuit Diagrams
- Safety Notice
- Important Safety Notice
- General Precautions
- Preparations For Work
- Precautions During Work
01 - GENERAL
- SPECIFICATION DIMENSION DRAWINGS
- Dimensions
- Working Ranges
- SPECIFICATIONS
- WEIGHT TABLE
- FUEL, COOLANT AND LUBRICANTS
- Lubrication Chart
10 - STRUCTURE AND FUNCTION
- ENGINE AND COOLING SYSTEM
- Engine Related Parts
- Radiator, Oil Cooler, Aftercooler, and Fuel Cooler
- POWER TRAIN
- Power Train
- Swing Machinery
- Swing Circle
- Final Drive
- UNDERCARRIAGE AND FRAME
- Track Frame and Idler Cushion
- HYDRAULIC SYSTEM
- Hydraulic Equipment Layout
- Valve Control
- Hydraulic Tank
- Oil Filler Cap
- CLSS
- Main Pump
- Control Valve
- Functions and Operation by Valve
- Swing Motor
- Travel Motor
- PPC Valve
- Solenoid Valve
- Attachment Circuit Selector Valve (For High Pressure Circuit) (If Equipped)
- Attachment Circuit Selector Valve (For Low Pressure Circuit) (If Equipped)
- Center Swivel Joint
- Accumulator
- WORK EQUIPMENT
- Work Equipment
- Work Equipment Shim
- Bucket Play Adjustment Shim
- CAB AND ITS ATTACHMENTS
- Cab Mount and Cab Tipping Stopper
- ROPS Cab
- ELECTRICAL SYSTEM
- Electrical Control System
- System Component Part
- MACHINE MONITOR SYSTEM
- Machine Monitor
- Switches
- KOMTRAX SYSTEM
- KOMTRAX terminal
- Input and Output Signals
- SENSORS
- Ambient Pressure Sensor
- Charge (Boost) Pressure and Temperature Sensor
- Coolant Temperature Sensor
- Ne (Crankshaft) Speed Sensor
- Bkup (Camshaft) Speed Sensor
- Common Rail Pressure Sensor
- Exhaust Manifold Pressure Sensor
- EGR Orifice Temperature Sensor
- EGR Valve Lift Sensor
- Turbo Speed Sensor
- KVGT Position Sensor
- Mass Air Flow and Temperature Sensor
- KDPF Differential Pressure and Outlet Pressure Sensor
- KDOC Inlet Temperature Sensor
- KDOC Outlet Temperature Sensor
- KDPF Outlet Temperature Sensor
- Crankcase Pressure Sensor
- Engine Oil Level Sensor
- Fuel Level Sensor
- Coolant Level Sensor
- Hydraulic Oil Temperature Sensor
- Front Pump Oil Pressure Sensor
- Rear Pump Oil Pressure Sensor
- PPC Oil Pressure Sensor
- Air Cleaner Clogging Sensor
- Front Pump Swash Plate Sensor
- Rear Pump Swash Plate Sensor
- Water-In-Fuel Sensor
20 - STANDARD VALUE TABLES
- STANDARD SERVICE VALUE TABLES
- Standard Value Table for Engine Related Parts
- Standard Value Table for Chassis Related Parts
- Posture of Machine for Measuring Performance and Measurement Procedure
30 - TESTING AND ADJUSTING
- GENERAL INFORMATION ON TESTING AND ADJUSTING
- Tools for Testing, Adjusting, and Troubleshooting
- Sketch of Tools for Testing and Adjusting
- ENGINE AND COOLING SYSTEM
- Checking Engine Speed
- Measuring Boost Pressure
- Measuring Exhaust Gas Color
- Measuring and Adjusting Valve Clearance
- Measuring Compression Pressure
- Measuring Blow-By Pressure
- Measuring Engine Oil Pressure
- Measuring EGR Valve and KVGT Oil Pressure
- Measuring Fuel Pressure
- Measuring Fuel Delivery, Return and Leakage
- Bleeding Air from Fuel System
- Checking Fuel Circuit for Leakage
- Handling Cylinder Cut-Out Mode Operation
- Handling No-Injection Cranking Operation
- Checking and Adjusting Air Conditioner Compressor Belt Tension
- Replacing Fan Belt
- POWER TRAIN
- Testing Swing Circle Bearing Clearance
- UNDERCARRIAGE AND FRAME
- Testing and Adjusting Track Shoe Tension
- HYDRAULIC SYSTEM
- Releasing Remaining Pressure from Hydraulic Circuit
- Measuring and Adjusting of Oil Pressure in Work Equipment, Swing, and Travel Circuits
- Measuring Oil Pressure in Control Circuit
- Measuring and Adjusting Oil Pressure in Pump PC Control Circuit
- Measuring and Adjusting Oil Pressure in Pump LS Control Circuit
- Measuring Solenoid Valve Output Pressure
- Measuring PPC Valve Output Pressure
- Adjusting Play of Work Equipment and Swing PPC Valves
- Testing Pump Swash Plate Sensor
- Isolating the Parts Causing Hydraulic Drift in Work Equipment
- Measuring Oil Leakage
- Bleeding Air From Hydraulic Circuit
- CAB AND ITS ATTACHMENTS
- Checking Cab Tipping Stopper
- Adjusting Mirrors
- ELECTRICAL SYSTEM
- Special Functions of Machine Monitor
- Ordinary Functions and Special Functions of Machine Monitor
- Display of KOMATSU Logo
