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KOMATSU HB335-1 HB335LC-1 HB365-1 HB365LC-1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06366-06 – PDF
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KOMATSU HB335-1 HB335LC-1 HB365-1 HB365LC-1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06366-06 – PDF DOWNLOAD
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KOMATSU HB335-1 HB335LC-1 HB365-1 HB365LC-1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06366-06 – PDF DOWNLOAD
Language : English
Pages : 1910
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU HB335-1 HB335LC-1 HB365-1 HB365LC-1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06366-06 – PDF DOWNLOAD
Cover........................................................................................................................................ 1 00 Index and foreword ................................................................................................................... 3 Index ............................................................................................................................... 4 Foreword, safety and general information ............................................................................................ 17 Important safety notice (Hybrid) ................................................................................................ 17 How to read the shop manual ..................................................................................................... 24 Explanation of terms for maintenance standard ................................................................................... 26 Handling equipment of fuel system devices ....................................................................................... 28 Handling of intake system parts ................................................................................................. 29 Handling of hydraulic equipment ................................................................................................. 30 Method of disconnecting and connecting of push-pull type coupler ................................................................ 32 Handling of electrical equipment ................................................................................................ 35 How to read electric wire code (Hybrid) ......................................................................................... 43 Precautions when performing operation ........................................................................................... 48 Practical use of KOMTRAX ........................................................................................................ 53 Handling hybrid components and high voltage wiring harness ...................................................................... 54 Standard tightening torque table ................................................................................................ 57 List of abbreviation ............................................................................................................ 63 Conversion table ................................................................................................................ 68 01 Specification ........................................................................................................................ 73 Table of contents ................................................................................................................... 74 Specifications ...................................................................................................................... 75 Specification drawing ........................................................................................................... 75 Working range drawings .......................................................................................................... 79 Specifications .................................................................................................................. 83 Weight table .................................................................................................................... 99 Table of fuel, coolant, and lubricants .......................................................................................... 107 10 Structure and function ............................................................................................................... 109 Table of contents ................................................................................................................... 110 Engine and cooling system ........................................................................................................... 111 Engine related parts ............................................................................................................ 111 KVGT ............................................................................................................................ 113 EGR system piping drawing ....................................................................................................... 120 EGR system circuit diagram ...................................................................................................... 122 EGR valve ....................................................................................................................... 124 EGR cooler ...................................................................................................................... 126 Cooling system .................................................................................................................. 127 Hybrid system ....................................................................................................................... 129 Outline of hybrid system ........................................................................................................ 129 Configuration of hybrid system .................................................................................................. 130 Protective function of hybrid component ......................................................................................... 131 Protection function for workers when disassembling hybrid component ............................................................. 133 Cooling system of hybrid component .............................................................................................. 135 Interlock function .............................................................................................................. 136 Motor-generator ................................................................................................................. 137 Electric swing motor ............................................................................................................ 138 Electric control unit ........................................................................................................... 140 High voltage wiring harness (power cable) ....................................................................................... 141 Water pump ...................................................................................................................... 142 Power train ......................................................................................................................... 143 Power train system .............................................................................................................. 143 Swing circle .................................................................................................................... 145 Swing machinery with swing brake ................................................................................................ 146 Final drive ..................................................................................................................... 148 Undercarriage and frame ............................................................................................................. 150 Track frame and idler cushion ................................................................................................... 150 Hydraulic system .................................................................................................................... 152 Hydraulic component layout ...................................................................................................... 152 Valve control ................................................................................................................... 154 Hydraulic tank .................................................................................................................. 155 CLSS ............................................................................................................................ 157 Main pump ....................................................................................................................... 162 Control valve ................................................................................................................... 194 Travel motor .................................................................................................................... 249 PPC valve ....................................................................................................................... 265 Solenoid valve .................................................................................................................. 288 Attachment circuit selector valve ............................................................................................... 292 Center swivel joint ............................................................................................................. 295 Accumulator ..................................................................................................................... 297 Work equipment ...................................................................................................................... 298 Work equipment .................................................................................................................. 298 Electrical system ................................................................................................................... 301 Electrical control system ....................................................................................................... 301 System component parts .......................................................................................................... 340 Machine monitor system .......................................................................................................... 355 KOMTRAX system (GPRS type) ...................................................................................................... 378 KOMTRAX system (Orbcomm type) ................................................................................................... 381 Sensor .......................................................................................................................... 384 20 Standard value tables ................................................................................................................ 405 Table of contents ................................................................................................................... 406 Standard service value table ........................................................................................................ 407 Standard value table for engine ................................................................................................. 407 Standard value table for machine ................................................................................................ 409 30 Testing and adjusting ................................................................................................................ 435 Table of contents ................................................................................................................... 436 Related information on testing and adjusting ........................................................................................ 437 Tools for testing and adjusting ................................................................................................. 