Komatsu HB365LC-3E0,HB365NLC-3E0 Hydraulic Excavator Shop Manual PDF

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Komatsu HB365LC-3E0,HB365NLC-3E0 Hydraulic Excavator Shop Manual UENBM00522 – PDF DOWNLOAD

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Komatsu HB365LC-3E0,HB365NLC-3E0 Hydraulic Excavator Shop Manual UENBM00522 – PDF DOWNLOAD

Language : English
Pages : 3268
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu HB365LC-3E0,HB365NLC-3E0 Hydraulic Excavator Shop Manual UENBM00522 – PDF DOWNLOAD

SERIAL NUMBERS

• 5001 and up
• K70001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 24
FOREWORD, SAFETY, BASIC INFORMATION . 30
HOW TO READ THE SHOP MANUAL . 30
SAFETY NOTICE FOR OPERATION . 32
PRECAUTIONS PARTICULARLY FOR HYBRID MACHINES 40
PRECAUTIONS TO PREVENT FIRE . 41
ACTIONS IF FIRE OCCURS 43
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 44
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 45
PRECAUTIONS FOR DEF . 46
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 46
PRECAUTIONS FOR ADDING 46
PRECAUTIONS FOR STORING . 46
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 46
THE OTHER PRECAUTIONS . 46
STORE Ad Blue/DEF 47
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 48
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 51
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 58
PRECAUTIONS FOR MAINTENANCE OF HYBRID SYSTEM 60
PRECAUTIONS AGAINST HIGH VOLTAGE AND HIGH TEMPERATURE . 61
PRECAUTIONS FOR NORMAL CHECK AND MAINTENANCE 62
PRECAUTIONS FOR THE MACHINE NOT TO BE TIPPED OVER AND FOR HYBRID COMPONENTS NOT TO BE DAMAGED . 63
PRECAUTIONS FOR THE MACHINE NOT TO BE SUBMERGED . 64
PRECAUTIONS FOR THE COLD SEASON . 65
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 66
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 67
PRACTICAL USE OF KOMTRAX 68
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 69
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 69
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 70
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 71
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 73
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 77
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 78
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 80
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 81
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 83
HOW TO READ THE CODES (SYMBOLS) FOR ELECTRIC CABLE 84
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 90
STANDARD TIGHTENING TORQUE TABLE 93
CONVERSION TABLE 100
01 SPECIFICATIONS . 105
CONTENTS 106
ABBREVIATION LIST . 107
SPECIFICATIONS 113
SPECIFICATION DRAWING . 113
SPECIFICATION DRAWING: HB365LC-3E0, HB365NLC-3E0 113
WORKING RANGE DRAWINGS 114
WORKING RANGE: HB365LC-3E0, HB365NLC-3E0 114
SPECIFICATIONS 115
SPECIFICATIONS: HB365LC-3E0, HB365NLC-3E0 . 115
WEIGHT TABLE 119
WEIGHT TABLE: HB365LC-3E0, HB365NLC-3E0 . 119
TABLE OF FUEL, COOLANT, AND LUBRICANTS 121
10 STRUCTURE AND FUNCTION . 123
CONTENTS 124
ABBREVIATION LIST . 128
UREA SCR SYSTEM . 134
LAYOUT DRAWING OF UREA SCR SYSTEM . 134
UREA SCR SYSTEM DIAGRAM . 138
FUNCTION OF UREA SCR SYSTEM . 139
FUNCTION OF AdBlue/DEF SYSTEM . 139
INDUCEMENT STRATEGY . 141
COMPONENT PARTS OF UREA SCR SYSTEM 159
AdBlue/DEF MIXING TUBE 159
SCR ASSEMBLY 159
AdBlue/DEF TANK . 162
AdBlue/DEF PUMP . 164
AdBlue/DEF INJECTOR . 165
AdBlue/DEF HOSE . 166
AdBlue/DEF TANK HEATING VALVE . 167
BOOT-UP SYSTEM 168
LAYOUT DRAWING OF BOOT-UP SYSTEM 168
SYSTEM OPERATING LAMP SYSTEM 170
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 170
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 170
BATTERY DISCONNECT SWITCH . 172
FUNCTION OF BATTERY DISCONNECT SWITCH . 172
ENGINE SYSTEM . 173
LAYOUT DRAWING OF ENGINE SYSTEM . 173
FUNCTION OF ENGINE SYSTEM . 174
ENGINE CONTROL SYSTEM . 175
ENGINE CONTROL SYSTEM DIAGRAM . 175
OPERATION OF ENGINE CONTROL SYSTEM 176
AUTO-DECELERATION SYSTEM 178
AUTO-DECELERATION SYSTEM DIAGRAM 178
FUNCTION OF AUTO-DECELERATION SYSTEM 178
OPERATION OF AUTO-DECELERATION SYSTEM . 179
ENGINE AUTOMATIC WARM-UP SYSTEM . 180
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 180
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 181
OVERHEAT PREVENTION SYSTEM 182
OVERHEAT PREVENTION SYSTEM DIAGRAM 182
FUNCTION OF OVERHEAT PREVENTION SYSTEM 183
TURBOCHARGER PROTECTION SYSTEM 185
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 185
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 186
AUTOMATIC IDLE STOP SYSTEM 187
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 187
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 187
COMPONENT PARTS OF ENGINE SYSTEM 191
VGT . 191
EGR SYSTEM 194
EGR VALVE . 196
EGR COOLER 198
KCCV SYSTEM . 199