- Display of Inputting Password
- Display of Check of Breaker Mode
- Display of Check Before Starting
- Display of Warning After Check Before Starting
- Display of Ending of Maintenance Interval
- Display of Check of Working Mode and Travel Speed
- Display of Standard Screen
- Display of End Screen
- Display of Engine Shutdown Secondary Switch Screen
- Selection of Auto-Deceleration
- Selection of Working Mode
- Selection of Travel Speed
- Operation to Stop Alarm Buzzer
- Operation of Windshield Wiper
- Operation of Window Washer
- Operation of Air Conditioner/Heater
- Operation to Display Camera Mode (If Camera is Installed)
- Operation to Display Clock and Service Meter
- Check of Maintenance Information
- Setting and Display of User Mode (Including KOMTRAX Messages for User)
- Display of ECO Guidance
- Display of Caution Monitor
- Display of KDPF Regeneration
- Display of Action Level and Failure Code
- Function of Checking Display of LCD (Liquid Crystal Display)
- Function of Checking Service Meter
- Function of Changing Attachment/Maintenance Password
- Monitoring / Pre-Defined
- Monitoring / Custom
- Monitoring Items Table
- Abnormality Record (Mechanical Systems)
- Abnormality Record (Electrical Systems)
- Maintenance Record
- Maintenance Mode Setting
- Phone Number Entry
- Default (Key-On Mode)
- Default (Unit)
- Default (With/Without Attachment)
- Default (Camera)
- Diagnostic Tests (Cylinder Cut-out)
- Diagnostic Tests (Regeneration for Service)
- Diagnostic Tests (KDPF Memory Reset)
- Adjustment (Pump Absorption Torque (F))
- Adjustment (Pump Absorption Torque (R))
- Adjustment (Low Speed)
- Adjustment (Attachment Flow Adjustment)
- Adjustment (Cal F Pump Swash Plate Sensor)
- Adjustment (Cal R Pump Swash Plate Sensor)
- Adjustment (Pump Calibration: Matching Speed Calibration)
- Adjustment (Pump Calibration: Matching Speed Check)
- No Injection
- KOMTRAX Settings (Terminal Status)
- KOMTRAX Settings (GPS and Communication Status)
- KOMTRAX Settings (Modem Information)
- Service Message
- Angle Adjustment of Rear View Camera
- Handling Voltage Circuit of Engine Controller
- Handling Battery Disconnect Switch
- Testing Diodes
- PM CLINIC
- PM Clinic Service
- Check Sheet
40 - TROUBLESHOOTING
- GENERAL INFORMATION ON TROUBLESHOOTING
- Points to Remember When Troubleshooting
- Sequence of Events in Troubleshooting
- Checks Before Troubleshooting
- Testing Procedure Before Troubleshooting
- Check of Water Separator, and Drainage of Water and Sediments
- Replacing Fuel Pre-Filter Cartridge
- Preparation Work for Troubleshooting of Electrical System
- Classification and Procedure for Troubleshooting
- Symptom of Probable Failure and Troubleshooting No.
- Information Mentioned in Troubleshooting Table
- Diagnostic Procedure for Wiring Harness Open Circuit of Pressure Sensor System
- Connection Table for Connector Pin Numbers
- T-Branch Box and T-Branch Adapter Table
- Fuse List and Location
- Precautions for Cleaning and Replacing KDPF (KCSF, KDOC)
- TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)
- Failure Codes Table
- Failure Code [879AKA] A/C Inner Sensor Open Circuit
- Failure Code [879AKB] A/C Inner Sensor Short Circuit
- Failure Code [879BKA] A/C Outer Sensor Open Circuit
- Failure Code [879BKB] A/C Outer Sensor Short Circuit
- Failure Code [879CKA] Ventilating Sensor Open Circuit
- Failure Code [879CKB] Ventilating Sensor Short Circuit
- Failure Code [879DKZ] Sunlight Sensor Open or Short Circuit
- Failure Code [879EMC] Ventilation Damper Abnormality
- Failure Code [879FMC] Air Mix Damper Abnormality
- Failure Code [879GKX] Refrigerant Abnormality
- Failure Code [989L00] Engine Controller Lock Caution 1
- Failure Code [989M00] Engine Controller Lock Caution 2
- Failure Code [989N00] Engine Controller Lock Caution 2
- Failure Code [A1U0N3] HC Desorb Request 1
- Failure Code [A1U0N4] HC Desorb Request 2
- Failure Code [AA10NX] Air Cleaner Clogging
- Failure Code [AB00KE] Charge Voltage Low
- Failure Code [B@BAZG] Engine Oil Pressure Low
- Failure Code [B@BAZK] Eng Oil Level Low
- Failure Code [B@BCNS] Engine Coolant Overheat
- Failure Code [B@BCZK] Radiator Coolant Level Low
- Failure Code [B@HANS] Hyd Oil Overheat
