Komatsu PC238USLC-11 Shop Manual SEN06635-CF

Data Size: 192.69 MB 
File Type: PDF 
Language: English 
Manufacturer: Komatsu 
Applicable Machine: Hydraulic Excavator 
Document: Shop Manual, Error Code, Electrical Schematic, Hydraulic Schematic 
Machine Model: Komatsu PC238USLC-11 Hydraulic Excavator 
Serial Number: C50001 and up 
Book Number: SEN06635-CF 
Page: 3200 Pages

List Contents:

00 Index and Foreword 
Abbreviation List 
Foreword, Safety, Basic Information 
How to Read the Shop Manual 
Safety Notice for Operation 
Precautions to Prevent Fire 
Procedures If Fire Occurs 
Precautions When You Discard Waste Materials 
Procedures for Exhaust Gas Regulations 
Precautions for DEF 
Precautions When You Handle Hydraulic Equipment 
Precautions When You Disconnect and Connect Pipings 
Precautions When You Handle Electrical Equipment 
Precautions When You Handle Fuel System Equipment 
Precautions When You Handle Intake System Equipment 
Practical Use of KOMTRAX 
Disconnect and Connect Push-Pull Type Coupler 
Precautions for Disconnection and Connection of Connectors 
Disconnect and Connect Deutsch Connector 
How to Disconnect and Connect Slide Lock Type Connector 
Disconnect and Connect Connector with Lock to Pull 
Disconnect and Connect Connector with Lock to Push 
Disconnect and Connect Connector with Housing to Rotate 
How to Read the Codes for Electric Cable 
Explanation of Terms for Maintenance Standard 
Standard Tightening Torque Table 
Conversion Table 
01 Specification 
Table of Contents 
Specifications 
Specification Drawing 
Working Range Drawings 
Specifications 
Weight Table 
Fuel, Coolant, Lubricants (For North America) 
10 Structure and Function 
Table of Contents 
Urea SCR System 
Layout Drawing of Urea SCR System 
Urea SCR System Diagram 
Function of Urea SCR System 
Component Parts of Urea SCR System 
Boot-up System 
Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal) 
Layout Drawing of Boot-up System (Machine with Gateway Function Controller) 
System Operating Lamp System 
Battery Disconnect Switch 
Engine System 
Layout Drawing of Engine System 
Engine Control System 
Auto-Deceleration System 
Engine Automatic Warm-up System 
Overheat Prevention System 
Turbocharger Protection System 
Automatic Idle Stop System 
Component Parts of Engine System 
00 Index and Foreword 
Abbreviation List 
Foreword, Safety, Basic Information 
How to Read the Shop Manual 
Safety Notice for Operation 
Precautions to Prevent Fire 
Procedures If Fire Occurs 
Precautions When You Discard Waste Materials 
Procedures for Exhaust Gas Regulations 
Precautions for DEF 
Precautions When You Handle Hydraulic Equipment 
Precautions When You Disconnect and Connect Pipings 
Precautions When You Handle Electrical Equipment 
Precautions When You Handle Fuel System Equipment 
Precautions When You Handle Intake System Equipment 
Practical Use of KOMTRAX 
Disconnect and Connect Push-Pull Type Coupler 
Precautions for Disconnection and Connection of Connectors 
Disconnect and Connect Deutsch Connector 
How to Disconnect and Connect Slide Lock Type Connector 
Disconnect and Connect Connector with Lock to Pull 
Disconnect and Connect Connector with Lock to Push 
Disconnect and Connect Connector with Housing to Rotate 
How to Read the Codes for Electric Cable 
Explanation of Terms for Maintenance Standard 
Standard Tightening Torque Table 
Conversion Table 
01 Specification 
Table of Contents 
Specifications 
Specification Drawing 
Working Range Drawings 
Specifications 
Weight Table 
Fuel, Coolant, Lubricants (For North America) 
10 Structure and Function 
Table of Contents 
Urea SCR System 
Layout Drawing of Urea SCR System 
Urea SCR System Diagram 
Function of Urea SCR System 
Component Parts of Urea SCR System 
Boot-up System 
Layout Drawing of Boot-up System (Machine with KOMTRAX Terminal) 
Layout Drawing of Boot-up System (Machine with Gateway Function Controller) 
System Operating Lamp System 
Battery Disconnect Switch 
Engine System 
Layout Drawing of Engine System 
Engine Control System 
Auto-Deceleration System 
Engine Automatic Warm-up System 
Overheat Prevention System 
Turbocharger Protection System 
Automatic Idle Stop System 
Component Parts of Engine System 
Cooling System 
Layout Drawing of Cooling System 
Fan Speed Control System of Fan Clutch 
Engine Output Control System of Fan Clutch 
Component Parts of Cooling System 
Control System 
Layout Drawing of Control System (Machine with KOMTRAX Terminal) 
Layout Drawing of Control System (Machine with Gateway Function Controller) 
Machine Monitor System 
KomVision System 
KOMTRAX System 
Component Parts of Control System 
Hydraulic System 
Layout Drawing of Hydraulic System 
CLSS 
Engine and Pump Combined Control System 
Pump and Valve Control System 
Component Parts of Hydraulic System 
Work Equipment System 
Layout Drawing of Work Equipment System 
One-Touch Power Maximizing System 
PPC Lock System 
Work Equipment and Travel Automatic Lock System 
Attachment Oil Flow Adjuster System 
Tool Control System 
Component Parts of Work Equipment System 
Swing System 
Layout Drawing of Swing System 
Swing Control System Diagram 
Component Parts of Swing System 
Travel System 
Layout Drawing of Travel System 
System Diagram of Travel Control System 
Component Parts of Travel System 
Undercarriage and Frame 
Layout Drawing of Undercarriage 
Work Equipment 
Structure of Work Equipment 
Function of Work Equipment 
Work Equipment Clearance Adjustment Shim 
Bucket Clearance Adjustment Shim 
CAB Related Parts 
ROPS CAB 
CAB Mount 
CAB Tipping Stopper 
Remove Wiring Harness Out of Cab 
20 Standard Value Table 
Table of Contents 
Standard Value Table for Engine 
Standard Value Table for Engine: PC238USLC-11 
Standard Value Table for Machine 
Standard Value Table for Machine: PC238USLC-11 
Machine Posture and Procedures to Measure Performance 
30 Testing and Adjusting 
Table of Contents 
Precautions Before Work 
Related Information on Testing and Adjusting 
Tools for Testing and Adjusting 
Sketch of Tools for Testing and Adjusting 
Engine and Cooling System 
Examine Engine Speed 
Examine Boost Pressure 
Examine Exhaust Gas Color 
Examine Mass Air Flow and Temperature Sensor 