KCCV VENTILATOR . 201
KDPF 202
COOLING SYSTEM 207
LAYOUT DRAWING OF COOLING SYSTEM 207
SPECIFICATIONS OF COOLING SYSTEM 208
HYBRID SYSTEM . 209
LAYOUT DRAWING OF HYBRID SYSTEM . 209
SYSTEM DIAGRAM OF HYBRID SYSTEM . 210
STRUCTURE OF HYBRID SYSTEM 211
HYBRID PROTECTION SYSTEM 212
SYSTEM DIAGRAM OF HYBRID PROTECTION SYSTEM 212
FUNCTION OF HYBRID PROTECTION SYSTEM 212
COOLING SYSTEM OF HYBRID COMPONENTS . 214
SYSTEM DIAGRAM OF COOLING SYSTEM OF HYBRID COMPONENTS . 214
INTERLOCK SYSTEM OF HYBRID COMPONENTS . 215
SYSTEM DIAGRAM OF INTERLOCK SYSTEM OF HYBRID COMPONENTS . 215
FUNCTION OF INTERLOCK SYSTEM OF HYBRID COMPONENTS . 215
WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID COMPONENTS . 216
SYSTEM DIAGRAM OF WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID COMPONENTS . 216
FUNCTION OF WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID COMPONENTS . 217
COMPONENT PARTS OF HYBRID SYSTEM 218
MOTOR-GENERATOR . 218
ELECTRIC CONTROL UNIT . 219
HIGH VOLTAGE WIRING (POWER CABLE) . 220
HYBRID WATER PUMP . 221
INVERTER (HYBRID CONTROLLER) 222
CONTROL SYSTEM 225
LAYOUT DRAWING OF CONTROL SYSTEM 225
MACHINE MONITOR SYSTEM 228
MACHINE MONITOR SYSTEM DIAGRAM 228
FUNCTION OF MACHINE MONITOR SYSTEM 228
KomVision SYSTEM 229
LAYOUT DRAWING OF KOMVISION SYSTEM 229
KomVision SYSTEM DIAGRAM 231
FUNCTION OF KomVision SYSTEM 231
KOMTRAX SYSTEM 233
KOMTRAX SYSTEM DIAGRAM 233
FUNCTION OF KOMTRAX SYSTEM 233
PPC LEVERS 234
LH PPC LEVER 234
RH PPC LEVER 235
AUTOMATIC GREASE SYSTEM . 236
OUTLINE OF AUTO GREASE SYSTEM . 236
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 250
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 250
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 250
COMPONENT PARTS OF CONTROL SYSTEM . 251
MACHINE MONITOR . 251
KomVision CAMERA 265
GATEWAY FUNCTION CONTROLLER . 266
COMMUNICATION TERMINAL 269
KomVision CONTROLLER 270
PUMP CONTROLLER . 275
RESISTOR FOR PC-EPC VALVE . 279
CAN TERMINATING RESISTOR 279
ENGINE CONTROLLER . 281
FUEL CONTROL DIAL . 287
HYDRAULIC SYSTEM 289
LAYOUT DRAWING OF HYDRAULIC SYSTEM 289
CLSS 292
STRUCTURE OF CLSS . 292
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 294
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 295
PRESSURE COMPENSATION CONTROL . 308
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 312
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 312
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 313
PUMP AND VALVE CONTROL SYSTEM . 318
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 318
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 319
COMPONENT PARTS OF HYDRAULIC SYSTEM . 321
HYDRAULIC TANK 321
MAIN PUMP . 323
CONTROL VALVE . 350
WORK EQUIPMENT SYSTEM . 404
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 404
STRUCTURE OF VALVE CONTROL 410
ONE-TOUCH POWER MAXIMIZING SYSTEM . 411
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 411
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 412
MACHINE PUSH-UP SYSTEM 413
MACHINE PUSH-UP SYSTEM DIAGRAM 413
FUNCTION OF MACHINE PUSH-UP SYSTEM 414
PPC LOCK SYSTEM . 415
PPC LOCK SYSTEM DIAGRAM . 415
FUNCTION OF PPC LOCK SYSTEM . 415
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 416
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 416
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 416
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 417
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 418
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT . 418
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 419
TOOL CONTROL SYSTEM . 420
TOOL CONTROL SYSTEM DIAGRAM . 420
FUNCTION OF TOOL CONTROL SYSTEM . 421
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 422
WORK EQUIPMENT AND SWING PPC VALVE 422
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 427
2ND-LINE ATTACHMENT PPC VALVE . 431
SOLENOID VALVE 433
ANTI-DROP VALVE FOR BOOM 436
ANTI-DROP VALVE FOR ARM . 439
ATTACHMENT CIRCUIT SELECTOR VALVE . 443
ATT EPC VALVE ASSEMBLY 446
PILOT CIRCUIT ACCUMULATOR . 447
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE . 448
ATTACHMENT BYPASS SOLENOID VALVE 451
SWING SYSTEM 453
LAYOUT DRAWING OF SWING SYSTEM 453
SWING CONTROL SYSTEM DIAGRAM 456
FUNCTION OF SWING CONTROL SYSTEM 457
COMPONENT PARTS OF SWING SYSTEM . 459
ELECTRIC SWING MOTOR 459
SWING MACHINERY WITH SWING PARKING BRAKE 460
SWING CIRCLE 462
TRAVEL SYSTEM . 463
LAYOUT DRAWING OF TRAVEL SYSTEM . 463
TRAVEL CONTROL SYSTEM DIAGRAM . 467
FUNCTION OF TRAVEL CONTROL SYSTEM . 468
COMPONENT PARTS OF TRAVEL SYSTEM 469
TRAVEL MOTOR 469
FINAL DRIVE . 482
TRAVEL PPC VALVE 483
CENTER SWIVEL JOINT . 488
UNDERCARRIAGE AND FRAME . 490
LAYOUT DRAWING OF UNDERCARRIAGE . 490
SPECIFICATIONS OF UNDERCARRIAGE . 490
WORK EQUIPMENT 492
STRUCTURE OF WORK EQUIPMENT . 492