- Failure Code [CA115] Eng Ne and Bkup Speed Sens Error
- Failure Code [CA122] Chg Air Press Sensor High Error
- Failure Code [CA123] Chg Air Press Sensor Low Error
- Failure Code [CA131] Throttle Sensor High Error
- Failure Code [CA132] Throttle Sensor Low Error
- Failure Code [CA144] Coolant Temp Sens High Error
- Failure Code [CA145] Coolant Temp Sens Low Error
- Failure Code [CA153] Chg Air Temp Sensor High Error
- Failure Code [CA154] Chg Air Temp Sensor High Error
- Failure Code [CA187] Sensor 2 Supply Volt Low Error
- Failure Code [CA221] Ambient Press Sensor High Error
- Failure Code [CA222] Ambient Press Sensor Low Error
- Failure Code [CA227] Sensor 2 Supply Volt High Error
- Failure Code [CA234] Eng Overspeed
- Failure Code [CA238] Ne Speed Sensor Supply Volt Error
- Failure Code [CA239] Ne Speed Sens Supply Volt High Error
- Failure Code [CA271] IMV/PCV1 Short Error
- Failure Code [CA272] IMV/PCV1 Open Error
- Failure Code [CA295] Ambient Press Sens In Range Error
- Failure Code [CA322] Inj #1 (L#1) Open/Short Error
- Failure Code [CA323] Inj #5 (L#5) Open/Short Error
- Failure Code [CA324] Inj #3 (L#3) Open/Short Error
- Failure Code [CA325] Inj #6 (L#6) Open/Short Error
- Failure Code [CA331] Inj #2 (L#2) Open/Short Error
- Failure Code [CA332] Inj #4 (L#4) Open/Short Error
- Failure Code [CA343] ECM Critical Internal Failure
- Failure Code [CA351] Injectors Drive Circuit Error
- Failure Code [CA352] Sensor 1 Supply Volt Low Error
- Failure Code [CA356] Mass Air Flow Sensor High Error
- Failure Code [CA357] Mass Air Flow Sensor Low Error
- Failure Code [CA386] Sensor 1 Supply Volt High Error
- Failure Code [CA428] Water in Fuel Sensor High Error
- Failure Code [CA429] Water in Fuel Sensor Low Error
- Failure Code [CA435] Eng Oil Press Sw Error
- Failure Code [CA441] Battery Voltage Low Error
- Failure Code [CA442] Battery Voltage High Error
- Failure Code [CA449] Rail Press Very High Error
- Failure Code [CA451] Rail Press Sensor High Error
- Failure Code [CA452] Rail Press Sensor Low Error
- Failure Code [CA488] Chg Air Temp High Torque Derate
- Failure Code [CA515] Rail Press Sens Sup Volt High Error
- Failure Code [CA516] Rail Press Sens Sup Volt Low Error
- Failure Code [CA553] Rail Press High Error
- Failure Code [CA555] Crankcase Press High Error 1
- Failure Code [CA556] Crankcase Press High Error 2
- Failure Code [CA559] Rail Press Low Error
- Failure Code [CA595] Turbo Speed High Error 2
- Failure Code [CA687] Turbo Speed Low Error
- Failure Code [CA689] Eng Ne Speed Sensor Error
- Failure Code [CA691] Intake Air Temp Sens High Error
- Failure Code [CA692] Intake Air Temp Sens Low Error
- Failure Code [CA697] ECM Int Temp Sensor High Error
- Failure Code [CA698] ECM Int Temp Sensor Low Error
- Failure Code [CA731] Eng Bkup Speed Sens Phase Error
- Failure Code [CA778] Eng Bkup Speed Sensor Error
- Failure Code [CA1117] Persistent Data Lost Error
- Failure Code [CA1664] KDOC Malfunction
- Failure Code [CA1691] Regeneration Ineffective
- Failure Code [CA1695] Sensor 5 Supply High Error
- Failure Code [CA1696] Sensor 5 Supply Volt Low Error
- Failure Code [CA1843] Crankcase Press Sens High Error
- Failure Code [CA1844] Crankcase Press Sens Low Error
- Failure Code [CA1879] KDPF Delta P Sensor High Error
- Failure Code [CA1881] KDPF Delta P Sensor Low Error
- Failure Code [CA1883] KDPF Delta P Sens In Range Error
- Failure Code [CA1921] KDPF Soot Load High Error 1
- Failure Code [CA1922] KDPF Soot Load High Error 2
- Failure Code [CA1942] Crankcase Press Sens In Range Error
- Failure Code [CA1993] KDPF Delta Pressure Low Error
- Failure Code [CA2185] Throt Sensor Sup Volt High Error
- Failure Code [CA2186] Throt Sensor Sup Volt Low Error
- Failure Code [CA2249] Rail Press Very Low Error
- Failure Code [CA2271] EGR Valve Pos Sens High Error
- Failure Code [CA2272] EGR Valve Pos Sens Low Error
- Failure Code [CA2288] Turbo Speed High Error 1
- Failure Code [CA2311] IMV Solenoid Error
- Failure Code [CA2349] EGR Valve Solenoid Open Error
- Failure Code [CA2353] EGR Valve Solenoid Short Error
- Failure Code [CA2357] EGR Differential Pressure
- Failure Code [CA2373] Exh Manifold Press. Sens Volt