437 Sketch of tools for testing and adjusting ....................................................................................... 440 Engine and cooling system ........................................................................................................... 442 Testing engine speed ............................................................................................................ 442 Testing boost pressure .......................................................................................................... 445 Testing exhaust gas color ....................................................................................................... 448 Testing and adjusting valve clearance ........................................................................................... 449 Testing compression pressure .................................................................................................... 452 Testing blowby pressure ......................................................................................................... 460 Testing engine oil pressure ..................................................................................................... 461 Testing EGR valve and KVGT oil pressures ........................................................................................ 462 Testing fuel pressure ........................................................................................................... 463 Testing fuel discharge, return and leakage ...................................................................................... 469 Bleeding air from fuel system ................................................................................................... 474 Testing fuel circuit for leakage ................................................................................................ 475 Handling cylinder cutout mode operation ......................................................................................... 476 Handling no-injection cranking operation ........................................................................................ 477 Checking and adjusting air conditioner compressor belt tension .................................................................. 478 Replacing fan belt .............................................................................................................. 479 Replacing alternator belt ....................................................................................................... 480 Hybrid system ....................................................................................................................... 481 Precautions related to hybrid equipment ......................................................................................... 481 Bleeding air from hybrid cooling system ......................................................................................... 482 Testing water pressure of hybrid coolant ........................................................................................ 484 Testing swing parking brake ..................................................................................................... 486 Cleaning and replacing oil filter of electric swing motor ....................................................................... 487 Testing operation of swing emergency stop switch ................................................................................ 488 Power train ......................................................................................................................... 491 Testing swing circle bearing clearance .......................................................................................... 491 Undercarriage and frame ............................................................................................................. 492 Testing and adjusting track tension ............................................................................................. 492 Hydraulic system .................................................................................................................... 493 Releasing remaining pressure from hydraulic circuit ............................................................................. 493 Testing oil pressure of control circuit ......................................................................................... 497 Testing and adjusting oil pressure in work equipment and travel circuits ........................................................ 498 Testing and adjusting oil pressure in pump PC control circuit ................................................................... 503 Testing and adjusting oil pressure in pump LS control circuit ................................................................... 507 Testing outlet pressure of solenoid valve ....................................................................................... 515 Testing PPC valve outlet pressure ............................................................................................... 519 Adjusting play of work equipment and swing PPC valves ........................................................................... 521 Testing pump swash plate sensor ................................................................................................. 522 Isolating the parts causing hydraulic drift in work equipment ................................................................... 523 Testing oil leakage ............................................................................................................. 525 Bleeding air from hydraulic circuit ............................................................................................. 527 Cab and its attachments ............................................................................................................. 529 Checking cab tipping stopper .................................................................................................... 529 Adjusting mirrors ............................................................................................................... 530 Electrical system ................................................................................................................... 533 Special functions of machine monitor ............................................................................................ 533 KOMTRAX terminal start-up procedure ............................................................................................. 603 Adjusting rearview camera angle ................................................................................................. 606 Handling voltage circuit of engine controller ................................................................................... 608 Testing diodes .................................................................................................................. 609 Pm clinic ........................................................................................................................... 610 Pm Clinic service ............................................................................................................... 610 40 Troubleshooting ...................................................................................................................... 627 Table of contents ................................................................................................................... 628 Related information on troubleshooting .............................................................................................. 636 Troubleshooting points .......................................................................................................... 636 Sequence of events in troubleshooting ........................................................................................... 638 Checks before troubleshooting ................................................................................................... 640 Inspection procedure before troubleshooting ..................................................................................... 642 Preparation work for troubleshooting of electrical system ....................................................................... 663 Classification and procedures for troubleshooting ............................................................................... 668 Symptom and troubleshooting numbers ............................................................................................. 671 Information in troubleshooting table ............................................................................................ 674 Troubleshooting method for open circuit in wiring harness of pressure sensor system ............................................. 676 Connector list and layout ....................................................................................................... 678 Connector contact identification ................................................................................................ 690 T-branch box and T-branch adapter table ......................................................................................... 728 Fuse location table ............................................................................................................. 733 Failure codes table ............................................................................................................. 735 Troubleshooting by failure code (Display of code) ................................................................................... 746 Failure code [879AKA] A/C Inner Sensor Open Circuit ............................................................................. 746 Failure code [879AKB] A/C Inner Sensor Short Circuit ............................................................................ 747 Failure code [879BKA] A/C Outer Sensor Open Circuit ............................................................................. 748 Failure code [879BKB] A/C Outer Sensor Short Circuit ............................................................................ 749 Failure code [879CKA] Ventilating Sensor Open Circuit ........................................................................... 750 Failure code [879CKB] Ventilating Sensor Short Circuit .......................................................................... 751 Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit ..................................................................... 752 Failure code [879EMC] Ventilation Damper Abnormality ............................................................................ 753 Failure code [879FMC] Air Mix Damper Abnormality ................................................................................ 754 Failure code [879GKX] Refrigerant Abnormality ................................................................................... 755 Failure code [989L00] Engine Controller Lock Caution 1 .......................................................................... 756 Failure code [989M00] Engine Controller Lock Caution 2 .......................................................................... 757 Failure code [989N00] Engine Controller Lock Caution 3 .......................................................................... 758 Failure code [AA10NX] Air Cleaner Clogging ...................................................................................... 759 Failure code [AB00KE] Charge Voltage Low ........................................................................................ 761 Failure code [B@BAZG] Eng Oil Press Low ......................................................................................... 763 Failure code [B@BAZK] Eng Oil Level Low ......................................................................................... 764 Failure code [B@BCNS] Eng Water Overheat ........................................................................................ 765 Failure code [B@BCZK] Eng Water Level Low ....................................................................................... 766 Failure code [B@HANS] Hyd Oil Overheat .......................................................................................... 768 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................................... 