Examine and Adjust Valve Clearance 
Examine Compression Pressure 
Examine Blowby Pressure 
Examine Engine Oil Pressure 
Examine EGR Valve and VGT Oil Pressure 
Examine Fuel Pressure 
Examine Fuel Discharge, Return and Leakage 
Bleed Air from Fuel System 
Examine Fuel Circuit for Leakage 
Handle Cylinder Cut-out Mode Operation 
Handle No-Injection Cranking Operation 
Examine and Adjust Air Conditioner Compressor Belt Tension 
Examine Fan Belt and Alternator Belt 
Examine Automatic Tensioner 
Examine Cooling Fan Speed 
Write Correction for Ash in Soot Accumulation to Engine Controller 
Examine SCR Related Functions 
Clean DEF Tank 
Clean DEF Pump 
Bleed Air from Coolant Circuit of DEF Tank 
Power Train 
Examine Swing Circle Bearing Clearance 
Undercarriage and Frame 
Examine and Adjust Track Tension 
Hydraulic System 
Release Remained Pressure in Hydraulic Circuit 
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 
Examine Oil Pressure of Control Circuit 
Examine and adjust oil pressure in pump PC control circuit 
Examine and Adjust Oil Pressure in Pump LS Control Circuit 
Examine Outlet Pressure of Solenoid Valve 
Examine PPC Valve Outlet Pressure 
Examine Attachment Circuit Oil Pressure 
Adjust Play of Work Equipment and Swing PPC Valves 
Examine Pump Swash Plate Sensor 
Examine Parts Which Cause Hydraulic Drift of Work Equipment 
Examine Oil Leakage 
Bleed Air from Hydraulic System 
Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 
Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) 
Replace Accumulator Bladder on High Pressure Side for Attachment Piping 
Work Equipment 
Adjust Boom Angle Potentiometer 
CAB Related Parts 
Examine CAB Tipping Stopper 
How to Adjust Mirrors 
Electrical System 
Set and Operate Machine Monitor 
How to Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal) 
How to Start Up KOMTRAX System (Machine with Gateway Function Controller) 
Adjust Rearview Camera Angle 
Adjust KomVision Camera Angle 
Adjust KomVision Related Function 
Set Region of Bluetooth® Compatible Radio 
Handle Voltage Circuit of Engine Controller 
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal) 
Handle Battery Disconnect Switch (Machine with Gateway Function Controller) 
Examine Diodes 
Pm Clinic 
Pm Clinic Service 
40 Troubleshooting 
Table of Contents 
Precautions Before Work 
Related Information to Troubleshooting 
General Troubleshooting Points 
Troubleshooting Points for Urea SCR System 
Sequence of Events in Troubleshooting 
Checks Before Troubleshooting 
Inspection Procedure Before Troubleshooting 
Test in Accordance with Testing Procedure 
Preparation for Troubleshooting of Electrical System 
Procedure for Troubleshooting 
Symptom and Troubleshooting Numbers 
Information Shown in Troubleshooting Table 
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 
Connector List and Layout (Machine with KOMTRAX Terminal) 
Connector List and Layout (Machine with Gateway Function Controller) 
Connector Contact Connection Table 
T-Branch Box and T-Branch Adapter Table 
Fuse Location Table (Machine with KOMTRAX Terminal) 
Fuse Location Table (Machine with Gateway Function Controller) 
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 
Failure Code Table 
Troubleshooting by Failure Code (Display of Code) 
Failure Code [879AKA] 
Failure Code [879AKB] 
Failure Code [879BKA] 
Failure Code [879BKB] 
Failure Code [879CKA] 
Failure Code [879CKB] 
Failure Code [879DKZ] 
Failure Code [879EMC] 
Failure Code [879FMC] 
Failure Code [879GKX] 
Failure Code [989L00] 
Failure Code [989M00] 
Failure Code [989N00] 
Failure Code [A1U0N3] 
Failure Code [A1U0N4] 
Failure Code [A900FR] 
Failure Code [A900N6] 
Failure Code [A900NY] 
Failure Code [AA10NX] 
Failure Code [AB00KE] 
Failure Code [AQ10N3] 
Failure Code [AS00N3] 
Failure Code [AS00R2] 
Failure Code [AS00R3] 
Adjust KomVision Camera Angle 
Adjust KomVision Related Function 
Set Region of Bluetooth® Compatible Radio 
Handle Voltage Circuit of Engine Controller 
Handle Battery Disconnect Switch (Machine with KOMTRAX Terminal) 
Handle Battery Disconnect Switch (Machine with Gateway Function Controller) 
Examine Diodes 
Pm Clinic 
Pm Clinic Service 
40 Troubleshooting 
Table of Contents 
Precautions Before Work 
Related Information to Troubleshooting 
General Troubleshooting Points 
Troubleshooting Points for Urea SCR System 
Sequence of Events in Troubleshooting 
Checks Before Troubleshooting 
Inspection Procedure Before Troubleshooting 
Test in Accordance with Testing Procedure 
Preparation for Troubleshooting of Electrical System 
Procedure for Troubleshooting 
Symptom and Troubleshooting Numbers 
Information Shown in Troubleshooting Table 
Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 
Connector List and Layout (Machine with KOMTRAX Terminal) 
Connector List and Layout (Machine with Gateway Function Controller) 
Connector Contact Connection Table 
T-Branch Box and T-Branch Adapter Table 
Fuse Location Table (Machine with KOMTRAX Terminal) 
Fuse Location Table (Machine with Gateway Function Controller) 
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) 
Failure Code Table 
Troubleshooting by Failure Code (Display of Code) 
Failure Code [879AKA] 
Failure Code [879AKB] 
Failure Code [879BKA] 
Failure Code [879BKB] 
Failure Code [879CKA] 
Failure Code [879CKB] 
Failure Code [879DKZ] 
Failure Code [879EMC] 
Failure Code [879FMC] 
Failure Code [879GKX] 
Failure Code [989L00] 
Failure Code [989M00] 
Failure Code [989N00] 
Failure Code [A1U0N3] 
Failure Code [A1U0N4] 
Failure Code [A900FR] 
Failure Code [A900N6] 
Failure Code [A900NY] 
Failure Code [AA10NX] 
Failure Code [AB00KE] 
Failure Code [AQ10N3] 
Failure Code [AS00N3] 
Failure Code [AS00R2] 
Failure Code [AS00R3] 
Failure Code [AS00R4] 
Failure Code [AS00R5] 
Failure Code [AS00R6] 
Failure Code [AS00ZK] 
Failure Code [AS10KM] 
Failure Code [AS10NR] 
Failure Code [AS10NT] 
Failure Code [B@BAZG] 
Failure Code [B@BAZK] 
Failure Code [B@BCNS] 
Failure Code [B@BCQA] 
Failure Code [B@BCZK] 
Failure Code [B@HANS] 
Failure Code [CA115] 
Failure Code [CA122] 
Failure Code [CA123] 
Failure Code [CA131] 
Failure Code [CA132] 
Failure Code [CA144] 
Failure Code [CA145] 
Failure Code [CA153] 
Failure Code [CA154] 
Failure Code [CA187] 