- Failure Code [CA2374] Exhaust Manifold Press Sens Low Error
- Failure Code [CA2375] EGR Orifice Temp Sens High Error
- Failure Code [CA2376] EGR Orifice Temp Sens Low Error
- Failure Code [CA2381] KVGT Pos Sens High Error
- Failure Code [CA2382] KVGT Pos Sens Low Error
- Failure Code [CA2383] KVGT Solenoid Open Error
- Failure Code [CA2386] KVGT Solenoid Short Error
- Failure Code [CA2387] KVGT Servo Error
- Failure Code [CA2554] Exh Manifold Press Sens In Range Error
- Failure Code [CA2555] Grid Htr Relay Volt Low Error
- Failure Code [CA2556] Grid Htr Relay Volt High Error
- Failure Code [CA2637] KDOC Face Plugging
- Failure Code [CA2639] Manual Stationary Regeneration Request
- Failure Code [CA2961] EGR Orifice Temp High Error 1
- Failure Code [CA2973] Chg Air Press Sensor In Range Error
- Failure Code [CA3133] KDPF Outlet Press Sens High Error
- Failure Code [CA3134] KDPF Outlet Press Sens Low Error
- Failure Code [CA3135] KDPF Outlet Press Sens In Range Error
- Failure Code [CA3251] KDOC Inlet Temp High Error
- Failure Code [CA3253] KDOC Temp Error - Non Regeneration
- Failure Code [CA3254] KDOC Outlet Temp High Error 1
- Failure Code [CA3255] KDPF Temp Error - Non Regeneration
- Failure Code [CA3256] KDPF Outlet Temp High Error 1
- Failure Code [CA3311] KDOC Outlet Temp High Error 2
- Failure Code [CA3312] KDPF Outlet Temp High Error 2
- Failure Code [CA3313] KDOC Inlet Temp Sensor Low Error
- Failure Code [CA3314] KDOC Inlet Temp Sens High Error
- Failure Code [CA3315] KDOC Inlet Temp Sens In Range Error
- Failure Code [CA3316] KDOC Outlet Temp Sens Low Error
- Failure Code [CA3317] KDOC Outlet Temp Sens High Error
- Failure Code [CA3318] KDOC Outlet Temp Sens In Range Error
- Failure Code [CA3319] KDPF Outlet Temp Sens High Error
- Failure Code [CA3321] KDPF Outlet Temp Sens Low Error
- Failure Code [CA3322] KDPF Outlet Temp Sens In Range Error
- Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error
- Failure Code [CA3421] Mass Air Flow Sensor Sup Volt Low Error
- Failure Code [CA3741] Rail Press Valve Trip Error
- Failure Code [D110KB] Battery Relay Output Voltage
- Failure Code [D19JKZ] Personal Code Relay Abnormality
- Failure Code [D811MC] KOMTRAX Error
- Failure Code [D862KA] GPS Antenna Open Circuit
- Failure Code [D8ALKA] Operating Lamp Open Circuit (KOMTRAX)
- Failure Code [D8ALKB] Operating Lamp Short Circuit (KOMTRAX)
- Failure Code [D8AQKR] CAN2 Discon (KOMTRAX)
- Failure Code [DA20MC] Pump Controller
- Failure Code [DA22KK] Pump Solenoid Power Low Error
- Failure Code [DA25KP] 5V Sensor 1 Power Abnormality
- Failure Code [DA29KQ] Model Selection Abnormality
- Failure Code [DA2LKA] Operating Lamp Open Circuit (Pump Con)
- Failure Code [DA2LKB] Operating Lamp Short Circuit (Pump Con)
- Failure Code [DA2QKR] CAN2 Discon (Pump Con)
- Failure Code [DA2QKR] CAN1 Discon (Pump Con)
- Failure Code [DAF0MB] Monitor ROM Abnormality
- Failure Code [DAF0MC] Monitor Error
- Failure Code [DAF8KB] Camera Power Supply Short Circuit
- Failure Code [DAF9KQ] Model Selection Abnormality
- Failure Code [DAFGMC] GPS Module Error
- Failure Code [DAFLKA] Operating Lamp Open Circuit (Monitor)
- Failure Code [DAFLKB] Operating Lamp Short Circuit (Monitor)
- Failure Code [DAFQKR] CAN2 Discon (Monitor)
- Failure Code [DAZ9KQ] A/C Model Selection Abnormality
- Failure Code [DAZQKR] CAN2 Discon (Aircon ECU)
- Failure Code [DB2QKR] CAN2 Discon (Engine Con)
- Failure Code [DB2RKR] CAN1 Discon (Engine Con)
- Failure Code [DGH2KB] Hyd Oil Sensor Short Circuit
- Failure Code [DHA4KA] Air Cleaner Clog Sensor Open Circuit
- Failure Code [DHPAMA] F Pump Press Sensor Abnormality
- Failure Code [DHPBMA] R Pump Press Sensor Abnormality
- Failure Code [DHS3MA] Arm Curl PPC Press Sensor Abnormality
- Failure Code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality
- Failure Code [DHS8MA] Boom Raise PPC Press Sensor Abnormality
- Failure Code [DHS9MA] Boom Lower PPC Press Sensor Abnormality
- Failure Code [DHSAMA] Swing RH PPC Press Sensor Abnormality
- Failure Code [DHSBMA] Swing LH PPC Press Sensor Abnormality
- Failure Code [DHSCMA] Arm Dump PPC Press Sensor Abnormality