769 Failure code [CA122] Chg Air Press Sensor High Error ............................................................................ 770 Failure code [CA123] Chg Air Press Sensor Low Error ............................................................................. 772 Failure code [CA131] Throttle Sensor High Error ................................................................................. 774 Failure code [CA132] Throttle Sensor Low Error .................................................................................. 776 Failure code [CA144] Coolant Temp Sens High Error ............................................................................... 778 Failure code [CA145] Coolant Temp Sens Low Error ................................................................................ 780 Failure code [CA153] Chg Air Temp Sensor High Error ............................................................................. 782 Failure code [CA154] Chg Air Temp Sensor Low Error .............................................................................. 784 Failure code [CA187] Sensor 2 Supply Volt Low Error ............................................................................. 786 Failure code [CA221] Ambient Press Sensor High Error ............................................................................ 788 Failure code [CA222] Ambient Press Sens Low Error ............................................................................... 790 Failure code [CA227] Sensor 2 Supply Volt High Error ............................................................................ 792 Failure code [CA234] Eng Overspeed .............................................................................................. 793 Failure code [CA238] Ne Speed Sensor Supply Volt Error .......................................................................... 794 Failure code [CA239] Ne Speed Sens Supply Volt High Error ....................................................................... 795 Failure code [CA271] IMV/PCV1 Short Error ....................................................................................... 796 Failure code [CA272] IMV/PCV1 Open Error ........................................................................................ 798 Failure code [CA281] Pump Press Balance Error ................................................................................... 800 Failure code [CA295] Ambient Press Sens In Range Error .......................................................................... 801 Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................................... 802 Failure code [CA323] Inj #5(L#5) Open/Short Error ............................................................................... 804 Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................................... 806 Failure code [CA325] Inj #6(L#6) Open/Short Error ............................................................................... 808 Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................................... 810 Failure code [CA332] Inj #4(L#4) Open/Short Error ............................................................................... 812 Failure code [CA343] ECM Critical Internal Failure .............................................................................. 814 Failure code [CA351] Injectors Drive Circuit Error .............................................................................. 815 Failure code [CA352] Sensor 1 Supply Volt Low Error ............................................................................. 816 Failure code [CA356] Mass Air Flow Sensor High Error ............................................................................ 818 Failure code [CA357] Mass Air Flow Sensor Low Error ............................................................................. 820 Failure code [CA386] Sensor 1 Supply Volt High Error ............................................................................ 822 Failure code [CA428] Water in Fuel Sensor High Error ............................................................................ 823 Failure code [CA429] Water in Fuel Sensor Low Error ............................................................................. 825 Failure code [CA435] Eng Oil Press Sw Error ..................................................................................... 827 Failure code [CA441] Battery Voltage Low Error .................................................................................. 828 Failure code [CA442] Battery Voltage High Error ................................................................................. 830 Failure code [CA449] Rail Press Very High Error ................................................................................. 831 Failure code [CA451] Rail Press Sensor High Error ............................................................................... 833 Failure code [CA452] Rail Press Sensor Low Error ................................................................................ 835 Failure code [CA488] Chg Air Temp High Torque Derate ............................................................................ 837 Failure code [CA515] Rail Press Sens Sup Volt High Error ........................................................................ 838 Failure code [CA516] Rail Press Sens Sup Volt Low Error ......................................................................... 840 Failure code [CA553] Rail Press High Error ...................................................................................... 842 Failure code [CA559] Rail Pump Press Low Error .................................................................................. 843 Failure code [CA595] Turbo Speed High Error 2 ................................................................................... 847 Failure code [CA687] Turbo Speed Low Error ...................................................................................... 848 Failure code [CA689] Eng Ne Speed Sensor Error .................................................................................. 850 Failure code [CA691] Intake Air Temp Sens High Error ............................................................................ 854 Failure code [CA692] Intake Air Temp Sens Low Error ............................................................................. 856 Failure code [CA697] ECM Internal Temp Sensor High Error ........................................................................ 858 Failure code [CA698] ECM Int Temp Sensor Low Error .............................................................................. 859 Failure code [CA731] Eng Bkup Speed Sens Phase Error ............................................................................ 860 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................ 862 Failure code [CA1117] Persistent Data Lost Error ................................................................................ 867 Failure code [CA1695] Sensor 5 Supply Volt High Error ........................................................................... 868 Failure code [CA1696] Sensor 5 Supply Volt Low Error ............................................................................ 869 Failure code [CA2185] Throt Sensor Sup Volt High Error .......................................................................... 870 Failure code [CA2186] Throt Sensor Sup Volt Low Error ........................................................................... 872 Failure code [CA2249] Rail Press Very Low Error ................................................................................. 874 Failure code [CA2265] Fuel Feed Pump Open Error ................................................................................. 875 Failure code [CA2266] Fuel Feed Pump Short Error ................................................................................ 877 Failure code [CA2271] EGR Valve Pos Sens High Error ............................................................................. 879 Failure code [CA2272] EGR Valve Pos Sens Low Error .............................................................................. 881 Failure code [CA2288] Turbo Speed High Error 1 .................................................................................. 885 Failure code [CA2311] IMV Solenoid Error ........................................................................................ 886 Failure code [CA2349] EGR Valve Solenoid Open Error ............................................................................. 887 Failure code [CA2353] EGR Valve Solenoid Short Error ............................................................................ 890 Failure code [CA2357] EGR Valve Servo Error ..................................................................................... 892 Failure code [CA2373] Exhaust Manifold Press Sens High Error .................................................................... 893 Failure code [CA2374] Exhaust Manifold Press Sens Low Error ..................................................................... 895 Failure code [CA2375] EGR Orifice Temp Sens High Error .......................................................................... 897 Failure code [CA2376] EGR Orifice Temp Sens Low Error ........................................................................... 899 Failure code [CA2381] KVGT Pos Sens High Error .................................................................................. 901 Failure code [CA2382] KVGT Pos Sens Low Error ................................................................................... 903 Failure code [CA2383] KVGT Solenoid Open Error .................................................................................. 906 Failure code [CA2386] KVGT Solenoid Short Error ................................................................................. 909 Failure code [CA2387] KVGT Servo Error .......................................................................................... 911 Failure code [CA2554] Exh Manifold Press Sens In Range Error .................................................................... 916 Failure code [CA2555] Grid Htr Relay Volt Low Error ............................................................................. 919 Failure code [CA2556] Grid Htr Relay Volt High Error ............................................................................ 921 Failure code [CA2961] EGR Orifice Temp High Error 1 ............................................................................. 923 Failure code [CA2973] Chg Air Press Sensor In Range Error ....................................................................... 924 Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error .................................................................. 925 Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ................................................................... 927 Failure code [CA3741] Rail Press Valve Trip Error ............................................................................... 929 Failure code [D110KB] Battery Relay Drive Short Circuit ......................................................................... 930 Failure code [D19JKZ] Personal Code Relay Abnormality ........................................................................... 932 Failure code [D811MC] KOMTRAX Error ............................................................................................. 935 Failure code [D862KA] GPS Antenna Open Circuit .................................................................................. 936 Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ..................................................................................... 937 Failure code [DA20MC] Pump Controller Malfunction ............................................................................... 939 Failure code [DA22KK] Pump Solenoid Power Low Error ............................................................................. 940 Failure code [DA25KP] 5V Sensor 1 Power Abnormality ............................................................................. 942 Failure code [DA29KQ] Model Selection Abnormality ............................................................................... 944 Failure code [DA2QKR] CAN2 Discon (Pump Con) .................................................................................... 