FUNCTION OF WORK EQUIPMENT 493
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 494
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 494
BUCKET CLEARANCE ADJUSTMENT SHIM 495
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 495
CAB AND ITS ATTACHMENTS . 496
ROPS CAB 496
STRUCTURE OF ROPS CAB . 496
FUNCTION OF ROPS CAB 496
CAB MOUNT . 497
STRUCTURE OF CAB MOUNT 497
FUNCTION OF CAB MOUNT . 497
CAB TIPPING STOPPER . 498
STRUCTURE OF CAB TIPPING STOPPER 498
FUNCTION OF CAB TIPPING STOPPER . 498
20 STANDARD VALUE TABLE . 499
CONTENTS 500
ABBREVIATION LIST . 501
STANDARD VALUE TABLE FOR ENGINE . 507
STANDARD VALUE TABLE FOR ENGINE:HB365LC-3E0, HB365NLC-3E0 . 507
STANDARD VALUE TABLE FOR MACHINE 513
STANDARD VALUE TABLE FOR MACHINE: HB365LC-3E0, HB365NLC-3E0 . 513
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 530
30 TESTING AND ADJUSTING 535
CONTENTS 536
ABBREVIATION LIST . 539
RELATED INFORMATION ON TESTING AND ADJUSTING 545
TOOLS FOR TESTING AND ADJUSTING . 545
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 552
ENGINE AND COOLING SYSTEM . 554
TEST ENGINE SPEED . 554
METHOD FOR TESTING ENGINE SPEED . 554
TEST BOOST PRESSURE . 557
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 557
METHOD FOR TESTING BOOST PRESSURE . 558
TEST EXHAUST GAS COLOR 559
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 559
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 560
TEST AND ADJUST VALVE CLEARANCE . 562
METHOD FOR TESTING VALVE CLEARANCE 562
METHOD FOR ADJUSTING VALVE CLEARANCE 564
TEST COMPRESSION PRESSURE . 565
METHOD FOR TESTING COMPRESSION PRESSURE . 565
TEST BLOWBY PRESSURE 568
METHOD FOR TESTING BLOWBY PRESSURE 568
TEST ENGINE OIL PRESSURE 570
METHOD FOR TESTING ENGINE OIL PRESSURE 570
TEST EGR VALVE AND VGT OIL PRESSURE . 572
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 572
TEST FUEL PRESSURE 574
METHOD FOR TESTING FUEL PRESSURE 575
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 582
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 583
BLEED AIR FROM FUEL SYSTEM 590
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 590
TEST FUEL CIRCUIT FOR LEAKAGE . 591
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 591
HANDLE CYLINDER CUT-OUT MODE OPERATION 593
HANDLE NO-INJECTION CRANKING OPERATION 594
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 595
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 595
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 595
TEST COOLING FAN SPEED 597
METHOD FOR TESTING COOLING FAN SPEED 597
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 598
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 598
TEST SCR RELATED FUNCTIONS 599
TEST AdBlue/DEF PUMP RAISED PRESSURE 602
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 605
TEST AdBlue/DEF LINE HEATER RELAY 1 . 609
TEST AdBlue/DEF LINE HEATER RELAY 2 . 611
TEST AdBlue/DEF PUMP HEATER RELAY . 614
TEST AdBlue/DEF TANK HEATER VALVE . 617
TEST DENITRATION EFFICIENCY OF SCR 620
CLEAN AdBlue/DEF TANK . 624
METHOD FOR CLEANING AdBlue/DEF TANK . 624
HYBRID SYSTEM . 629
PRECAUTIONS FOR USING HYBRID SYSTEMS 629
DRAIN, REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT . 630
METHOD FOR DRAINING THE HYBRID SYSTEM COOLANT . 631
REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT 634
WATER PRESSURE TEST OF THE HYBRID SYSTEM COOLANT 636
METHOD FOR TESTING THE WATER PRESSURE OF THE HYBRID SYSTEM COOLANT 636
TEST LUBRICATION CIRCUIT OIL PRESSURE OF HYBRID SYSTEM 638
TEST LUBRICATION CIRCUIT OIL PRESSURE OF ELECTRIC SWING MOTOR CASE 638
TEST LUBRICATION CIRCUIT OIL PRESSURE OF MOTOR-GENERATOR OIL CASE . 638
TEST SWING PARKING BRAKE PRESSURE . 640
METHOD FOR TESTING THE SWING PARKING BRAKE PRESSURE . 640
TEST AND CLEAN DELIVERY FILTER OF SWING MOTOR . 642
METHOD FOR CHECKING AND CLEANING ELECTRIC SWING MOTOR COOLING OIL DELIVERY FILTER . 642
POWER TRAIN . 643
TEST SWING CIRCLE BEARING CLEARANCE . 643
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 643
UNDERCARRIAGE AND FRAME . 644
TEST AND ADJUST TRACK TENSION . 644
METHOD FOR TESTING TRACK TENSION 644
METHOD FOR ADJUSTING TRACK TENSION 644
HYDRAULIC SYSTEM 646
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 646
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK . 646
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT . 646
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT . 651
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUITS 652
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, AND TRAVEL CIRCUITS 653
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,AND TRAVEL CIRCUITS . 658
TEST OIL PRESSURE OF CONTROL CIRCUIT 661
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 661
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 663