- Failure Code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality
- Failure Code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality
- Failure Code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality
- Failure Code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality
- Failure Code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality
- Failure Code [DKR0MA] F Pump Swash Plate Sensor Abnormality
- Failure Code [DKR1MA] R Pump Swash Plate Sensor Abnormality
- Failure Code [DR21KX] Camera 2 Picture Rev. Drive Abnormality
- Failure Code [DR31KX] Camera 3 Picture Rev. Drive Abnormality
- Failure Code [DV20KB] Travel Alarm Short Circuit
- Failure Code [DW43KA] Travel Speed Sol Open Circuit
- Failure Code [DW43KB] Travel Speed Sol Short Circuit
- Failure Code [DW45KA] Swing Brake Sol Open Circuit
- Failure Code [DW45KB] Swing Brake Sol Short Circuit
- Failure Code [DW91KA] Travel Junction Sol Open Circuit
- Failure Code [DW91KB] Travel Junction Sol Short Circuit
- Failure Code [DWA2KA] Attachment Sol Open Circuit
- Failure Code [DWA2KB] Attachment Sol Short Circuit
- Failure Code [DWK0KA] 2-Stage Relief Sol Open Circuit
- Failure Code [DWK0KB] 2-Stage Relief Sol Short Circuit
- Failure Code [DWK2KA] Variable Back Press Sol Open Circuit
- Failure Code [DWK2KB] Variable Back Press Sol Short Circuit
- Failure Code [DWK8KA] Swing Press C/O Sol Open Circuit
- Failure Code [DWK8KB] Swing Press C/O Sol Short Circuit
- Failure Code [DXA8KA] PC-EPC (F) Sol Open Circuit
- Failure Code [DXA8KB] PC-EPC (F) Sol Short Circuit
- Failure Code [DXA9KA] PC-EPC (R) Sol Open Circuit
- Failure Code [DXA9KB] PC-EPC (R) Sol Short Circuit
- Failure Code [DXE0KA] LS-EPC Sol Open Circuit
- Failure Code [DXE0KB] LS-EPC Sol Short Circuit
- Failure Code [DXE4KA] Attachment Flow EPC Open Circuit
- Failure Code [DXE4KB] Attachment Flow EPC Short Circuit
- Failure Code [DXE5KA] Merge-divide Main Sol Open Circuit
- Failure Code [DXE5KB] Merge-divide Main Sol Short Circuit
- Failure Code [DXE6KA] Merge-divide LS Sol Open Circuit
- Failure Code [DXE6KB] Merge-divide LS Sol Short Circuit
- Failure Code [DY20KA] Wiper Working Abnormality
- Failure Code [DY20MA] Wiper Parking Abnormality
- Failure Code [DY2CKB] Washer Drive Short Circuit
- Failure Code [DY2DKB] Wiper Drive (Fwd) Short Circuit
- Failure Code [DY2EKB] Wiper Drive (Rev) Short Circuit
- TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)
- E-1 Engine Does Not Start (Engine Does Not Rotate)
- E-2 Manual Pre-Heating System Does Not Work
- E-3 Automatic Pre-Heating System Does Not Work
- E-4 Pre-Heating Monitor Does Not Light Up When Pre-Heater is Operated
- E-5 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing
- E-6 When Starting Switch is Turned to ON Position (Before Starting Engine), Engine Oil Level Monitor Lights Up in Yellow
- E-7 When Starting Switch is Turned to ON Position (Before Starting Engine), Radiator Coolant Level Monitor Lights Up in Yellow
- E-8 Coolant Temperature Monitor Lights Up in White While Engine is Running
- E-9 Hydraulic Oil Temperature Monitor Lights Up in White While Engine is Running
- E-10 Charge Level Monitor Lights Up While Engine is Running
- E-11 Fuel Level Monitor Lights Up in Red While Engine is Running
- E-12 Air Cleaner Clogging Monitor Lights Up in Yellow While Engine is Running
- E-13 Water Separator Monitor Lights Up While Engine is Running
- E-14 Coolant Temperature Monitor Lights Up in Red While Engine is Running
- E-15 Hydraulic Oil Temperature Monitor Lights Up in Red While Engine is Running
- E-16 Engine Oil Pressure Monitor Lights Up in Red While Engine is Running
- E-17 Fuel Gauge Indicates Either Full or Empty and Does Not Move
- E-18 Fuel Gauge Indicates Incorrect Amount (Indicates Neither Full Nor Empty)
- E-19 Coolant Temperature Gauge Indicates Either Min or Max and Does Not Move
- E-20 Coolant Temperature Gauge Indicates Incorrect Temperature (Indicates Neither Min Nor Max)
- E-21 Hydraulic Oil Temperature Gauge Indicates Either Min or Max and Does Not Move
- E-22 Hydraulic Oil Temperature Gauge Indicates Incorrect Temperature (Indicates Neither Min nor Max)
- E-23 Content of Display on Machine Monitor is Different From That of Actual Machine