946 Failure code [DA2RKR] CAN1 Discon (Pump Con) .................................................................................... 949 Failure code [DAF0MB] Monitor ROM Abnormality ................................................................................... 950 Failure code [DAF0MC] Monitor Error ............................................................................................. 951 Failure code [DAF8KB] Camera Power Supply Short Circuit ......................................................................... 952 Failure code [DAF9KQ] Model Selection Abnormality ............................................................................... 954 Failure code [DAFGMC] GPS Module Error .......................................................................................... 955 Failure code [DAFQKR] CAN2 Discon (Monitor) ..................................................................................... 956 Failure code [DAZ9KQ] AC Model Selection Abnormality ............................................................................ 957 Failure code [DAZQKR] CAN2 Discon (Aircon ECU) .................................................................................. 958 Failure code [DB2QKR] CAN2 Discon (Engine Con) .................................................................................. 959 Failure code [DB2RKR] CAN1 Discon (Engine Con) .................................................................................. 964 Failure code [DGH2KB] Hyd Oil Sensor Short Circuit .............................................................................. 970 Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit .................................................................. 972 Failure code [DHPAMA] F Pump Press Sensor Abnormality ........................................................................... 974 Failure code [DHPBMA] R Pump Press Sensor Abnormality ........................................................................... 977 Failure code [DHS3MA] Arm Curl PPC Press Sensor Abnormality ..................................................................... 980 Failure code [DHS4MA] Bucket Curl PPC Press Sensor Abnormality .................................................................. 983 Failure code [DHS8MA] Boom Raise PPC Press Sensor Abnormality ................................................................... 986 Failure code [DHS9MA] Boom Lower PPC Press Sensor Abnormality ................................................................... 989 Failure code [DHSAKZ] Swing RH PPC Press Sensor Abnormality ..................................................................... 992 Failure code [DHSBKZ] Swing LH PPC Press Sensor Abnormality ..................................................................... 995 Failure code [DHSCMA] Arm Dump PPC Press Sensor Abnormality ..................................................................... 998 Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ..................................................................1001 Failure code [DHSFMA] Travel Fwd LH PPC Press Sensor Abnormality ................................................................1004 Failure code [DHSGMA] Travel Fwd RH PPC Press Sensor Abnormality ................................................................1007 Failure code [DHSHMA] Travel Rev LH PPC Press Sensor Abnormality ................................................................1010 Failure code [DHSJMA] Travel Rev RH PPC Press Sensor Abnormality ................................................................1013 Failure code [DHVAKZ] HYB Swng-R PPC Pr. Sen. Opn/Short Cirt. ...................................................................1016 Failure code [DHVAL8] HYB Swing-R PPC Pr. Sen. Signal Mismatch ..................................................................1019 Failure code [DHVAMA] HYB Swing-R PPC Sensor Malfunction ........................................................................1020 Failure code [DHVBKZ] HYB Swng-L PPC Pr. Sen. Opn/Short Cir. ....................................................................1021 Failure code [DHVBL8] HYB Swing-L PPC Pr. Sen. Signal Mismatch ..................................................................1024 Failure code [DHVBMA] HYB Swing-L PPC Sensor Malfunction ........................................................................1025 Failure code [DKR0MA] F Pump Swash Plate Sensor Abnormality .....................................................................1026 Failure code [DKR1MA] R Pump Swash Plate Sensor Abnormality .....................................................................1029 Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ...................................................................1031 Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ...................................................................1033 Failure code [DV20KB] Travel Alarm Short Circuit ................................................................................1034 Failure code [DW43KA] Travel Speed Sol Open Circuit .............................................................................1036 Failure code [DW43KB] Travel Speed Sol Short Circuit ............................................................................1038 Failure code [DW45KA] Swing Brake Sol Open Circuit ..............................................................................1040 Failure code [DW45KB] Swing Brake Sol Short Circuit .............................................................................1043 Failure code [DW45KK] Swing Brake Sol. Valve Low Sup. Voltage ...................................................................1045 Failure code [DW45KY] Swing Brake Sol. Val. Pow. Short Cir. .....................................................................1047 Failure code [DW91KA] Travel Junction Sol Open Circuit ..........................................................................1049 Failure code [DW91KB] Travel Junction Sol Short Circuit .........................................................................1051 Failure code [DWA2KA] Attachment Sol Open Circuit ...............................................................................1053 Failure code [DWA2KB] Attachment Sol Short Circuit ..............................................................................1055 Failure code [DWK0KA] 2-Stage Relief Sol Open Circuit ...........................................................................1057 Failure code [DWK0KB] 2-Stage Relief Sol Short Circuit ..........................................................................1059 Failure code [DWK2KA] Variable Back Press Sol Open Circuit ......................................................................1061 Failure code [DWK2KB] Variable Back Press Sol Short Circuit .....................................................................1063 Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit ...............................................................................1065 Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit ..............................................................................1067 Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ...............................................................................1069 Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ..............................................................................1071 Failure code [DXE0KA] LS-EPC Sol Open Circuit ...................................................................................1073 Failure code [DXE0KB] LS-EPC Sol Short Circuit ..................................................................................1075 Failure code [DXE4KA] Attachment Flow EPC Open Circuit ..........................................................................1077 Failure code [DXE4KB] Attachment Flow EPC Short Circuit .........................................................................1078 Failure code [DXE5KA] Merge-divide Main Sol Open Circuit ........................................................................1080 Failure code [DXE5KB] Merge-divide Main Sol Short Circuit .......................................................................1082 Failure code [DXE6KA] Merge-divide LS Sol Open Circuit ..........................................................................1084 Failure code [DXE6KB] Merge-divide LS Sol Short Circuit .........................................................................1086 Failure code [DY20KA] Wiper Working Abnormality .................................................................................1088 Failure code [DY20MA] Wiper Parking Abnormality .................................................................................1090 Failure code [DY2CKB] Washer Drive Short Circuit ................................................................................1092 Failure code [DY2DKB] Wiper Drive (Fwd) Short Circuit ...........................................................................1094 Failure code [DY2EKB] Wiper Drive (Rev) Short Circuit ...........................................................................1096 Failure code [GA****] Precautions for hybrid components and troubleshooting of high voltage parts ...............................1098 Failure code [GA——] Table and check sheet of monitoring items on hybrid components ..............................................1120 Failure code [GA00NS] HYB Equipment Overheat ....................................................................................1125 Failure code [GA01KA] Power Cable Interlock Open Circuit ........................................................................1126 Failure code [GA02KZ] DC Line Open & Short Circuit ..............................................................................1128 Failure code [GA04KG] Abnormal DC HW Volt. Before Booster .......................................................................1129 Failure code [GA05KG] Abnormal DC SW Volt. Before Booster .......................................................................1130 Failure code [GA05KP] Low DC SW Output Volt. Bef. Booster .......................................................................1131 Failure code [GA06KZ] DC Vlt. Sen. Opn./Shrt.Cir. Bef. Booster ..................................................................1134 Failure code [GA08KG] Abnorm. DC HW Volt. After Booster .........................................................................1135 Failure code [GA09KG] Abnorm. DC SW Volt. After Booster .........................................................................1136 Failure code [GA09KP] Low DC SW Output Volt. After Booster ......................................................................1137 Failure code [GA0AKZ] DC Vlt. Sen. Op./Shrt Cir. Aft. Booster ...................................................................1138 Failure code [GA0BKZ] AC Line Open & Short Circuit ..............................................................................1139 Failure code [GA10MC] HYB Controller Error ......................................................................................1140 Failure code [GA12NK] High-Voltage Line Start-up Failure ........................................................................1141 Failure code [GA12NL] High-Voltage Line Discharge Failure .......................................................................1142 Failure code [GA13MC] HYB Control. Sen. Power Sup. Failure ......................................................................1143 Failure code [GA15KZ] HYB Cont. Bad Insul. Sen. Opn/Short. Cir ..................................................................1145 Failure code [GA17KR] Gen. Mot. Drv. Communication Failure ......................................................................1146 Failure code [GA17KY] Gen. Mot Dr. Power Line Short Circuit .....................................................................1147 Failure code [GA17MB] Gen. Mot. Drv. Function Degraded ..........................................................................1148 Failure code [GA18MC] Gen. Mo.Dr. Excite. Pow. Sup. Failure .....................................................................1149 Failure code [GA19KR] Gen. Motor Driver Sub-CPU Comm. Failure ...................................................................1150 Failure code [GA19KT] Int. Abnorm. Gen. Mot. Drv. Sub-CPU