Failure Code [CA221] 
Failure Code [CA222] 
Failure Code [CA227] 
Failure Code [CA234] 
Failure Code [CA238] 
Failure Code [CA239] 
Failure Code [CA249] 
Failure Code [CA256] 
Failure Code [CA271] 
Failure Code [CA272] 
Failure Code [CA322] 
Failure Code [CA323] 
Failure Code [CA324] 
Failure Code [CA325] 
Failure Code [CA331] 
Failure Code [CA332] 
Failure Code [CA343] 
Failure Code [CA351] 
Failure Code [CA352] 
Failure Code [CA356] 
Failure Code [CA357] 
Failure Code [CA386] 
Failure Code [CA428] 
Failure Code [CA429] 
Failure Code [CA435] 
Failure Code [CA441] 
Failure Code [CA442] 
Failure Code [CA449] 
Failure Code [CA451] 
Failure Code [CA452] 
Failure Code [CA488] 
Failure Code [CA515] 
Failure Code [CA516] 
Failure Code [CA553] 
Failure Code [CA555] 
Failure Code [AS00R4] 
Failure Code [AS00R5] 
Failure Code [AS00R6] 
Failure Code [AS00ZK] 
Failure Code [AS10KM] 
Failure Code [AS10NR] 
Failure Code [AS10NT] 
Failure Code [B@BAZG] 
Failure Code [B@BAZK] 
Failure Code [B@BCNS] 
Failure Code [B@BCQA] 
Failure Code [B@BCZK] 
Failure Code [B@HANS] 
Failure Code [CA115] 
Failure Code [CA122] 
Failure Code [CA123] 
Failure Code [CA131] 
Failure Code [CA132] 
Failure Code [CA144] 
Failure Code [CA145] 
Failure Code [CA153] 
Failure Code [CA154] 
Failure Code [CA187] 
Failure Code [CA221] 
Failure Code [CA222] 
Failure Code [CA227] 
Failure Code [CA234] 
Failure Code [CA238] 
Failure Code [CA239] 
Failure Code [CA249] 
Failure Code [CA256] 
Failure Code [CA271] 
Failure Code [CA272] 
Failure Code [CA322] 
Failure Code [CA323] 
Failure Code [CA324] 
Failure Code [CA325] 
Failure Code [CA331] 
Failure Code [CA332] 
Failure Code [CA343] 
Failure Code [CA351] 
Failure Code [CA352] 
Failure Code [CA356] 
Failure Code [CA357] 
Failure Code [CA386] 
Failure Code [CA428] 
Failure Code [CA429] 
Failure Code [CA435] 
Failure Code [CA441] 
Failure Code [CA442] 
Failure Code [CA449] 
Failure Code [CA451] 
Failure Code [CA452] 
Failure Code [CA488] 
Failure Code [CA515] 
Failure Code [CA516] 
Failure Code [CA553] 
Failure Code [CA555] 
Failure Code [CA556] 
Failure Code [CA559] 
Failure Code [CA595] 
Failure Code [CA687] 
Failure Code [CA689] 
Failure Code [CA691] 
Failure Code [CA692] 
Failure Code [CA697] 
Failure Code [CA698] 
Failure Code [CA731] 
Failure Code [CA778] 
Failure Code [CA1117] 
Failure Code [CA1664] 
Failure Code [CA1669] 
Failure Code [CA1673] 
Failure Code [CA1677] 
Failure Code [CA1678] 
Failure Code [CA1682] 
Failure Code [CA1683] 
Failure Code [CA1684] 
Failure Code [CA1686] 
Failure Code [CA1691] 
Failure Code [CA1694] 
Failure Code [CA1695] 
Failure Code [CA1696] 
Failure Code [CA1712] 
Failure Code [CA1713] 
Failure Code [CA1714] 
Failure Code [CA1715] 
Failure Code [CA1776] 
Failure Code [CA1777] 
Failure Code [CA1843] 
Failure Code [CA1844] 
Failure Code [CA1879] 
Failure Code [CA1881] 
Failure Code [CA1883] 
Failure Code [CA1885] 
Failure Code [CA1887] 
Failure Code [CA1921] 
Failure Code [CA1922] 
Failure Code [CA1942] 
Failure Code [CA1993] 
Failure Code [CA2185] 
Failure Code [CA2186] 
Failure Code [CA2249] 
Failure Code [CA2271] 
Failure Code [CA2272] 
Failure Code [CA2288] 
Failure Code [CA2311] 
Failure Code [CA2349] 
Failure Code [CA2353] 
Failure Code [CA2357] 
Failure Code [CA2381] 
Failure Code [CA2382] 
Failure Code [CA2383] 
Failure Code [CA2386] 
Failure Code [CA2387] 
Failure Code [CA2555] 
Failure Code [CA2556] 
Failure Code [CA2637] 
Failure Code [CA2639] 
Failure Code [CA2771] 
Failure Code [CA2777] 
Failure Code [CA2976] 
Failure Code [CA3133] 
Failure Code [CA3134] 
Failure Code [CA3135] 
Failure Code [CA3142] 
Failure Code [CA3143] 
Failure Code [CA3144] 
Failure Code [CA3146] 
Failure Code [CA3147] 
Failure Code [CA3148] 
Failure Code [CA3151] 
Failure Code [CA3165] 
Failure Code [CA3229] 
Failure Code [CA3231] 
Failure Code [CA3232] 
Failure Code [CA3235] 
Failure Code [CA3239] 
Failure Code [CA3241] 
Failure Code [CA3242] 
Failure Code [CA3251] 
Failure Code [CA3253] 
Failure Code [CA3254] 
Failure Code [CA3255] 
Failure Code [CA3256] 
Failure Code [CA3311] 
Failure Code [CA3312] 
Failure Code [CA3313] 
Failure Code [CA3314] 
Failure Code [CA3315] 
Failure Code [CA3316] 
Failure Code [CA3317] 
Failure Code [CA3318] 
Failure Code [CA3319] 
Failure Code [CA3321] 
Failure Code [CA3322] 
Failure Code [CA3419] 
Failure Code [CA3421] 
Failure Code [CA3497] 
Failure Code [CA3498] 
Failure Code [CA3543] 
Failure Code [CA3545] 
Failure Code [CA3547] 
Failure Code [CA3558] 
Failure Code [CA3559] 
Failure Code [CA3562] 
Failure Code [CA3563] 
Failure Code [CA3567] 
Failure Code [CA3568] 
Failure Code [CA3571] 
Failure Code [CA3572] 
Failure Code [CA3574] 
Failure Code [CA3575] 
Failure Code [CA3577] 
Failure Code [CA3578] 
Failure Code [CA3582] 
Failure Code [CA3583] 
Failure Code [CA3596] 
Failure Code [CA3649] 
Failure Code [CA3681] 
Failure Code [CA3682] 
Failure Code [CA3713] 
Failure Code [CA3717] 
Failure Code [CA3718] 
Failure Code [CA3725] 
Failure Code [CA3741] 
Failure Code [CA3748] 
Failure Code [CA3751] 
Failure Code [CA3755] 
Failure Code [CA3866] 
Failure Code [CA3867] 
Failure Code [CA3868] 
Failure Code [CA3899] 
Failure Code [CA3911] 
Failure Code [CA3912] 
Failure Code [CA3932] 
Failure Code [CA3933] 
Failure Code [CA3934] 
Failure Code [CA3935] 
Failure Code [CA3936] 
Failure Code [CA4151] 
Failure Code [CA4152] 
Failure Code [CA4155] 
Failure Code [CA4156] 
Failure Code [CA4157] 
Failure Code [CA4158] 
Failure Code [CA4159] 
Failure Code [CA4161] 
Failure Code [CA4162] 
Failure Code [CA4163] 
Failure Code [CA4164] 
Failure Code [CA4165] 
Failure Code [CA4166] 
Failure Code [CA4168] 
Failure Code [CA4169] 
Failure Code [CA4171] 
Failure Code [CA4249] 
Failure Code [CA4251] 
Failure Code [CA4259] 
Failure Code [CA4261] 
Failure Code [CA4277] 
Failure Code [CA4281] 
Failure Code [CA4459] 
Failure Code [CA4461] 
Failure Code [CA4658] 
Failure Code [CA4731] 
Failure Code [CA4732] 
Failure Code [CA4739] 
Failure Code [CA4768] 
Failure Code [CA4769] 
Failure Code [CA4842] 
Failure Code [CA4952] (Machine with KOMTRAX Terminal) 
Failure Code [CA4952] (Machine with Gateway Function Controller) 
Failure Code [CA5115] 
Failure Code [CA5179] 
Failure Code [CA5181] 
Failure Code [CA5383] 