- E-24 Machine Monitor Does Not Display Some Items
- E-25 Function Switch Does Not Work
- E-26 Automatic Pre-Heating System Does Not Work (In Cold Season)
- E-27 Auto-Deceleration Monitor Does Not Light Up or Does Not Go Out When Auto-Deceleration Switch is Operated
- E-28 Auto-Deceleration is Not Actuated or Canceled When Lever is Operated
- E-29 Working Mode Selector Screen Selection Screen is Not Displayed When Working Mode Switch is Operated
- E-30 Engine or Hydraulic Pump Setting Does Not Change When Working Mode is Changed
- E-31 Travel Speed Monitor Does Not Change When Travel Speed Switch is Operated
- E-32 Travel Speed Does Not Change When Travel Speed is Shifted
- E-33 Alarm Buzzer Does Not Stop Sounding
- E-34 When Starting Switch is Turned to OFF Position, Service Meter is Not Displayed
- E-35 Service Mode Cannot be Selected
- E-36 Any of Work Equipment, Swing and Travel Does Not Work
- E-37 Any of Work Equipment, Swing and Travel Can Not be Locked
- E-38 Machine Can Not Swing While Swing Brake Cancel Switch is Canceled
- E-39 Swing Brake Does Not Operate While Swing Brake Cancel Switch is Locked
- E-40 One-Touch Power Maximizing Function Does Not Work Or Monitor is Not Displayed
- E-41 One-Touch Power Maximizing Function Cannot be Released
- E-42 Travel Alarm Does Not Sound When Machine Travels
- E-43 Travel Alarm Does Not Stop Sounding When Machine Stops
- E-44 Horn Does Not Sound
- E-45 Horn Does Not Stop Sounding
- E-46 Wiper Monitor Does Not Light Up or Go Out When Wiper Switch is Operated
- E-47 Wiper Does Not Operate When Wiper Switch is Operated
- E-48 Window Washer Does Not Operate When Window Washer Switch is Operated
- E-49 BOOM LOWER Indication is Not Displayed Properly With Monitoring Function
- E-50 ARM DUMP Indication is Not Displayed Properly With Monitoring Function
- E-51 ARM IN Indication is Not Displayed Properly With Monitoring Function
- E-52 BOOM RAISE Indication is Not Displayed Properly With Monitoring Function
- E-53 BUCKET CURL Indication is Not Displayed Properly With Monitoring Function
- E-54 BUCKET DUMP Indication is Not Displayed Properly With Monitoring Function
- E-55 SWING Indication is Not Displayed Properly With Monitoring Function
- E-56 TRAVEL Indication is Not Displayed Properly With Monitoring Function
- E-57 Service is Not Displayed Properly With Monitoring Function
- E-58 Attachment Hydraulic Circuit Cannot be Changed
- E-59 KOMTRAX System Does Not Work Properly
- TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)
- Information Mentioned in Troubleshooting Table (H Mode)
- Failure Mode and Cause Table
- H-1 All of Work Equipment, Swing and Travel Operation Lacks Speed or Power
- H-2 Engine Speed Lowers Significantly or Engine Stalls
- H-3 Any of Work Equipment, Swing and Travel Does Not Work
- H-4 Unusual Sound is Heard from Around Hydraulic Pump
- H-5 Fine Control Performance or Response is Poor
- H-6 Boom Operation Lacks Speed or Power
- H-7 Arm Operation Lacks Speed or Power
- H-8 Bucket Operation Lacks Speed or Power
- H-9 Work Equipment Does Not Move in Single Operation
- H-10 Hydraulic Drift of Boom is Large
- H-11 Hydraulic Drift of Arm is Large
- H-12 Hydraulic Drift of Bucket is Large
- H-13 Time Lag of Work Equipment is Large
- H-14 When Part of Work Equipment is Relieved Singly, Other Parts of Work Equipment Move
- H-15 One-Touch Power Maximizing Function Does Not Work
- H-16 In Combined Operation of Work Equipment, Equipment Having Heavier Load Moves Slower
- H-17 In Combined Operations of Swing and Boom RAISE, Boom Rising Speed is Low
- H-18 In Combined Operations of Swing and Travel, Travel Speed Drops Largely
- H-19 Machine Does Not Travel Straight
- H-20 Travel Speed is Too Low
- H-21 Machine ishard to Steer or Travel Power is Low
- H-22 Travel Speed Does Not Change, or Travel Speed is Too Low or High
- H-23 One of Tracks Dose Not Run
- H-24 Upper Structure Does Not Swing to the Right or Left
- H-25 Upper Structure Swing Only to the Right or Left
- H-26 Swing Acceleration is Poor or Swing Speed is Low (Both Right and Left)
- H-27 Swing Aceleration is Poor or Swing Speed is Low (Either Right or Left)