METHOD FOR TESTING PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 663
METHOD FOR TESTING PC-EPC VALVE OUTLET PRESSURE . 664
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 665
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 667
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR 667
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE . 668
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 670
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 672
METHOD FOR ADJUSTING LS VALVE . 672
TEST OUTLET PRESSURE OF SOLENOID VALVE 674
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 674
OPERATING CONDITION OF SOLENOID VALVE . 675
TEST PPC VALVE OUTPUT PRESSURE 678
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 678
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 680
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 680
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 681
TEST PUMP SWASH PLATE SENSOR 683
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 683
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 684
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 684
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 684
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 685
TEST OIL LEAKAGE 686
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 686
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 687
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 687
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 688
BLEED AIR FROM HYDRAULIC CIRCUIT 689
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 689
CAB AND ITS ATTACHMENTS . 692
TEST CAB TIPPING STOPPER 692
METHOD FOR TESTING CAB TIPPING STOPPER 692
METHOD FOR ADJUSTING MIRRORS 693
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 693
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 694
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 695
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 696
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 697
ELECTRICAL SYSTEM . 699
SET AND OPERATE MACHINE MONITOR . 699
OPERATOR MODE . 702
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 703
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 703
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 704
CHECKING FUNCTION OF SERVICE METER 704
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 704
SERVICE MODE 707
METHOD FOR OPERATING SERVICE MODE . 707
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 709
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 718
ABNORMALITY RECORD MENU . 731
METHOD FOR CONFIRMING MAINTENANCE RECORD 736
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 737
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 740
DEFAULT MENU 741
DIAGNOSTIC TESTS MENU . 753
ADJUSTMENT MENU . 767
METHOD FOR PERFORMING NO-INJECTION CRANKING . 787
KOMTRAX SETTINGS MENU . 788
METHOD FOR DISPLAYING SERVICE MESSAGE . 790
METHOD FOR STARTING UP KOMTRAX TERMINAL . 792
ADJUST REARVIEW CAMERA ANGLE 797
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE . 797
ADJUST KomVision CAMERA ANGLE . 800
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 801
ADJUST KomVision RELATED ITEMS 805
SETTING OF KomVision (MAIN SETTING) . 805
SETTING OF KomVision (CAMERA SETTING) . 807
SETTING OF KomVision (CAMERA CALIBRATION) . 809
KomVision screen – Check 12 m visibility 822
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 825
HANDLE BATTERY DISCONNECT SWITCH 826
TEST DIODES . 827
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 827
METHOD FOR TESTING DIODE USING ANALOG TESTER 827
Pm CLINIC . 828
Pm CLINIC SERVICE . 828
Pm CLINIC CHECK SHEET:HB365LC-3E0, HB365NLC-3E0 . 829
40 TROUBLESHOOTING 841
CONTENTS 842
ABBREVIATION LIST . 855
RELATED INFORMATION ON TROUBLESHOOTING 861
GENERAL TROUBLESHOOTING POINTS 861
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 862
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 874
PRECAUTIONS FOR USING HYBRID SYSTEMS, TROUBLESHOOTING FOR HIGH-VOLTAGE EQUIPMENT 876
TABLE OF SELF-DEFINE MONITORING ITEMS AND CHECK SHEET FOR HYBRID COMPONENTS . 883
CHECKS BEFORE TROUBLESHOOTING . 889
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 891
WALK-AROUND CHECK . 891
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 893
CHECK FUEL LEVEL AND TYPE . 893
CHECK IMPURE INGREDIENT IN FUEL . 894
CHECK FUEL PREFILTER 894
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 894
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 895
CHECK MAIN FILTER . 898
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 900
CHECK OIL LEVEL IN MOTOR-GENERATOR CASE . 901
CHECK COOLANT LEVEL (RESERVOIR TANK) 902
CHECK CLOGGING OF AIR CLEANER . 903
OUTER ELEMENT – CLEAN . 904
ELEMENTS – REPLACE 906