Failure Code [D110KB] 
Failure Code [D19JKZ] 
Failure Code [D811MC] (Machine with KOMTRAX Terminal) 
Failure Code [D811MC] (Machine with Gateway Function Controller) 
Failure Code [D862KA] (Machine with KOMTRAX Terminal) 
Failure Code [D862KA] (Machine with Gateway Function Controller) 
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal) 
Failure Code [D8ALKA] (Machine with Gateway Function Controller) 
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal) 
Failure Code [D8ALKB] (Machine with Gateway Function Controller) 
Failure Code [D8AQKR] (Machine with KOMTRAX Terminal) 
Failure Code [D8AQKR] (Machine with Gateway Function Controller) 
Failure Code [D8ARKR] 
Failure Code [D8G1KT] 
Failure Code [D8G6KT] 
Failure Code [DA20MC] 
Failure Code [DA22KK] 
Failure Code [DA25KP] 
Failure Code [DA26KP] 
Failure Code [DA29KQ] 
Failure Code [DA2LKA] (Machine with KOMTRAX Terminal) 
Failure Code [DA2LKA] (Machine with Gateway Function Controller) 
Failure Code [DA2LKB] (Machine with KOMTRAX Terminal) 
Failure Code [DA2LKB] (Machine with Gateway Function Controller) 
Failure Code [DA2QKR] (Machine with KOMTRAX Terminal) 
Failure Code [DA2QKR] (Machine with Gateway Function Controller) 
Failure Code [DA2RKR] (Machine with KOMTRAX Terminal) 
Failure Code [DA2RKR] (Machine with Gateway Function Controller) 
Failure Code [DAF0KM] 
Failure Code [DAF0MB] 
Failure Code [DAF0MC] 
Failure Code [DAF8KB] 
Failure Code [DAF9KQ] 
Failure Code [DAFGMC] (Machine with KOMTRAX Terminal) 
Failure Code [DAFGMC] (Machine with Gateway Function Controller) 
Failure Code [DAFLKA] (Machine with KOMTRAX Terminal) 
Failure Code [DAFLKA] (Machine with Gateway Function Controller) 
Failure Code [DAFLKB] (Machine with KOMTRAX Terminal) 
Failure Code [DAFLKB] (Machine with Gateway Function Controller) 
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal) 
Failure Code [DAFQKR] (Machine with Gateway Function Controller) 
Failure Code [DAZ9KQ] 
Failure Code [DAZQKR] (Machine with KOMTRAX Terminal) 
Failure Code [DAZQKR] (Machine with Gateway Function Controller) 
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal) 
Failure Code [DB2QKR] (Machine with Gateway Function Controller) 
Failure Code [DB2RKR] (Machine with KOMTRAX Terminal) 
Failure Code [DB2RKR] (Machine with Gateway Function Controller) 
Failure Code [DBP0KM] 
Failure Code [DBP0KT] 
Failure Code [DBP5KB] 
Failure Code [DBP5KY] 
Failure Code [DBPQKR] (Machine with KOMTRAX Terminal) 
Failure Code [CA4952] (Machine with Gateway Function Controller) 
Failure Code [CA5115] 
Failure Code [CA5179] 
Failure Code [CA5181] 
Failure Code [CA5383] 
Failure Code [D110KB] 
Failure Code [D19JKZ] 
Failure Code [D811MC] (Machine with KOMTRAX Terminal) 
Failure Code [D811MC] (Machine with Gateway Function Controller) 
Failure Code [D862KA] (Machine with KOMTRAX Terminal) 
Failure Code [D862KA] (Machine with Gateway Function Controller) 
Failure Code [D8ALKA] (Machine with KOMTRAX Terminal) 
Failure Code [D8ALKA] (Machine with Gateway Function Controller) 
Failure Code [D8ALKB] (Machine with KOMTRAX Terminal) 
Failure Code [D8ALKB] (Machine with Gateway Function Controller) 
Failure Code [D8AQKR] (Machine with KOMTRAX Terminal) 
Failure Code [D8AQKR] (Machine with Gateway Function Controller) 
Failure Code [D8ARKR] 
Failure Code [D8G1KT] 
Failure Code [D8G6KT] 
Failure Code [DA20MC] 
Failure Code [DA22KK] 
Failure Code [DA25KP] 
Failure Code [DA26KP] 
Failure Code [DA29KQ] 
Failure Code [DA2LKA] (Machine with KOMTRAX Terminal) 
Failure Code [DA2LKA] (Machine with Gateway Function Controller) 
Failure Code [DA2LKB] (Machine with KOMTRAX Terminal) 
Failure Code [DA2LKB] (Machine with Gateway Function Controller) 
Failure Code [DA2QKR] (Machine with KOMTRAX Terminal) 
Failure Code [DA2QKR] (Machine with Gateway Function Controller) 
Failure Code [DA2RKR] (Machine with KOMTRAX Terminal) 
Failure Code [DA2RKR] (Machine with Gateway Function Controller) 
Failure Code [DAF0KM] 
Failure Code [DAF0MB] 
Failure Code [DAF0MC] 
Failure Code [DAF8KB] 
Failure Code [DAF9KQ] 
Failure Code [DAFGMC] (Machine with KOMTRAX Terminal) 
Failure Code [DAFGMC] (Machine with Gateway Function Controller) 
Failure Code [DAFLKA] (Machine with KOMTRAX Terminal) 
Failure Code [DAFLKA] (Machine with Gateway Function Controller) 
Failure Code [DAFLKB] (Machine with KOMTRAX Terminal) 
Failure Code [DAFLKB] (Machine with Gateway Function Controller) 
Failure Code [DAFQKR] (Machine with KOMTRAX Terminal) 
Failure Code [DAFQKR] (Machine with Gateway Function Controller) 
Failure Code [DAZ9KQ] 
Failure Code [DAZQKR] (Machine with KOMTRAX Terminal) 
Failure Code [DAZQKR] (Machine with Gateway Function Controller) 
Failure Code [DB2QKR] (Machine with KOMTRAX Terminal) 
Failure Code [DB2QKR] (Machine with Gateway Function Controller) 
Failure Code [DB2RKR] (Machine with KOMTRAX Terminal) 
Failure Code [DB2RKR] (Machine with Gateway Function Controller) 
Failure Code [DBP0KM] 
Failure Code [DBP0KT] 
Failure Code [DBP5KB] 
Failure Code [DBP5KY] 
Failure Code [DBPQKR] (Machine with KOMTRAX Terminal) 
Failure Code [DBPQKR] (Machine with Gateway Function Controller) 
Failure Code [DDNRKA] 
Failure Code [DDNRKY] 
Failure Code [DDNS00] 
Failure Code [DFB1KZ] 
Failure Code [DFB2KZ] 
Failure Code [DFB3L8] 
Failure Code [DFB4L8] 
Failure Code [DFB5KZ] 
Failure Code [DFB6KZ] 
Failure Code [DGH2KA] 
Failure Code [DGH2KB] 
Failure Code [DHA4KA] 
Failure Code [DHAAMA] 
Failure Code [DHACMA] 
Failure Code [DHPAMA] 
Failure Code [DHPBMA] 
Failure Code [DHS3MA] 
Failure Code [DHS4MA] 
Failure Code [DHS8MA] 
Failure Code [DHS9MA] 
Failure Code [DHSAMA] 
Failure Code [DHSBMA] 
Failure Code [DHSCMA] 
Failure Code [DHSDMA] 
Failure Code [DHSFMA] 
Failure Code [DHSGMA] 
Failure Code [DHSHMA] 
Failure Code [DHSJMA] 
Failure Code [DHZAMA] 
Failure Code [DHZCL8] 
Failure Code [DKR0MA] 
Failure Code [DKR1MA] 
Failure Code [DKULKA] 
Failure Code [DKULKB] 
Failure Code [DKULKY] 
Failure Code [DLM5KA] 
Failure Code [DLM5MB] 
Failure Code [DR10KA] 
Failure Code [DR12KA] 
Failure Code [DR20KA] 
Failure Code [DR21KX] 
Failure Code [DR31KX] 
Failure Code [DR40KA] 
Failure Code [DUMBKA] (Machine with KOMTRAX Terminal) 
Failure Code [DUMBKA] (Machine with Gateway Function Controller) 