- H-28 Upper Structure Overruns Excessively When it Stops Swinging (Both Right and Left)
- H-29 Upper Structure Overruns Excessively When it Stops Swinging (Either Right or Left)
- H-30 Shock is Large When Upper Structure Stops Swinging
- H-31 Large Unusual Noise is Heard When Upper Structure Stops Swinging
- H-32 Swing Drift on a Slope is Large While Swing Holding Brake is Applied
- H-33 Swing Drift On a Slope is Large While Swing Holding Brake is Released
- H-34 Attachment Circuit Cannot be Changed While Attachment is Installed
- H-35 Oil Flow in Attachment Circuit Cannot be Controlled
- TROUBLESHOOTING OF ENGINE (S-MODE)
- Information Mentioned in Troubleshooting Table (S-Mode)
- S-1 When Starting Switch is Turned to START Position, Engine Does Not Crank
- S-2 When Engine Cranks, Smoke Does Not Come Out
- S-3 Engine Does Not Start While Fuel is Injected (Incomplete Combustion)
- S-4 Startability is Poor
- S-5 Engine Does Not Pick Up Smoothly
- S-6 Engine Stops During Operation
- S-7 Engine Runs Rough or is Unstable
- S-8 Engine Lacks Power
- S-9 Exhaust Smoke is Black (KDPF Clogs Up Early)
- S-10 Engine Oil Consumption is Too Much
- S-11 Oil Becomes Contaminated Early
- S-12 Fuel Consumption is Excessive
- S-13 Oil is in Coolant (or Coolant Spurts or Coolant Level Goes Down)
- S-14 Engine Oil Pressure Drops
- S-15 Fuel is Contaminated in Engine Oil
- S-16 Coolant is Contaminated in Engine Oil (Oil Becomes Cloudy White)
- S-17 Coolant Temperature Rises Too High (Overheating)
- S-18 Unusual Noise is Heard
- S-19 Vibration is Excessive
- S-20 Automatic Regeneration is Operated Frequently
- S-21 Active Regeneration is Operated for Long
- S-22 White Smoke Comes Out in the Process of Active Regeneration
50 - DISASSEMBLY AND ASSEMBLY
- HOW TO READ THIS SECTION
- Removal And Installation Of Assemblies
- Disassembly And Assembly Of Assemblies
- Coating Materials List
- SKETCHES OF SPECIAL TOOLS
- CONNECTOR REPAIR PROCEDURES
- Stripping Insulation
- Wire Inspection
- Contact Terminal Removal (HD30 Type)
- Crimping Contact Terminal (HD30 Type)
- Insertion Of Contact Terminal (HD30 Type)
- Contact Terminal Removal (DT Type)
- Crimping Contact Terminal (DT Type)
- Insertion Of Contact Terminal (DT Type)
- ENGINE AND COOLING SYSTEM
- Removal and Installation of Supply Pump Assembly
- Fuel Injector Assembly
- Removal and Installation of Cylinder Head Assembly
- Removal and Installation of Radiator Assembly
- Removal and Installation of Hydraulic Oil Cooler Assembly
- Removal and Installation of Aftercooler Assembly
- Removal and Installation Engine And Main Pump Assembly
- Special Tools
- Removal and Installation of Engine Front Oil Seal
- Removal and Installation of Engine Rear Oil Seal
- Removal and Installation of Fuel Cooler Assembly
- Removal and Installation of Fuel Tank Assembly
- Removal and Installation of Engine Hood Assembly
- Removal and Installation of KDPF Assembly
- Disassembly and Assembly of KDPF
- Removal and Installation of KCCV Assembly
- Removal and Installation of Air Cleaner Assembly
- POWER TRAIN
- Removal and Installation of Travel Motor and Final Drive Assembly
- Disassembly and Assembly of Final Drive
- Removal and Installation of Swing Motor and Swing Machinery Assembly
- Disassembly and Assembly of Swing Machinery
- Removal and Installation of Swing Circle Assembly
- UNDERCARRIAGE AND FRAME
- Separation and Connection of Track Shoe Assembly
- Removal and Installation of Sprocket
- Removal and Installation of Idler and Idler Cushion Assembly
- Disassembly and Assembly of Idler
- Disassembly and Assembly of Idler Cushion
- Disassembly and Assembly of Track Roller
- Disassembly and Assembly of Carrier Roller
- Removal and Installation of Revolving Frame Assembly
- Removal and Installation of Counterweight Assembly
- HYDRAULIC SYSTEM
- Center Swivel Joint
- Disassembly and Assembly of Swivel Joint
- Removal and Installation of Hydraulic Tank Assembly
- Removal and Installation of Main Pump Assembly
- Removal and Installation of Control Valve
- Disassembly and Assembly of Control Valve
- Disassembly and Assembly of Work Equipment PPC Valve
- Disassembly and Assembly of Travel PPC Valve
- WORK EQUIPMENT