Con. ..................................................................1151 Failure code [GA19MA] Gen. Mot. Drv. Sub-CPU Malfunction ........................................................................1152 Failure code [GA1BMA] Gen. Mot. Dr. DC Vlt. Sens. Malfunction ...................................................................1153 Failure code [GA1FKR] Swing Mot. Drv. Communication Failure .....................................................................1155 Failure code [GA1FMA] Abnormal Swing Motor Driver ...............................................................................1156 Failure code [GA1GKR] Swg Mot. Driver Sub-CPU Comm. Failure .....................................................................1157 Failure code [GA1GKT] Swing Mot. Drv. Sub-CPU Cont. Abnormal ....................................................................1158 Failure code [GA1GMA] Swing Motor Drv. Sub-CPU Malfunction ......................................................................1159 Failure code [GA1GMB] Swing Mot. Drv. Sub-CPU Funct. Degraded ...................................................................1160 Failure code [GA1HKZ] Swg Mot. Dr. Ph-U Tem. Sens Opn/Shrt Cir ..................................................................1161 Failure code [GA1JKZ] Swg Mot. Dr. Ph-V Tem. Sens Opn/Shrt Cir ..................................................................1162 Failure code [GA1KKZ] Swg Mot. Dr. Ph-W Tem. Sens Opn/Shrt Cir ..................................................................1163 Failure code [GA1LKZ] Swg Mot. Dr. Current. Sens. Opn/Shrt Cir ..................................................................1164 Failure code [GA1MKZ] Swg Mot. Dr. DC Vlt. Sen. Opn/Shrt Cir. ...................................................................1165 Failure code [GA1NNS] Swing Motor Driver IGBT Overheat ..........................................................................1166 Failure code [GA1SFS] Contactor Locked ..........................................................................................1167 Failure code [GA1SMC] Contactor Failure .........................................................................................1168 Failure code [GA1TKP] Capacitor Low Output Voltage ..............................................................................1169 Failure code [GA1TNS] Capacitor Overheat ........................................................................................1172 Failure code [GA1UKZ] Capacitor Temp. Sensor Opn/short Cir. .....................................................................1174 Failure code [GA1VFS] Capacitor Contactor Locked ................................................................................1176 Failure code [GA1VMC] Capacitor Contactor Failure ...............................................................................1177 Failure code [GA1XKZ] Boost. Ind. Temp. Sens. Open/Shrt. Circ. ..................................................................1178 Failure code [GA1YNS] Booster Inductor Overheat .................................................................................1179 Failure code [GA1ZKZ] Booster IGBT Temp. Sens. Opn/Shrt. Circ. ..................................................................1180 Failure code [GA1ZNS] Booster IGBT Temp. Sens. Overheat .........................................................................1181 Failure code [GA21KB] Booster IGBT Short Circuit ................................................................................1182 Failure code [GA22NS] Booster IGBT Junction Overheat ............................................................................1183 Failure code [GA23KZ] Gen. Mot. Dr. Temp. Sen.0 Opn/Short Cir. ..................................................................1184 Failure code [GA24KZ] Gen. Mot. Dr. Temp. Sen.1 Opn/Short Cir. ..................................................................1185 Failure code [GA25MA] Gen. Motor Driver IGBT 0 Abnormality ......................................................................1186 Failure code [GA25NS] Gen. Motor Driver IGBT 0 Overheat .........................................................................1187 Failure code [GA26MA] Gen. Motor Driver IGBT 1 Abnormality ......................................................................1188 Failure code [GA26NS] Gen. Motor Driver IGBT 1 Overheat .........................................................................1189 Failure code [GA27KZ] DC Cur. Sens. Bef. Booster Opn/Short Cir ..................................................................1190 Failure code [GA28KZ] DC Cur. Sens. Aft. Booster Opn/Short Cir ..................................................................1191 Failure code [GA2QKR] CAN2 Discon (Hyb Con) .....................................................................................1192 Failure code [GA2RKR] CAN1 Discon (Hyb Con) .....................................................................................1195 Failure code [GA60MC] Generator Motor Failure ...................................................................................1196 Failure code [GA60N1] Generator Motor Overrun ...................................................................................1197 Failure code [GA61KZ] Gen. Motor Temp. Sens. Opn/Short Cir. .....................................................................1198 Failure code [GA61NS] Generator Motor Temp. Sensor Overheat .....................................................................1200 Failure code [GA62KY] Gen. Mot. Ph-A Cur. Sen. Power Short Cir ..................................................................1201 Failure code [GA62KZ] Gen. Mot. Ph-A Cur. Sen. Open/Short Cir ...................................................................1202 Failure code [GA62MA] Gen. Mot. Ph-A Current Sen. Malfunction ...................................................................1203 Failure code [GA63KY] Gen. Mot. Ph-B Cur. Sen. Power Short Cir ..................................................................1204 Failure code [GA63KZ] Gen. Mot. Ph-B Cur. Sen. Open/Short Cir ...................................................................1205 Failure code [GA63MA] Gen. Mot. Ph-B Current Sen. Malfunction ...................................................................1206 Failure code [GA64KY] Gen. Mot. Ph-C Cur. Sen. Power Short Cir ..................................................................1207 Failure code [GA64KZ] Gen. Mot. Ph-C Cur. Sen. Open/Short Cir ...................................................................1208 Failure code [GA64MA] Gen. Mot. Ph-C Current Sen. Malfunction ...................................................................1209 Failure code [GA70KB] HYB Swing Motor Short Circuit .............................................................................1210 Failure code [GA70MD] HYB Swing Motor Defective Stirr. Motion ...................................................................1211 Failure code [GA70NS] HYB Swing Motor Overheat ..................................................................................1212 Failure code [GA71KZ] HYB Swing Mot. Temp. Sens. Opn/Shrt Cir. ..................................................................1213 Failure code [GA72MA] HYB Swing Motor Resolver Malfunction ......................................................................1215 Failure code [GA72MC] HYB Swing Motor Resolver Defect Op. .......................................................................1217 Failure code [GA81KZ] Swing Motor Power Cable Opn/Shrt Circ. ....................................................................1218 Failure code [GAA0KB] HYB Con. Battery Relay Drive Short Cir. ...................................................................1219 Failure code [GAA100] Swing Emergency Stop Operation ............................................................................1221 Failure code [GAA2KB] Swing Brake Sol. Supply Line Short Cir. ...................................................................1222 Troubleshooting of electrical system (E-mode) .......................................................................................1224 E-1 Engine does not start (Engine does not crank) ...............................................................................1224 E-2 Manual preheating system does not work ......................................................................................1230 E-3 Automatic preheating system does not work ...................................................................................1233 E-4 While preheating is working, preheating monitor does not light up ...........................................................1235 E-5 When starting switch is turned to ON position, machine monitor displays nothing .............................................1237 E-6 While starting switch is turned to ON position (with engine stopped), engine oil level monitor lights up in yellow ..........1240 E-7 While starting switch is turned to ON position (with engine stopped), radiator coolant level monitor lights up in yellow ....1241 E-8 Engine coolant temperature monitor lights up in white while engine is running ...............................................1242 E-9 Hydraulic oil temperature monitor lights up in white while engine is running ................................................1243 E-10 Charge level monitor lights up in red while engine is running ..............................................................1244 E-11 Fuel level monitor lights up in red while engine is running ................................................................1245 E-12 Air cleaner clogging monitor lights up in yellow while engine is running ...................................................1246 E-13 Engine coolant temperature monitor lights up in red while engine is running ................................................1247 E-14 Hydraulic oil temperature monitor lights up in red while engine is running .................................................1248 E-15 Engine oil pressure monitor lights up in red while engine is running .......................................................1249 E-16 Fuel gauge display does not move from minimum or maximum ...................................................................1250 E-17 Fuel gauge indicates incorrect amount ......................................................................................1251 E-18 Engine coolant temperature gauge display does not move from minimum or maximum .............................................1252 E-19 Engine coolant temperature gauge indicates incorrect temperature ...........................................................1253 E-20 Hydraulic oil temperature gauge display does not move from minimum or maximum ..............................................1254 E-21 Hydraulic oil temperature gauge indicates incorrect temperature ............................................................1256 E-22 Hybrid temperature gauge does not indicate correct temperature .............................................................1257 E-23 Some areas of machine monitor screen are not displayed .....................................................................1259 E-24 Function switch does not work ..............................................................................................1260 E-25 Automatic warm-up system does not operate (in cold season) .................................................................1261 E-26 Auto-deceleration monitor does not light up, or does not go out, while auto-deceleration switch is operated ................1262 E-27 Auto-deceleration function does not operate or is not canceled while lever is operated .....................................1263 E-28 Working mode selection screen is not displayed while working mode selector switch is operated ..............................1264 E-29 Setting of engine and hydraulic pump is not changed while working mode is changed ..........................................1265 E-30 Travel speed monitor does not change when travel speed switch is operated ..................................................1266 E-31 Travel speed does not change while travel speed selection is changed .......................................................1267 E-32 Alarm buzzer does not stop sounding ........................................................................................1268 E-33 Service meter is not displayed, while starting switch is in OFF position ...................................................1269 E-34 Service mode cannot be selected ............................................................................................1270 E-35 Any of work equipment, swing and travel does not work ......................................................................1271 E-36 Any of work equipment, swing and travel cannot be locked ...................................................................1273 E-37 Upper structure does not swing while swing parking brake cancel switch is set to CANCEL position ...........................1275 E-38 Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position .............................1277 E-39 One-touch power maximizing function does not operate properly, or indicator is not displayed on monitor ....................1279 E-40 One-touch power maximizing function cannot be canceled .....................................................................1281 E-41 Alarm does not sound during travel .........................................................................................1282 E-42 Alarm does not stop sounding while machine is stopped ......................................................................1284 E-43 Horn does not sound ........................................................................................................1285 E-44 Horn does not stop sounding ................................................................................................1287 E-45 Wiper monitor does not light up, or does not go out, while wiper switch is operated ........................................1288 E-46 Wiper does not operate while wiper switch is operated ......................................................................1289 E-47 Window washer does not operate while window washer switch is operated ......................................................1291 E-48 Boom LOWER is not displayed correctly with monitoring function .............................................................1292 E-49 Arm OUT is not displayed correctly with monitoring function ................................................................1293 E-50 Arm IN is not displayed correctly with monitoring function .................................................................1294 E-51 Boom RAISE is not displayed correctly with monitoring function .............................................................1295 E-52 Bucket CURL is not displayed correctly with monitoring function ............................................................1296 E-53 Bucket DUMP is not displayed correctly with monitoring function ............................................................1297 E-54 Swing is not displayed correctly with monitoring function ..................................................................1298 E-55 Travel is not displayed correctly with monitoring function .................................................................1299 E-56 Service is not displayed correctly with monitoring function ................................................................1300 E-57 Attachment hydraulic circuit cannot be changed .............................................................................1302 E-58 KOMTRAX system does not operate normally ...................................................................................1303 E-59 Machine push-up function is not canceled ...................................................................................1304 E-60 Machine push-up function does not operate ..................................................................................1306 Troubleshooting of hydraulic and mechanical system (H-mode) .........................................................................1307 Information described in troubleshooting table (H-mode) .........................................................................1307 System chart of hydraulic and mechanical systems ................................................................................1308 Failure mode and cause table ....................................................................................................1310 H-1 All of work equipments and travel operations lack speed or power ............................................................1314 H-2 Engine speed drops significantly or engine stalls ...........................................................................1318 H-3 Any of work equipment and travel does not work ..............................................................................1321 H-4 Unusual sound is heard from around hydraulic pump ...........................................................................1322 H-5 Fine control performance or response is poor ...............................................................................1323 H-6 Boom speed or power is low ..................................................................................................1325 H-7 Arm speed or power is low ...................................................................................................1329 H-8 Bucket speed or power is low ................................................................................................1334 H-9 Work equipment does not move in single operation ............................................................................1338 H-10 Hydraulic drift of boom is large ...........................................................................................1339 H-11 Hydraulic drift of arm is large ............................................................................................1340 H-12 Hydraulic drift of bucket is large .........................................................................................1342 H-13 Time lag of work equipment is large ........................................................................................1343 H-14 When part of work equipment is relieved singly, other parts of work equipment move .........................................1345 H-15 One-touch power maximizing function does not work ..........................................................................1346 H-16 Machine push up function does not work .....................................................................................1347 H-17 In combined operation of work equipment, equipment having heavier load moves slower ........................................1348 H-18 Machine does not travel straight ...........................................................................................1349 H-19 Travel speed is slow .......................................................................................................1352 H-20 Machine is hard to steer or travel power is low ............................................................................1354 H-21 Travel speed does not change, or travel speed is too slow or fast ..........................................................1357 H-22 One of tracks does not run .................................................................................................1358 H-23 Upper structure does not swing to the right or left ........................................................................1360 H-24 Upper structure swing only to the right or left ............................................................................1361 H-25 Swing acceleration or swing speed is low in both directions (right and left) ...............................................1362 H-26 Swing acceleration performance is poor or swing speed is slow in only one direction ........................................1363 H-27 Upper structure overruns excessively when it stops swinging (both right and left) ..........................................1364 H-28 Upper structure overruns excessively when it stops swinging (either right or left) .........................................1365 H-29 Shock is large when upper structure stops swinging .........................................................................1366 H-30 Large unusual noise is heard when upper structure stops swinging ...........................................................1367 H-31 Swing drift on a slope is large while swing parking brake is applied .......................................................1368 H-32 Swing drift on a slope is large while swing parking brake is released ......................................................1369 H-33 Attachment hydraulic circuit cannot be changed while attachment is installed ...............................................1370 H-34 Oil flow in attachment circuit cannot be controlled ........................................................................1371 Troubleshooting of engine (S-mode) ..................................................................................................1372 Information contained in troubleshooting table (S mode) .........................................................................1372 S-1 Engine does not crank when starting switch is turned to START position ......................................................1373 S-2 The engine cranks but exhaust smoke does not come out .......................................................................1374 S-3 Fuel is being injected but engine does not start (incomplete combustion: engine cranks but does not start) ..................1375 S-4 Engine startability is poor .................................................................................................1376 S-5 Engine does not pick up smoothly ............................................................................................1378 S-6 Engine stops during operation ...............................................................................................1380 S-7 Engine runs rough or is unstable ............................................................................................1382 S-8 Engine lacks power ..........................................................................................................1383 S-9 Exhaust smoke is black ......................................................................................................1385 S-10 Engine oil consumption is excessive ........................................................................................1387 S-11 Oil becomes contaminated quickly ...........................................................................................1388 S-12 Fuel consumption is excessive ..............................................................................................1389 S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ...........................................................1390 S-14 Oil pressure drops .........................................................................................................1391 S-15 Fuel mixes into engine oil .................................................................................................1392 S-16 Water mixes into engine oil (milky) ........................................................................................1393 S-17 Coolant temperature rises too high (overheating) ...........................................................................1394 S-18 Unusual noise is heard .....................................................................................................1395 S-19 Vibration is excessive .....................................................................................................1396 S-20 Air cannot be bled from fuel circuit .......................................................................................1397 Troubleshooting for hybrid systems (Y mode) .........................................................................................1398 Precautions related to hybrid equipment .........................................................................................1398 Y-1 Hybrid monitor does not go out ..............................................................................................1399 Y-2 Machine does not swing ......................................................................................................1400 Y-3 Swing acceleration or swing speed is low ....................................................................................1402 Y-4 Upper structure