Failure Code [DUMBKB] (Machine with KOMTRAX Terminal) 
Failure Code [DUMBKB] (Machine with Gateway Function Controller) 
Failure Code [DV00KB] 
Failure Code [DV20KB] 
Failure Code [DW43KA] 
Failure Code [DW43KB] 
Failure Code [DW43KY] 
Failure Code [DW45KA] 
Failure Code [DW45KB] 
Failure Code [DW45KY] 
Failure Code [DW4CKY] 
Failure Code [DW4GKA] 
Failure Code [DW4GKB] 
Failure Code [DW91KA] 
Failure Code [DW91KB] 
Failure Code [DW91KY] 
Failure Code [DWA2KA] 
Failure Code [DWA2KB] 
Failure Code [DWA2KY] 
Failure Code [DWK0KA] 
Failure Code [DWK0KB] 
Failure Code [DWK0KY] 
Failure Code [DWK2KA] 
Failure Code [DWK2KB] 
Failure Code [DWK2KY] 
Failure Code [DWK8KA] 
Failure Code [DWK8KB] 
Failure Code [DWK8KY] 
Failure Code [DWN5KA] 
Failure Code [DWN5KB] 
Failure Code [DWN5KY] 
Failure Code [DWPUKA] 
Failure Code [DWPUKB] 
Failure Code [DWPUKY] 
Failure Code [DXA8KA] 
Failure Code [DXA8KB] 
Failure Code [DXA9KA] 
Failure Code [DXA9KB] 
Failure Code [DXE0KA] 
Failure Code [DXE0KB] 
Failure Code [DXE4KA] 
Failure Code [DXE4KB] 
Failure Code [DXE4KY] 
Failure Code [DXE5KA] 
Failure Code [DXE5KB] 
Failure Code [DXE6KA] 
Failure Code [DXE6KB] 
Failure Code [DXE7KA] 
Failure Code [DXE7KB] 
Failure Code [DXE7KY] 
Failure Code [DXE8KA] 
Failure Code [DXE8KB] 
Failure Code [DXE8KY] 
Failure Code [DXE9KA] 
Failure Code [DXE9KB] 
Failure Code [DXE9KY] 
Failure Code [DXEAKA] 
Failure Code [DXEAKB] 
Failure Code [DXEAKY] 
Failure Code [DXEKKA] 
Failure Code [DXEKKB] 
Failure Code [DXEKKY] 
Failure Code [DXELKA] 
Failure Code [DXELKB] 
Failure Code [DXELKY] 
Failure Code [DY20KA] 
Failure Code [DY20MA] 
Failure Code [DY2CKB] 
Failure Code [DY2DKB] 
Failure Code [DY2EKB] 
Failure Code [F311KA] 
Failure Code [F311KB] 
Failure Code [F312KA] 
Failure Code [F312KB] 
Failure Code [F313KA] 
Failure Code [F313KB] 
Failure Code [F314KA] 
Failure Code [F314KB] 
Failure Code [F315KB] 
Failure Code [F315KY] 
Failure Code [F316KB] 
Failure Code [F316KY] 
Failure Code [F318KB] 
Failure Code [F318KY] 
Failure Code [F31AKB] 
Failure Code [F31AKY] 
Failure Code [F31BKB] 
Failure Code [F31BKY] 
Failure Code [F31CKB] 
Failure Code [F31CKY] 
Failure Code [F31DKB] 
Failure Code [F31DKY] 
Failure Code [F31EKB] 
Failure Code [F31EKY] 
Failure Code [F7FQKR] (Machine with KOMTRAX Terminal) 
Failure Code [F7FQKR] (Machine with Gateway Function Controller) 
Failure Code [F7G0MC] 
Troubleshooting of Electrical System (E-Mode) 
E-1 Engine Does Not Start (Engine Does Not Crank) 
E-2 Manual Preheating System Does Not Operate 
E-3 Automatic Preheating System Does Not Operate 
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor 
Comes On in Yellow 
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level 
Monitor Comes On in Yellow 
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation 
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs 
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs 
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation 
E-12 Fuel Level Monitor Comes On in Red While Engine Runs 
E-13 Water Separator Monitor Comes On in Red While Engine Runs 
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum 
E-18 Display of Fuel Gauge is Different from Actual Fuel Level 
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum 
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 
E-23 Some Areas of Machine Monitor Screen are Not Shown 
E-24 Function Switch Does Not Operate 
E-25 Automatic Warm-up System Does Not Work (in Cold Weather) 
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or 
Does Not Go Out 
E-27 Auto-Decelerator is Not Operated or Canceled with Lever 
Failure Code [F311KA] 
Failure Code [F311KB] 
Failure Code [F312KA] 
Failure Code [F312KB] 
Failure Code [F313KA] 
Failure Code [F313KB] 
Failure Code [F314KA] 
Failure Code [F314KB] 
Failure Code [F315KB] 
Failure Code [F315KY] 
Failure Code [F316KB] 
Failure Code [F316KY] 
Failure Code [F318KB] 
Failure Code [F318KY] 
Failure Code [F31AKB] 
Failure Code [F31AKY] 
Failure Code [F31BKB] 
Failure Code [F31BKY] 
Failure Code [F31CKB] 
Failure Code [F31CKY] 
Failure Code [F31DKB] 
Failure Code [F31DKY] 
Failure Code [F31EKB] 
Failure Code [F31EKY] 
Failure Code [F7FQKR] (Machine with KOMTRAX Terminal) 
Failure Code [F7FQKR] (Machine with Gateway Function Controller) 
Failure Code [F7G0MC] 
Troubleshooting of Electrical System (E-Mode) 
E-1 Engine Does Not Start (Engine Does Not Crank) 
E-2 Manual Preheating System Does Not Operate 
E-3 Automatic Preheating System Does Not Operate 
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor 
Comes On in Yellow 
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level 
Monitor Comes On in Yellow 
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation 
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs 
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs 
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation 
E-12 Fuel Level Monitor Comes On in Red While Engine Runs 
E-13 Water Separator Monitor Comes On in Red While Engine Runs 
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum 
E-18 Display of Fuel Gauge is Different from Actual Fuel Level 
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum 
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature 
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum 
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature 
E-23 Some Areas of Machine Monitor Screen are Not Shown 
E-24 Function Switch Does Not Operate 
E-25 Automatic Warm-up System Does Not Work (in Cold Weather) 
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or 
Does Not Go Out 
E-27 Auto-Decelerator is Not Operated or Canceled with Lever 
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown 
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed 
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change 
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change 
E-32 Alarm Buzzer Cannot be Canceled 
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position 
E-34 Service Mode Cannot be Selected 
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move 
E-36 All Work Equipment, Swing and Travel Do Not Lock 
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing 