CHECK HYDRAULIC OIL LEVEL . 908
CHECK HYDRAULIC OIL STRAINER 909
CHECK HYDRAULIC FILTER 910
CHECK CAPACITOR . 911
CHECK OIL LEVEL IN ELECTRIC SWING MOTOR CASE 911
CHECK OIL LEVEL IN SWING MACHINERY CASE . 912
CHECK OIL LEVEL IN FINAL DRIVE CASE . 913
BLEED AIR FROM FUEL SYSTEM 914
BLEED AIR FROM HYDRAULIC SYSTEM . 914
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod 914
AUTOMATIC GREASE SYSTEM . 919
FINDING MALFUNCTIONS 919
MALFUNCTION FINDING PROCEDURES 923
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 925
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 925
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 925
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 926
PREPARATION FOR TROUBLESHOOTING OF GATEWAY TERMINAL . 926
PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER . 926
PREPARATION FOR TROUBLESHOOTING OF INVERTER (HYBRID CONTROLLER) . 927
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 927
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 931
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 934
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 938
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 940
CONNECTOR LIST AND LAYOUT . 943
CONNECTOR CONTACT IDENTIFICATION 957
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE . 997
FUSE LOCATION TABLE (MACHINE WITH KOMTRAX TERMINAL) .1003
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) .1006
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) .1010
FAILURE CODES TABLE .1012
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .1033
FAILURE CODE [879AKA] .1033
FAILURE CODE [879AKB] .1034
FAILURE CODE [879BKA] .1035
FAILURE CODE [879BKB] .1037
FAILURE CODE [879CKA] .1039
FAILURE CODE [879CKB] .1040
FAILURE CODE [879DKZ] .1041
FAILURE CODE [879EMC] .1043
FAILURE CODE [879FMC] .1044
FAILURE CODE [879GKX] .1045
FAILURE CODE [989L00] .1047
FAILURE CODE [989M00] .1048
FAILURE CODE [989N00] .1049
FAILURE CODE [A1U0N3] .1050
FAILURE CODE [A1U0N4] .1052
FAILURE CODE [A900FR] .1054
FAILURE CODE [A900N6] .1055
FAILURE CODE [A900NY] .1056
FAILURE CODE [AA10NX] .1057
FAILURE CODE [AB00KE] .1059
FAILURE CODE [AQ10N3] .1061
FAILURE CODE [AS00N3] .1063
FAILURE CODE [AS00R2] .1065
FAILURE CODE [AS00R3] .1066
FAILURE CODE [AS00R4] .1067
FAILURE CODE [AS00R5] .1068
FAILURE CODE [AS00R6] .1069
FAILURE CODE [AS00ZK] .1070
FAILURE CODE [AS10KM] .1071
FAILURE CODE [AS10NR] .1072
FAILURE CODE [AS10NT] .1073
FAILURE CODE [B@BAZG] .1074
FAILURE CODE [B@BAZK] .1075
FAILURE CODE [B@BCNS] .1077
FAILURE CODE [B@BCZK] .1078
FAILURE CODE [B@HANS] .1079
FAILURE CODE [CA115] 1080
FAILURE CODE [CA122] 1081
FAILURE CODE [CA123] 1083
FAILURE CODE [CA131] 1085
FAILURE CODE [CA132] 1087
FAILURE CODE [CA144] 1089
FAILURE CODE [CA145] 1091
FAILURE CODE [CA153] 1093
FAILURE CODE [CA154] 1096
FAILURE CODE [CA187] 1099
FAILURE CODE [CA221] 1101
FAILURE CODE [CA222] 1103
FAILURE CODE [CA227] 1105
FAILURE CODE [CA234] 1106
FAILURE CODE [CA238] 1107
FAILURE CODE [CA239] 1109
FAILURE CODE [CA249] 1111
FAILURE CODE [CA256] 1113
FAILURE CODE [CA271] 1115
FAILURE CODE [CA272] 1117
FAILURE CODE [CA281] 1119
FAILURE CODE [CA322] 1120
FAILURE CODE [CA323] 1122
FAILURE CODE [CA324] 1124
FAILURE CODE [CA325] 1126
FAILURE CODE [CA331] 1128
FAILURE CODE [CA332] 1130
FAILURE CODE [CA343] 1132
FAILURE CODE [CA351] 1133
FAILURE CODE [CA352] 1134
FAILURE CODE [CA356] 1137
FAILURE CODE [CA357] 1139
FAILURE CODE [CA386] 1141
FAILURE CODE [CA428] 1142
FAILURE CODE [CA429] 1144
FAILURE CODE [CA435] 1146
FAILURE CODE [CA441] 1148
FAILURE CODE [CA442] 1150
FAILURE CODE [CA449] 1151
FAILURE CODE [CA451] 1154
FAILURE CODE [CA452] 1157
FAILURE CODE [CA488] 1159
FAILURE CODE [CA515] 1160
FAILURE CODE [CA516] 1162
FAILURE CODE [CA553] 1164
FAILURE CODE [CA555] 1165
FAILURE CODE [CA556] 1166
FAILURE CODE [CA559] 1167
FAILURE CODE [CA595] 1171
FAILURE CODE [CA687] 1172
FAILURE CODE [CA689] 1174
FAILURE CODE [CA691] 1179
FAILURE CODE [CA692] 1181
FAILURE CODE [CA697] 1183
FAILURE CODE [CA698] 1184
FAILURE CODE [CA731] 1185
FAILURE CODE [CA778] 1187
FAILURE CODE [CA1117] .1192
FAILURE CODE [CA1664] .1193
FAILURE CODE [CA1669] .1195
FAILURE CODE [CA1673] .1196
FAILURE CODE [CA1677] .1197
FAILURE CODE [CA1678] .1198
FAILURE CODE [CA1682] .1199
FAILURE CODE [CA1683] .1201
FAILURE CODE [CA1684] .1203
FAILURE CODE [CA1686] .1205
FAILURE CODE [CA1691] .1206
FAILURE CODE [CA1694] .1209
FAILURE CODE [CA1695] .1212
FAILURE CODE [CA1696] .1213
FAILURE CODE [CA1712] .1215
FAILURE CODE [CA1713] .1218
FAILURE CODE [CA1714] .1220
FAILURE CODE [CA1715] .1221
FAILURE CODE [CA1776] .1222
FAILURE CODE [CA1777] .1225
FAILURE CODE [CA1843] .1228
FAILURE CODE [CA1844] .1230
FAILURE CODE [CA1879] .1232
FAILURE CODE [CA1881] .1235
FAILURE CODE [CA1883] .1237