overruns excessively when it stops swinging .................................................................1403 Y-5 Shock is large when upper structure stops swinging ..........................................................................1404 Y-6 Large unusual noise is heard when upper structure stops swinging ............................................................1405 Y-7 Swing drift on a slope is large .............................................................................................1406 Y-8 Electric swing motor temperature increases abnormally .......................................................................1407 Y-9 Motor-generator temperature increases abnormally ............................................................................1408 Y-10 Inverter temperature increases abnormally ..................................................................................1409 Y-11 Capacitor temperature increases abnormally .................................................................................1410 50 Disassembly and assembly .............................................................................................................1411 Table of contents ...................................................................................................................1412 Related information on disassembly and assembly .....................................................................................1414 How to read this manual .........................................................................................................1414 Precautions related to hybrid equipment .........................................................................................1416 Coating materials list ..........................................................................................................1417 Special tools list ..............................................................................................................1421 Sketches of special tools .......................................................................................................1427 Engine and cooling system ...........................................................................................................1433 Removal and installation of supply pump assembly ................................................................................1433 Removal and installation of injector assembly ...................................................................................1442 Removal and installation of cylinder head assembly ..............................................................................1454 Removal and installation of radiator assembly ...................................................................................1479 Removal and installation of hydraulic oil cooler assembly .......................................................................1482 Removal and installation of aftercooler core ....................................................................................1485 Removal and installation of engine, motor-generator, and main pump assembly .....................................................1487 Removal and installation of fan belt ............................................................................................1502 Removal and installation of alternator belt .....................................................................................1504 Removal and installation of engine front oil seal ...............................................................................1507 Removal and installation of engine rear oil seal ................................................................................1512 Removal and installation of fuel tank assembly ..................................................................................1520 Removal and installation of air cleaner assembly ................................................................................1522 Removal and installation of air conditioner compressor assembly .................................................................1524 Removal and installation of air conditioner condenser assembly ..................................................................1526 Removal and installation of EGR (Exhaust Gas Recirculation) valve assembly ......................................................1528 Removal and installation of EGR (Exhaust Gas Recirculation) cooler assembly .....................................................1530 Hybrid system .......................................................................................................................1533 Draining coolant, refilling with coolant, and bleeding air for hybrid system ....................................................1533 Removal and installation of hybrid system radiator assembly .....................................................................1538 Removal and installation of hybrid system water pump assembly ...................................................................1540 Removal and installation of inverter assembly ...................................................................................1542 Removal and installation of inverter and capacitor assembly .....................................................................1547 Procedure for draining and refilling generator lubricating oil ..................................................................1553 Removal and installation of motor-generator and housing assembly ................................................................1555 Removal and installation of electric swing motor assembly .......................................................................1561 Power train system ..................................................................................................................1566 Removal and installation of travel motor and final drive assembly ...............................................................1566 Disassembly and assembly of final drive assembly ................................................................................1567 Removal and installation of electric swing motor and swing machinery assembly ...................................................1576 Disassembly and assembly of swing machinery assembly ............................................................................1580 Removal and installation of swing circle assembly ...............................................................................1594 Undercarriage and frame .............................................................................................................1595 Separation and connection of track shoe assembly ................................................................................1595 Removal and installation of sprocket ............................................................................................1598 Removal and installation of idler and idler cushion assembly ....................................................................1599 Disassembly and assembly of idler ...............................................................................................1600 Disassembly and assembly of idler cushion assembly ..............................................................................1603 Disassembly and assembly of track roller assembly ...............................................................................1605 Disassembly and assembly of carrier roller assembly .............................................................................1607 Removal and installation of revolving frame assembly ............................................................................1610 Removal and installation of counterweight assembly ..............................................................................1612 Hydraulic system ....................................................................................................................1615 Removal and installation of center swivel joint assembly ........................................................................1615 Disassembly and assembly of center swivel joint assembly ........................................................................1617 Removal and installation of hydraulic tank assembly .............................................................................1618 Removal and installation of main pump assembly ..................................................................................1622 Removal and installation of control valve assembly ..............................................................................1627 Disassembly and assembly of control valve assembly ..............................................................................1634 Procedure for replacing pressure compensation valve seal ........................................................................1635 Assembly of control valve assembly ..............................................................................................1636 Disassembly and assembly of work equipment PPC valve assembly ...................................................................1639 Disassembly and assembly of travel PPC valve assembly ...........................................................................1641 Work equipment ......................................................................................................................1643 Removal and installation of bucket assembly .....................................................................................1643 Removal and installation of arm assembly ........................................................................................1644 Removal and installation of work equipment assembly .............................................................................1646 Disassembly and assembly of work equipment cylinder assembly ....................................................................1649 Cab and its attachments .............................................................................................................1655 Removal and installation of operator's cab assembly .............................................................................1655 Removal and installation of operator's cab glass (adhered glass) ................................................................1660 Removal and installation of front window assembly ...............................................................................1670 Removal and installation of floor frame assembly ................................................................................1676 Removal and installation of air conditioner unit assembly .......................................................................1682 Removal and installation of operator's seat .....................................................................................1686 Removal and installation of seat belt ...........................................................................................1687 Removal and installation of work equipment control lever assembly................................................................1688 Removal and installation of front wiper assembly ................................................................................1702 Electrical system ...................................................................................................................1708 Removal and installation of engine controller assembly ..........................................................................1708 Removal and installation of pump controller assembly ............................................................................1711 Removal and installation of machine monitor assembly ............................................................................1714 Removal and installation of pump swash plate sensor .............................................................................1716 Removal and installation of KOMTRAX terminal assembly ...........................................................................1717 60 Maintenance standard .................................................................................................................1719 Table of contents ...................................................................................................................1720 