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate 
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show 
E-40 One-Touch Power Maximizing Function is Not Cancelled 
E-41 Alarm Does Not Sound During Travel 
E-42 Alarm Does Not Stop When Machine Stops 
E-43 Horn Does Not Sound 
E-44 Horn Does Not Stop 
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out 
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate 
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated 
E-48 "Boom RAISE" is Not Shown Correctly with Monitoring Function 
E-49 "Boom LOWER" is Not Shown Correctly with Monitoring Function 
E-50 "Arm OUT" is Not Shown Correctly with Monitoring Function 
E-51 "Arm IN" is Not Shown Correctly with Monitoring Function 
E-52 "Bucket DUMP" is Not Shown Correctly with Monitoring Function 
E-53 "Bucket CURL" is Not Shown Correctly with Monitoring Function 
E-54 "Swing" is Not Shown Correctly with Monitoring Function 
E-55 "Travel" is Not Shown Correctly with Monitoring Function 
E-56 Service is Not Shown Correctly with Monitoring Function 
E-57 Attachment Hydraulic Circuit Cannot be Changed 
E-58 KOMTRAX System Does Not Operate Correctly 
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 
Information Shown in Troubleshooting Table (H-Mode) 
System Chart of Hydraulic and Mechanical Systems 
Failure Mode and Cause Table 
H-1 All Work Equipment, Swing and Travel Do Not Work 
H-2 All Work Equipment, Swing and Travel Lack Speed and Power 
H-3 Fine Control Performance or Response is Unsatisfactory 
H-4 Unusual Noise is Heard from Around Hydraulic Pump 
H-5 Engine Speed Drops Largely or Engine Stops 
H-6 Speed or Power of Boom is Low 
H-7 Arm Speed or Power is Low 
H-8 Bucket Speed or Power is Low 
H-9 Work Equipment Does Not Move in Single Operation 
H-10 Hydraulic Drift of Boom is Large 
H-11 Hydraulic Drift of Arm is Large 
H-12 Hydraulic Drift of Bucket is Large 
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 
H-14 Time Lag of Work Equipment is Large 
H-15 One-Touch Power Maximizing Function Does Not Operate 
H-16 Attachment Circuit Cannot be Changed 
H-17 Oil Flow in Attachment Circuit Cannot be Changed 
H-18 The Set Pressure of Attachment is Not Output 
H-19 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower 
H-20 In Mixed Operation of Swing and Travel, Travel Speed Drops Largely 
H-21 In Mixed Operation of Swing and Boom Raise, Boom Raise Speed is Low 
H-22 Machine Does Not Travel Straight 
H-23 Machine is Not Steered Correctly or Steering Power is Low 
H-24 Travel Speed is Low 
H-25 One of Tracks Does Not Run 
H-26 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 
H-27 Machine Does Not Swing to Right or Left 
H-28 Upper Structure Swings Only to Right or Left 
H-29 Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left 
H-30 Swing Acceleration or Swing Speed is Low in Only One Direction 
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 
H-32 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 
H-33 Shock is Large When Upper Structure Stops Swing Operation 
H-34 There is Large Unusual Noise When It Stops Swing Operation 
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 
H-36 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 
H-37 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 
H-38 Unusual Noise is Heard from Around Fan 
Troubleshooting of Engine (S-Mode) 
Information Shown in Troubleshooting Table (S-Mode) 
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 
S-2 Engine Cranks but No Exhaust Smoke Comes Out 
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 
S-4 Engine Startability is Unsatisfactory 
S-5 Engine Does Not Pick Up Smoothly 
S-6 Engine Stops During Operation 
S-7 Engine Runs Rough or is Not Stable 
S-8 Engine Lacks Power 
S-9 KDPF Becomes Clogged in a Short Time 
S-10 Engine Oil Consumption is Excessive 
S-11 Oil Becomes Dirty Quickly 
S-12 Fuel Consumption is Excessive 
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 
S-14 Oil Pressure Drops 
S-15 Fuel Mixes Into Engine Oil 
S-16 Water Mixes Into Engine Oil (Milky) 
S-17 Coolant Temperature Increases Too High (Overheating) 
S-18 Unusual Noise is Heard 
S-19 Vibration is Excessive 
S-20 Air Cannot be Bled from Fuel Circuit 
S-21 Active Regeneration is Done Frequently 
S-22 Active Regeneration Continues Long 
S-23 White Smoke is Exhausted During Active Regeneration 
S-24 DEF Consumption is Excessive 
S-25 There is Unusual Smell (Irritating Odor) 
S-26 Foreign Materials Enter DEF (DEF Increases) 
50 Disassembly and Assembly 
Table of Contents 
Precautions Before Work 
Related Information on Disassembly and Assembly 
How to Read This Manual 
Coating Materials List 
Special Tool List 
Sketches of Special Tools 
Engine and Cooling System 
Remove and Install Supply Pump Assembly 
Remove and Install Injector Assembly 
Remove and Install Cylinder Head Assembly 
Remove and Install EGR Valve Assembly 
H-22 Machine Does Not Travel Straight 
H-23 Machine is Not Steered Correctly or Steering Power is Low 
H-24 Travel Speed is Low 
H-25 One of Tracks Does Not Run 
H-26 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast 
H-27 Machine Does Not Swing to Right or Left 
H-28 Upper Structure Swings Only to Right or Left 
H-29 Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left 
H-30 Swing Acceleration or Swing Speed is Low in Only One Direction 
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 
H-32 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 
H-33 Shock is Large When Upper Structure Stops Swing Operation 
H-34 There is Large Unusual Noise When It Stops Swing Operation 
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 
H-36 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) 
H-37 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 
H-38 Unusual Noise is Heard from Around Fan 
Troubleshooting of Engine (S-Mode) 
Information Shown in Troubleshooting Table (S-Mode) 
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 
S-2 Engine Cranks but No Exhaust Smoke Comes Out 
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 
S-4 Engine Startability is Unsatisfactory 
S-5 Engine Does Not Pick Up Smoothly 
S-6 Engine Stops During Operation 