FAILURE CODE [CA1885] .1240
FAILURE CODE [CA1887] .1242
FAILURE CODE [CA1921] .1244
FAILURE CODE [CA1922] .1247
FAILURE CODE [CA1942] .1252
FAILURE CODE [CA1993] .1253
FAILURE CODE [CA2185] .1256
FAILURE CODE [CA2186] .1257
FAILURE CODE [CA2249] .1259
FAILURE CODE [CA2265] .1260
FAILURE CODE [CA2266] .1262
FAILURE CODE [CA2271] .1264
FAILURE CODE [CA2272] .1266
FAILURE CODE [CA2288] .1269
FAILURE CODE [CA2311] .1270
FAILURE CODE [CA2349] .1271
FAILURE CODE [CA2353] .1274
FAILURE CODE [CA2357] .1276
FAILURE CODE [CA2381] .1277
FAILURE CODE [CA2382] .1279
FAILURE CODE [CA2383] .1282
FAILURE CODE [CA2386] .1285
FAILURE CODE [CA2387] .1287
FAILURE CODE [CA2555] .1288
FAILURE CODE [CA2556] .1291
FAILURE CODE [CA2637] .1294
FAILURE CODE [CA2639] .1296
FAILURE CODE [CA2771] .1299
FAILURE CODE [CA2777] .1305
FAILURE CODE [CA2976] .1308
FAILURE CODE [CA3133] .1310
FAILURE CODE [CA3134] .1312
FAILURE CODE [CA3135] .1314
FAILURE CODE [CA3142] .1317
FAILURE CODE [CA3143] .1318
FAILURE CODE [CA3144] .1319
FAILURE CODE [CA3146] .1321
FAILURE CODE [CA3147] .1322
FAILURE CODE [CA3148] .1323
FAILURE CODE [CA3151] .1325
FAILURE CODE [CA3165] .1332
FAILURE CODE [CA3229] .1334
FAILURE CODE [CA3231] .1336
FAILURE CODE [CA3232] .1338
FAILURE CODE [CA3235] .1342
FAILURE CODE [CA3239] .1344
FAILURE CODE [CA3241] .1347
FAILURE CODE [CA3242] .1350
FAILURE CODE [CA3251] .1353
FAILURE CODE [CA3253] .1355
FAILURE CODE [CA3254] .1358
FAILURE CODE [CA3255] .1361
FAILURE CODE [CA3256] .1365
FAILURE CODE [CA3311] .1367
FAILURE CODE [CA3312] .1369
FAILURE CODE [CA3313] .1372
FAILURE CODE [CA3314] .1373
FAILURE CODE [CA3315] .1374
FAILURE CODE [CA3316] .1376
FAILURE CODE [CA3317] .1377
FAILURE CODE [CA3318] .1378
FAILURE CODE [CA3319] .1380
FAILURE CODE [CA3321] .1381
FAILURE CODE [CA3322] .1383
FAILURE CODE [CA3419] .1385
FAILURE CODE [CA3421] .1387
FAILURE CODE [CA3497] .1389
FAILURE CODE [CA3498] .1390
FAILURE CODE [CA3543] .1391
FAILURE CODE [CA3545] .1397
FAILURE CODE [CA3547] .1399
FAILURE CODE [CA3558] .1400
FAILURE CODE [CA3559] .1402
FAILURE CODE [CA3562] .1404
FAILURE CODE [CA3563] .1406
FAILURE CODE [CA3567] .1409
FAILURE CODE [CA3568] .1412
FAILURE CODE [CA3571] .1416
FAILURE CODE [CA3572] .1418
FAILURE CODE [CA3574] .1420
FAILURE CODE [CA3575] .1422
FAILURE CODE [CA3577] .1424
FAILURE CODE [CA3578] .1426
FAILURE CODE [CA3582] .1428
FAILURE CODE [CA3583] .1434
FAILURE CODE [CA3596] .1436
FAILURE CODE [CA3649] .1439
FAILURE CODE [CA3681] .1441
FAILURE CODE [CA3682] .1446
FAILURE CODE [CA3713] .1451
FAILURE CODE [CA3717] .1454
FAILURE CODE [CA3718] .1455
FAILURE CODE [CA3725] .1456
FAILURE CODE [CA3741] .1459
FAILURE CODE [CA3748] .1460
FAILURE CODE [CA3751] .1463
FAILURE CODE [CA3755] .1465
FAILURE CODE [CA3866] .1467
FAILURE CODE [CA3867] .1471
FAILURE CODE [CA3868] .1474
FAILURE CODE [CA3899] .1478
FAILURE CODE [CA3911] .1480
FAILURE CODE [CA3912] .1484
FAILURE CODE [CA3932] .1486
FAILURE CODE [CA3933] .1488
FAILURE CODE [CA3934] .1490
FAILURE CODE [CA3935] .1493
FAILURE CODE [CA3936] .1495
FAILURE CODE [CA4151] .1497
FAILURE CODE [CA4152] .1501
FAILURE CODE [CA4155] .1505
FAILURE CODE [CA4156] .1507
FAILURE CODE [CA4157] .1510
FAILURE CODE [CA4158] .1512
FAILURE CODE [CA4159] .1513
FAILURE CODE [CA4161] .1514
FAILURE CODE [CA4162] .1517
FAILURE CODE [CA4163] .1520
FAILURE CODE [CA4164] .1522
FAILURE CODE [CA4165] .1524
FAILURE CODE [CA4166] .1526
FAILURE CODE [CA4168] .1528
FAILURE CODE [CA4169] .1531
FAILURE CODE [CA4171] .1533
FAILURE CODE [CA4249] .1536
FAILURE CODE [CA4251] .1538
FAILURE CODE [CA4259] .1540
FAILURE CODE [CA4261] .1543
FAILURE CODE [CA4277] .1546
FAILURE CODE [CA4281] .1550
FAILURE CODE [CA4459] .1554
FAILURE CODE [CA4461] .1557
FAILURE CODE [CA4658] .1560
FAILURE CODE [CA4731] .1564
FAILURE CODE [CA4732] .1565
FAILURE CODE [CA4739] .1566
FAILURE CODE [CA4768] .1567
FAILURE CODE [CA4769] .1569
FAILURE CODE [CA4842] .1571
FAILURE CODE [CA4952] .1575
FAILURE CODE [CA5115] .1577
FAILURE CODE [CA5179] .1580
FAILURE CODE [CA5181] .1582
FAILURE CODE [CA5383] .1584
FAILURE CODE [D110KB] .1586
FAILURE CODE [D19JKZ] .1588
FAILURE CODE [D811MC] .1591
FAILURE CODE [D862KA] .1592
FAILURE CODE [D8ALKA] .1594
FAILURE CODE [D8ALKB] .1597
FAILURE CODE [D8AQKR] .1599
FAILURE CODE [D8G1KT] .1606
FAILURE CODE [DA20MC] .1607
FAILURE CODE [DA22KK] .1608
FAILURE CODE [DA25KP] .1611
FAILURE CODE [DA26KP] .1613
FAILURE CODE [DA29KQ] .1616
FAILURE CODE [DA2LKA] .1618
FAILURE CODE [DA2LKB] .1621
FAILURE CODE [DA2QKR] .1623
FAILURE CODE [DA2RKR] .1632
FAILURE CODE [DAF0KM] .1637
FAILURE CODE [DAF0MB] .1638
FAILURE CODE [DAF0MC] .1639
FAILURE CODE [DAF8KB] .1640
FAILURE CODE [DAF9KQ] .1642
FAILURE CODE [DAFGMC] .1643
FAILURE CODE [DAFLKA] .1644
FAILURE CODE [DAFLKB] .1647
FAILURE CODE [DAFQKR] .1649