Engine and cooling system ...........................................................................................................1721 Engine mount ....................................................................................................................1721 Cooling system ..................................................................................................................1722 Power train system ..................................................................................................................1723 Swing circle ....................................................................................................................1723 Swing machinery with swing brake ................................................................................................1724 Final drive .....................................................................................................................1726 Sprocket ........................................................................................................................1728 Undercarriage and frame .............................................................................................................1730 Track frame and idler cushion ...................................................................................................1730 Idler ...........................................................................................................................1732 Track roller ....................................................................................................................1734 Carrier roller ..................................................................................................................1736 Track shoe ......................................................................................................................1737 Hydraulic system ....................................................................................................................1740 Hydraulic tank ..................................................................................................................1740 Main pump .......................................................................................................................1741 Control valve ...................................................................................................................1744 Travel motor ....................................................................................................................1754 PPC valve .......................................................................................................................1757 Solenoid valve ..................................................................................................................1767 Attachment circuit selector valve ...............................................................................................1768 Center swivel joint .............................................................................................................1769 Work equipment ......................................................................................................................1770 Work equipment ..................................................................................................................1770 Work equipment cylinder .........................................................................................................1783 80 Appendix .............................................................................................................................1787 Table of contents ...................................................................................................................1788 Air conditioner components ..........................................................................................................1789 Precautions for refrigerant .....................................................................................................1789 Air conditioner component .......................................................................................................1790 Configuration and function of refrigeration cycle ...............................................................................1792 Outline of refrigeration cycle ..................................................................................................1793 Air conditioner unit ............................................................................................................1795 Dual pressure switch ............................................................................................................1802 Air conditioner controller ......................................................................................................1803 Compressor ......................................................................................................................1804 Condenser .......................................................................................................................1805 Receiver drier ..................................................................................................................1806 Sunlight sensor .................................................................................................................1807 Outer temperature sensor (outside air temperature sensor) .......................................................................1808 Procedure for testing and troubleshooting .......................................................................................1809 Circuit diagram and arrangement of connector pins ...............................................................................1811 System diagram ..................................................................................................................1813 Parts and connectors layout .....................................................................................................1816 Testing air leakage (duct) ......................................................................................................1820 Testing with self-diagnosis function ............................................................................................1823 Testing vent (mode) changeover ..................................................................................................1826 Testing FRESH/RECIRC air changeover .............................................................................................1828 Testing sunlight sensor .........................................................................................................1829 Testing (dual) pressure switch for refrigerant ..................................................................................1830 Testing relays ..................................................................................................................1832 Troubleshooting chart 1 .........................................................................................................1833 Troubleshooting chart 2 .........................................................................................................1834 Information in troubleshooting table ............................................................................................1837 Failure code list related to air conditioner ....................................................................................1838 Failure code [879AKA] A/C Inner sensor Open Circuit .............................................................................1839 Failure code [879AKB] A/C Inner sensor Short Circuit ............................................................................1840 Failure code [879BKA] A/C Outer sensor Open Circuit .............................................................................1841 Failure code [879BKB] A/C Outer sensor Short Circuit ............................................................................1843 Failure code [879CKA] Ventilating sensor Open Circuit ...........................................................................1845 Failure code [879CKB] Ventilating sensor Short Circuit ..........................................................................1846 Failure code [879DKZ] Sunlight sensor Open or Short Circuit .....................................................................1847 Failure code [879EMC] Ventilating Damper Abnormality ............................................................................1849 Failure code [879FMC] Air Mix Damper Abnormality ................................................................................1850 Failure code [879GKX] Refrigerant Abnormality ...................................................................................1851 A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................................................1852 A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ...................................................1854 A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ..........................................1858 A-4 Troubleshooting for FRESH/RECIRC air changeover .............................................................................1860 Troubleshooting with gauge pressure .............................................................................................1862 Connection of service tool ......................................................................................................1865 Precautions for disconnecting and connecting air conditioner piping .............................................................1867 Handling of compressor oil ......................................................................................................1869 90 Diagrams and drawings ................................................................................................................1871 Table of contents ...................................................................................................................1872 Hydraulic circuit diagram ...........................................................................................................1873 Symbols in hydraulic circuit diagram ............................................................................................1873 Hydraulic circuit diagram .......................................................................................................1877 Electric circuit diagram ............................................................................................................1881 Symbols in electric circuit diagram .............................................................................................1881 Electrical circuit diagram ......................................................................................................1885 Electrical circuit diagram of air conditioner unit ..............................................................................1897 INDEX....................................................................................................................................1899
DESCRIPTION:
KOMATSU HB335-1 HB335LC-1 HB365-1 HB365LC-1 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06366-06 – PDF DOWNLOAD
General precautions
• Before performing any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
• Locate a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
• When performing any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
• Always wear the protective eyeglasses when hitting parts with a hammer.
• Always wear the protective eyeglasses when grinding parts with a grinder, etc.
• When performing any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning tag in the operator’s compartment.
• Only qualified workers must perform the work and operation which require license or qualification.
• Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Before starting work, thoroughly check the tools, machine, forklift truck, service car, etc.
• If welding repairs are needed, always have a trained and experienced welder perform the work. When performing welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
• Before starting work, warm up your body thoroughly to start work under good condition.
• Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition and at the provided place.
S.S 27/12/24