S-7 Engine Runs Rough or is Not Stable 
S-8 Engine Lacks Power 
S-9 KDPF Becomes Clogged in a Short Time 
S-10 Engine Oil Consumption is Excessive 
S-11 Oil Becomes Dirty Quickly 
S-12 Fuel Consumption is Excessive 
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 
S-14 Oil Pressure Drops 
S-15 Fuel Mixes Into Engine Oil 
S-16 Water Mixes Into Engine Oil (Milky) 
S-17 Coolant Temperature Increases Too High (Overheating) 
S-18 Unusual Noise is Heard 
S-19 Vibration is Excessive 
S-20 Air Cannot be Bled from Fuel Circuit 
S-21 Active Regeneration is Done Frequently 
S-22 Active Regeneration Continues Long 
S-23 White Smoke is Exhausted During Active Regeneration 
S-24 DEF Consumption is Excessive 
S-25 There is Unusual Smell (Irritating Odor) 
S-26 Foreign Materials Enter DEF (DEF Increases) 
50 Disassembly and Assembly 
Table of Contents 
Precautions Before Work 
Related Information on Disassembly and Assembly 
How to Read This Manual 
Coating Materials List 
Special Tool List 
Sketches of Special Tools 
Engine and Cooling System 
Remove and Install Supply Pump Assembly 
Remove and Install Injector Assembly 
Remove and Install Cylinder Head Assembly 
Remove and Install EGR Valve Assembly 
Remove and Install EGR Cooler Assembly 
Remove and Install Starter Assembly 
Remove and Install Alternator Belt 
Remove and Install Radiator Assembly 
Remove and Install Hydraulic Oil Cooler Assembly 
Remove and Install Aftercooler Assembly 
Remove and Install Fan Clutch Assembly 
Remove and Install Engine Assembly 
Remove and Install Engine Front Oil Seal 
Remove and Install Engine Rear Oil Seal 
Remove and Install Fuel Cooler Assembly 
Remove and Install Engine Hood Assembly 
Remove and Install Fuel Tank Assembly 
Remove and Install DEF Tank Assembly 
Remove and Install DEF Tank Sensor Flange Assembly 
Remove and Install DEF Tank Sensor 
Remove and Install DEF Tank Strainer 
Remove and Install DEF Tank Filler Port Filter 
Remove and Install KDPF Assembly 
Disassemble and Assemble KDPF Assembly 
Remove and Install SCR Assembly 
Remove and Install KDPF and SCR Assembly 
Remove and Install KDPF and SCR Assembly Bracket 
Remove and Install Bellows Pipe Assembly 
Remove and Install KCCV Assembly 
Remove and Install DEF Mixing Tube 
Remove and Install DEF Injector 
Remove and Install DEF Pump 
Remove and Install DEF Hose 
Remove and Install Air Cleaner Assembly 
Remove and Install Air Conditioner Compressor Assembly 
Remove and Install Air Conditioner Condenser Assembly 
Power Train 
Remove and Install Travel Motor and Final Drive Assembly 
Disassemble and Assemble Final Drive Assembly 
Remove and Install Swing Motor and Swing Machinery Assembly 
Disassemble and Assemble Swing Machinery Assembly 
Remove and Install Swing Circle Assembly 
Undercarriage and Frame 
Separate and Connect Track Assembly 
Remove and Install Sprocket 
Remove and Install Idler and Idler Cushion Assembly 
Disassemble and Assemble Idler Assembly 
Disassemble and Assemble Idler Cushion Assembly 
Disassemble and Assemble Track Roller Assembly 
Disassemble and Assemble Carrier Roller Assembly 
Remove and Install Revolving Frame Assembly 
Remove and Install Counterweight Assembly 
Remove and Install Counterweight Assembly for Maintenance 
Hydraulic System 
Remove and Install Center Swivel Joint Assembly 
Disassemble and Assemble Center Swivel Joint Assembly 
Remove and Install Hydraulic Tank Assembly 
Remove and Install Main Pump Assembly 
Remove and Install Control Valve Assembly 
Disassemble and Assemble Control Valve Assembly 
Disassemble and Assemble Work Equipment PPC Valve Assembly 
Disassemble and Assemble Travel PPC Valve Assembly 
Work Equipment 
Remove and Install Work Equipment Assembly 
Disassemble and Assemble Work Equipment Cylinder Assembly 
CAB Related Parts 
Remove and Install Operator Cab Assembly 
Remove and Install Operator Cab Door 
Remove and Install Operator Cab Glass (Adhered Glass) 
Remove and Install Front Window Assembly 
Remove and Install Floor Frame Assembly 
Remove and Install Air Conditioner Unit Assembly 
Remove and Install Operator Seat 
How to Remove and Install Seat Belt 
Remove and Install Work Equipment Control Lever Assembly 
Remove and Install Front Wiper Assembly 
Electrical System 
Remove and Install Engine Controller Assembly 
Remove and Install Pump Controller Assembly 
Remove and Install KomVision Controller Assembly 
Remove and Install Machine Monitor Assembly 
Remove and Install Mass Air Flow and Temperature Sensor 
Remove and Install KCCV Crankcase Pressure Sensor 
Remove and Install SCR Temperature Sensor 
Remove and Install KomVision Camera 
Remove and Install KOMTRAX Terminal Assembly 
Remove and Install Gateway Function Controller Assembly 
Remove and Install Communication Terminal 
Remove and Install Communication Terminal Wiring Harness 
60 Maintenance Standard 
Table of Contents 
Engine and Cooling System 
Maintenance Standard for Engine Mount 
Maintenance Standard for Cooling System 
Power Train 
Maintenance Standard for Swing Circle 
Maintenance Standard for Swing Machinery 
Maintenance Standard for Final Drive 
Maintenance Standard for Sprocket 
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing 
Undercarriage and Frame 
Maintenance Standard for Track Frame and Idler Cushion 
Maintenance Standard for Idler 
Maintenance Standard for Track Roller 
Maintenance Standard for Carrier Roller 
Maintenance Standard for Track Shoes 
Maintenance Standard for Triple Shoes 
Maintenance Standard for Road Liner 
Maintenance Standard for Flat Shoes 
Hydraulic System 
Maintenance Standard for Hydraulic Tank 
Maintenance Standard for Main Pump 
Maintenance Standard for LS-EPC Valve 
Maintenance Standard for PC-EPC Valve 
Maintenance Standard for Swing Motor 
Maintenance Standard for Travel Motor 
Maintenance Standard for Control Valve 
Maintenance Standard for Work Equipment and Swing PPC Valve 
Maintenance Standard for Travel PPC Valve 
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 
Work Equipment 
Remove and Install Work Equipment Assembly 
Disassemble and Assemble Work Equipment Cylinder Assembly 
CAB Related Parts 
Remove and Install Operator Cab Assembly 
Remove and Install Operator Cab Door 