FAILURE CODE [DAZ9KQ] .1657
FAILURE CODE [DAZQKR] .1658
FAILURE CODE [DB2QKR] .1665
FAILURE CODE [DB2RKR] .1673
FAILURE CODE [DBP0KM] .1678
FAILURE CODE [DBP0KT] .1679
FAILURE CODE [DBPQKR] .1680
FAILURE CODE [DDNRKA] .1688
FAILURE CODE [DDNRKY] .1690
FAILURE CODE [DDNS00] .1692
FAILURE CODE [DFB1KZ] .1694
FAILURE CODE [DFB2KZ] .1696
FAILURE CODE [DFB3L8] .1698
FAILURE CODE [DFB4L8] .1700
FAILURE CODE [DFB5KZ] .1702
FAILURE CODE [DFB6KZ] .1704
FAILURE CODE [DGH2KA] .1706
FAILURE CODE [DGH2KB] .1708
FAILURE CODE [DHA4KA] .1710
FAILURE CODE [DHAAMA] .1712
FAILURE CODE [DHACMA] .1714
FAILURE CODE [DHPAMA] .1716
FAILURE CODE [DHPBMA] .1718
FAILURE CODE [DHS3MA] .1720
FAILURE CODE [DHS4MA] .1722
FAILURE CODE [DHS8MA] .1724
FAILURE CODE [DHS9MA] .1726
FAILURE CODE [DHSAKZ] .1728
FAILURE CODE [DHSBKZ] .1730
FAILURE CODE [DHSCMA] .1732
FAILURE CODE [DHSDMA] .1734
FAILURE CODE [DHSFMA] .1736
FAILURE CODE [DHSGMA] .1738
FAILURE CODE [DHSHMA] .1740
FAILURE CODE [DHSJMA] .1742
FAILURE CODE [DHVAKZ] .1744
FAILURE CODE [DHVAL8] .1746
FAILURE CODE [DHVAMA] .1748
FAILURE CODE [DHVBKZ] .1749
FAILURE CODE [DHVBL8] .1751
FAILURE CODE [DHVBMA] .1753
FAILURE CODE [DKR0MA] .1754
FAILURE CODE [DKR1MA] .1756
FAILURE CODE [DKULKA] .1758
FAILURE CODE [DKULKB] .1760
FAILURE CODE [DKULKY] .1762
FAILURE CODE [DLM5KA] .1763
FAILURE CODE [DLM5MB] .1765
FAILURE CODE [DR10KA] .1767
FAILURE CODE [DR21KX] .1770
FAILURE CODE [DUMBKA] .1772
FAILURE CODE [DUMBKB] .1775
FAILURE CODE [DV00KA] .1777
FAILURE CODE [DV00KB] .1778
FAILURE CODE [DV20KB] .1779
FAILURE CODE [DW43KA] .1781
FAILURE CODE [DW43KB] .1783
FAILURE CODE [DW43KY] .1784
FAILURE CODE [DW45KA] .1785
FAILURE CODE [DW45KB] .1788
FAILURE CODE [DW45KK] .1791
FAILURE CODE [DW45KY] .1793
FAILURE CODE [DW4CKY] .1795
FAILURE CODE [DW91KA] .1796
FAILURE CODE [DW91KB] .1798
FAILURE CODE [DW91KY] .1799
FAILURE CODE [DWA2KA] .1800
FAILURE CODE [DWA2KB] .1802
FAILURE CODE [DWA2KY] .1803
FAILURE CODE [DWK0KA] .1804
FAILURE CODE [DWK0KB] .1806
FAILURE CODE [DWK0KY] .1808
FAILURE CODE [DWK2KA] .1809
FAILURE CODE [DWK2KB] .1811
FAILURE CODE [DWK2KY] .1813
FAILURE CODE [DWN5KA] .1814
FAILURE CODE [DWN5KB] .1816
FAILURE CODE [DWN5KY] .1817
FAILURE CODE [DWPUKA] .1818
FAILURE CODE [DWPUKB] .1820
FAILURE CODE [DWPUKY] .1822
FAILURE CODE [DXA8KA] .1824
FAILURE CODE [DXA8KB] .1827
FAILURE CODE [DXA9KA] .1829
FAILURE CODE [DXA9KB] .1832
FAILURE CODE [DXE0KA] .1834
FAILURE CODE [DXE0KB] .1836
FAILURE CODE [DXE4KA] .1837
FAILURE CODE [DXE4KB] .1839
FAILURE CODE [DXE4KY] .1840
FAILURE CODE [DXE5KA] .1841
FAILURE CODE [DXE5KB] .1843
FAILURE CODE [DXE6KA] .1845
FAILURE CODE [DXE6KB] .1847
FAILURE CODE [DXE7KA] .1849
FAILURE CODE [DXE7KB] .1851
FAILURE CODE [DXE7KY] .1853
FAILURE CODE [DXE8KA] .1855
FAILURE CODE [DXE8KB] .1857
FAILURE CODE [DXE8KY] .1859
FAILURE CODE [DXE9KA] .1861
FAILURE CODE [DXE9KB] .1863
FAILURE CODE [DXE9KY] .1865
FAILURE CODE [DXEAKA] .1867
FAILURE CODE [DXEAKB] .1869
FAILURE CODE [DXEAKY] .1871
FAILURE CODE [DXEKKA] .1873
FAILURE CODE [DXEKKB] .1875
FAILURE CODE [DXEKKY] .1877
FAILURE CODE [DXELKA] .1879
FAILURE CODE [DXELKB] .1881
FAILURE CODE [DXELKY] .1883
FAILURE CODE [DY20KA] .1885
FAILURE CODE [DY20MA] .1887
FAILURE CODE [DY2CKB] .1889
FAILURE CODE [DY2DKB] .1891
FAILURE CODE [DY2EKB] .1893
FAILURE CODE [F313KA] .1895
FAILURE CODE [F313KB] .1897
FAILURE CODE [F318KB] .1900
FAILURE CODE [F318KY] .1903
FAILURE CODE [GA00NS] .1905
FAILURE CODE [GA01KA] .1906
FAILURE CODE [GA02KZ] .1908
FAILURE CODE [GA04KG] .1911
FAILURE CODE [GA05KG] .1914
FAILURE CODE [GA05KP] .1917
FAILURE CODE [GA06KZ] .1920
FAILURE CODE [GA08KG] .1921
FAILURE CODE [GA09KG] .1929
FAILURE CODE [GA09KP] .1937
FAILURE CODE [GA0AKZ] .1938
FAILURE CODE [GA0BKZ] .1939
FAILURE CODE [GA10MA] .1946
FAILURE CODE [GA10MC] .1953
FAILURE CODE [GA12NK] .1954
FAILURE CODE [GA13KP] .1960
FAILURE CODE [GA13KY] .1962
FAILURE CODE [GA15KZ] .1964
FAILURE CODE [GA17KR] .1972
FAILURE CODE [GA17MB] .1973
FAILURE CODE [GA18MC] .1974
FAILURE CODE [GA19KR] .1979
FAILURE CODE [GA19KT] .1980
FAILURE CODE [GA1BMA] .1981
FAILURE CODE [GA1FKR] .1983
FAILURE CODE [GA1FMA] .1984
FAILURE CODE [GA1GKR] .1987
FAILURE CODE [GA1GKT] .1988
FAILURE CODE [GA1GMB] .1989
FAILURE CODE [GA1HKZ] .1990
FAILURE CODE [GA1JKZ] .1991
FAILURE CODE [GA1KKZ] .1992
FAILURE CODE [GA1LKZ] .1993
FAILURE CODE [GA1MKZ] .1994
FAILURE CODE [GA1NNS] .1995
FAILURE CODE [GA1SFS] .1996
FAILURE CODE [GA1SMC] .1997
FAILURE CODE [GA1TKP] .1998
FAILURE CODE [GA1TNS] .2001
FAILURE CODE [GA1UKZ] .2004
FAILURE CODE [GA1VFS] .2007
FAILURE CODE [GA1VMC] .2008
FAILURE CODE [GA1XKZ] .2009
FAILURE CODE [GA1YNS] .2010
FAILURE CODE [GA1ZKZ] .2011
FAILURE CODE [GA1ZNS] .2012
FAILURE CODE [GA22NS] .2013
FAILURE CODE [GA23KZ] .2014
FAILURE CODE [GA24KZ] .2015