- Removal and Installation of Work Equipment Assembly
- CAB AND ITS ATTACHMENTS
- Removal and Installation of Operator's Cab Assembly
- Removal and Installation of Operator Cab Glass (Fixed Glass)
- Removal and Installation of Front Window Assembly
- Removal and Installation of Floor Frame Assembly
- Removal and Installation of Air Conditioner Unit Assembly
- Removal and Installation of Operator’s Seat
- Removal and Installation of Seat Belt
- Removal and Installation of Front Wiper Assembly
- ELECTRICAL SYSTEM
- Removal and Installation of Air Conditioner Compressor Assembly
- Removal and Installation of Air Conditioner Condenser Assembly
- Removal and Installation of Engine Controller Assembly
- Removal and Installation of Pump Controller Assembly
- Removal and Installation of Machine Monitor Assembly
- Removal and Installation of Pump Swash Plate Sensor
- Removal and Installation of Mass Air Flow and Temperature Sensor
- Removal and Installation of KOMTRAX Terminal Assembly
60 - MAINTENANCE STANDARD
- ENGINE AND COOLING SYSTEM
- Engine Mounts
- Cooling System
- POWER TRAIN
- Swing Circle
- Swing Machinery
- Final Drive
- Sprocket
- UNDERCARRIAGE AND FRAME
- Track Frame and Idler Cushion
- Idler
- Track Roller
- Carrier Roller
- Track Shoe
- Triple Grouser Shoe
- Swamp Shoe
- Road Liner
- HYDRAULIC SYSTEM
- Hydraulic Tank
- Main Pump
- Control Valve
- Swing Motor
- Travel Motor
- PPC Valve
- Solenoid Valve
- Attachment Circuit Selector Valve
- Center Swivel Joint
- WORK EQUIPMENT
- Dimensions of Components
- Dimensions of Arm
- Boom Cylinder
- Arm Cylinder
- Bucket Cylinder
80 - AIR CONDITIONER
- AIR CONDITIONING SYSTEM
- Precautions for Refrigerant
- Air Conditioner Component
- Structure and Function of Refrigeration System
- Overview of Refrigeration System
- Air Conditioner Unit
- Functions of Major Components
- Inspection and Troubleshooting Procedure of Air Conditioner
- Air Conditioner Circuit Diagram and Arrangement of Connector Pins
- System Diagram
- Air Conditioner Controller Input and Output Signals
- Parts and Connectors Layout
- Layout of Air Conditioner Related Parts and Connectors
- Testing Air Leakage (Duct)
- Testing with Self-Diagnosis Function
- How to Enter Air Conditioner "Electrical Systems" Screen in Service Mode of the Machine Monitor
- Testing Vent (Mode) Changeover
- Testing FRESH/RECIRC Air Changeover
- Testing Sunlight Sensor
- Testing (Dual) Pressure Switch for Refrigerant
- Testing Relay
- Troubleshooting Chart 1
- Troubleshooting Chart 2
- Information Mentioned in Troubleshooting Table
- Failure Code List Related to Air Conditioner
- Failure Code [879AKA] A/C Inner Sensor Open Circuit
- Failure Code [879AKB] A/C Inner Sensor Short Circuit
- Failure Code [879BKA] A/C Outer Sensor Open Circuit
- Failure Code [879BKB] A/C Outer Sensor Short Circuit
- Failure Code [879CKA] Ventilating Sensor Open Circuit
- Failure Code [879CKB] Ventilating Sensor Short Circuit
- Failure code [879DKZ] Sunlight Sensor Open or Short Circuit
- Failure Code [879EMC] Ventilation Damper Abnormality
- Failure Code [879FMC] Ventilation Damper Abnormality
- Failure Code [879GKX] Refrigerant Abnormality
- A-1 Troubleshooting for Power Supply System (The Air Conditioner Does Not Operate)
- A-2 Troubleshooting of Compressor System (Air is Not Cooled)
- A-3 Troubleshooting of Blower Motor System (Air Does Not Come Out or Air Flow is Normal)
- A-4 Troubleshooting for FRESH/RECIRC Air Changeover
- Troubleshooting with Gauge Pressure
- Testing Refrigerant Pressure
- Precautions for Disconnecting and Connecting Refrigerant Piping
- Tightening Torque for Joint Portion of Refrigerant Piping
- Filling Compressor Oil
- Desiccant Replacement
90 DIAGRAMS AND SCHEMATICS
- HYDRAULIC SYSTEM
- Symbols in Hydraulic Circuit Diagrams
- Hydraulic Circuit Diagram and Name of Valves
- Hydraulic Circuit Diagram (1/2)
- Hydraulic Circuit Diagram (2/2)
- ELECTRICAL SYSTEM
- Symbols in Electrical Circuit Diagrams
- Air Conditioner Electrical Circuit
- Electrical Control System Diagram
- Electrical Diagram (1/5)
- Electrical Diagram (2/5)
- Electrical Diagram (3/5)
- Electrical Diagram (4/5)
- Electrical Diagram (5/5)
- Connector List and Stereogram