Remove and Install Operator Cab Glass (Adhered Glass) 
Remove and Install Front Window Assembly 
Remove and Install Floor Frame Assembly 
Remove and Install Air Conditioner Unit Assembly 
Remove and Install Operator Seat 
How to Remove and Install Seat Belt 
Remove and Install Work Equipment Control Lever Assembly 
Remove and Install Front Wiper Assembly 
Electrical System 
Remove and Install Engine Controller Assembly 
Remove and Install Pump Controller Assembly 
Remove and Install KomVision Controller Assembly 
Remove and Install Machine Monitor Assembly 
Remove and Install Mass Air Flow and Temperature Sensor 
Remove and Install KCCV Crankcase Pressure Sensor 
Remove and Install SCR Temperature Sensor 
Remove and Install KomVision Camera 
Remove and Install KOMTRAX Terminal Assembly 
Remove and Install Gateway Function Controller Assembly 
Remove and Install Communication Terminal 
Remove and Install Communication Terminal Wiring Harness 
60 Maintenance Standard 
Table of Contents 
Engine and Cooling System 
Maintenance Standard for Engine Mount 
Maintenance Standard for Cooling System 
Power Train 
Maintenance Standard for Swing Circle 
Maintenance Standard for Swing Machinery 
Maintenance Standard for Final Drive 
Maintenance Standard for Sprocket 
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing 
Undercarriage and Frame 
Maintenance Standard for Track Frame and Idler Cushion 
Maintenance Standard for Idler 
Maintenance Standard for Track Roller 
Maintenance Standard for Carrier Roller 
Maintenance Standard for Track Shoes 
Maintenance Standard for Triple Shoes 
Maintenance Standard for Road Liner 
Maintenance Standard for Flat Shoes 
Hydraulic System 
Maintenance Standard for Hydraulic Tank 
Maintenance Standard for Main Pump 
Maintenance Standard for LS-EPC Valve 
Maintenance Standard for PC-EPC Valve 
Maintenance Standard for Swing Motor 
Maintenance Standard for Travel Motor 
Maintenance Standard for Control Valve 
Maintenance Standard for Work Equipment and Swing PPC Valve 
Maintenance Standard for Travel PPC Valve 
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 
Maintenance Standard for 2nd-Line Attachment PPC Valve 
Maintenance Standard for Solenoid Valve 
Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure) 
Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure) 
Maintenance Standard for Center Swivel Joint 
Work Equipment 
Maintenance Standard for Work Equipment Linkage 
Maintenance Standard for Boom Cylinder (Large Diameter Piston) 
Maintenance Standard for Arm Cylinder 
Maintenance Standard for Bucket Cylinder 
80 Appendix 
Table of Contents 
Precautions Before Work 
Air Conditioner System 
Precautions for Refrigerant 
Air Conditioner Component 
Specifications of Air Conditioner 
Structure and Function of Refrigeration Cycle 
Outline of Refrigeration Cycle 
Component Parts of Air Conditioner System 
Air Conditioner Unit 
Component Parts of Air Conditioner Unit 
Air Conditioner Controller 
Compressor 
Condenser 
Air Conditioner Related Sensors 
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 
System Diagram of Air Conditioner 
Input and Output Signals of Air Conditioner Controller 
Locations of Air Conditioner Parts and Layout of Connectors 
Examine Air Leakage (Duct) 
How to Examine Air Leakage (Duct) 
Examine Air Conditioner with Self-Diagnosis Function 
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 
Examine Vent (Mode) Changeover 
How to Examine Vent (Mode) Changeover 
Examine Fresh/Recirc Air Changeover 
How to Examine Fresh/Recirc Air Changeover 
Examine Sunlight Sensor 
How to Examine Sunlight Sensor 
Examine Refrigerant (Dual) Pressure Switch 
How to Examine Refrigerant (Dual) Pressure Switch 
Examine Relay 
How to Examine Relay 
Air Conditioner Troubleshooting Chart 1 
Air Conditioner Troubleshooting Chart 2 
Information Shown in Troubleshooting Table 
Failure Code [879AKA] 
Failure Code [879AKB] 
Failure Code [879BKA] 
Failure Code [879BKB] 
Failure Code [879CKA] 
Failure Code [879CKB] 
Failure Code [879DKZ] 
Failure Code [879EMC] 
Failure Code [879FMC] 
Failure Code [879GKX] 
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 
A-4 Troubleshooting for Fresh/Recirc Air Changeover 
Troubleshooting by Gauge Pressure 
Connect Service Tool 
How to Connect Service Tool 
Precautions for Disconnection and Connection of Air Conditioner Piping 
Handle Compressor Oil 
Replace Desiccant 
90 Circuit Diagrams 
Table of Contents 
Hydraulic Circuit Diagram 
Symbols Used in Hydraulic Circuit Diagram 
Hydraulic Circuit Diagram (1/5) 
Hydraulic Circuit Diagram (2/5) 
Hydraulic Circuit Diagram (3/5) 
Hydraulic Circuit Diagram (4/5) 
Hydraulic Circuit Diagram (5/5) 
Electrical Circuit Diagram 
Symbols Used in Electric Circuit Diagram 
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (1/9) 
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (2/9) 
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (3/9) 
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (4/9) 
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (5/9) 
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (6/9) 
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (7/9) 
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (8/9) 
Electrical Circuit Diagram (Machine with KOMTRAX Terminal) (9/9) 
Electrical Circuit Diagram (Machine with Gateway Function Controller) (1/12) 
Electrical Circuit Diagram (Machine with Gateway Function Controller) (2/12) 
Electrical Circuit Diagram (Machine with Gateway Function Controller) (3/12) 
Electrical Circuit Diagram (Machine with Gateway Function Controller) (4/12) 
Electrical Circuit Diagram (Machine with Gateway Function Controller) (5/12) 
Electrical Circuit Diagram (Machine with Gateway Function Controller) (6/12) 
Electrical Circuit Diagram (Machine with Gateway Function Controller) (7/12) 
Electrical Circuit Diagram (Machine with Gateway Function Controller) (8/12) 
Electrical Circuit Diagram (Machine with Gateway Function Controller) (9/12) 
Electrical Circuit Diagram (Machine with Gateway Function Controller) (10/12) 
Electrical Circuit Diagram (Machine with Gateway Function Controller) (11/12) 
Electrical Circuit Diagram (Machine with Gateway Function Controller) (12/12) 
INDEX