FAILURE CODE [GA25MA] .2016
FAILURE CODE [GA25NS] .2021
FAILURE CODE [GA26MA] .2022
FAILURE CODE [GA26NS] .2027
FAILURE CODE [GA27KZ] .2028
FAILURE CODE [GA2QKR] .2029
FAILURE CODE [GA2RKR] .2034
FAILURE CODE [GA60MC] .2039
FAILURE CODE [GA60N1] .2041
FAILURE CODE [GA61KZ] .2043
FAILURE CODE [GA61NS] .2045
FAILURE CODE [GA62KY] .2046
FAILURE CODE [GA62KZ] .2051
FAILURE CODE [GA62MA] .2055
FAILURE CODE [GA63KY] .2056
FAILURE CODE [GA63KZ] .2061
FAILURE CODE [GA63MA] .2065
FAILURE CODE [GA64KY] .2066
FAILURE CODE [GA64KZ] .2071
FAILURE CODE [GA64MA] .2075
FAILURE CODE [GA70KB] .2076
FAILURE CODE [GA70MD] .2079
FAILURE CODE [GA70NS] .2081
FAILURE CODE [GA71KZ] .2082
FAILURE CODE [GA72MA] .2084
FAILURE CODE [GA72MC] .2086
FAILURE CODE [GA81KZ] .2088
FAILURE CODE [GAA0KB] .2091
FAILURE CODE [GAA2KB] .2093
FAILURE CODE [GAA6KP] .2095
FAILURE CODE [GAA6KY] .2097
FAILURE CODE [GACA00] .2099
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .2100
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .2100
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 2106
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .2109
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .2111
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .2113
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 2116
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 2117
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .2118
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 2119
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .2120
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2121
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2122
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2123
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2124
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2125
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2126
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .2127
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .2129
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .2130
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 2131
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2132
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .2134
E-23 MONITOR TEMPERATURE GAUGE OF HYBRID SYSTEMS DOES NOT INDICATE CORRECT TEMPERATURE 2135
E-24 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .2136
E-25 FUNCTION SWITCH DOES NOT OPERATE .2137
E-26 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .2138
E-27 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 2139
E-28 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 2140
E-29 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .2141
E-30 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 2142
E-31 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .2143
E-32 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 2144
E-33 ALARM BUZZER CANNOT BE CANCELED 2145
E-34 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .2146
E-35 SERVICE MODE CANNOT BE SELECTED 2147
E-36 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 2148
E-37 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .2150
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .2151
E-39 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .2154
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .2156
E-41 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .2158
E-42 ALARM DOES NOT SOUND DURING TRAVEL .2159
E-43 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 2161
E-44 HORN DOES NOT SOUND 2162
E-45 HORN DOES NOT STOP SOUNDING 2165
E-46 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .2167
E-47 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .2168
E-48 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 2170
E-49 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2171
E-50 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2172
E-51 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .2173
E-52 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2174
E-53 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .2175
E-54 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .2176
E-55 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .2177
E-56 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2178
E-57 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .2179
E-58 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .2181
E-59 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .2182
E-60 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED 2183
E-61 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 2185
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .2186
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .2186
FAILURE MODE AND CAUSE TABLE 2187
H-1 ALL WORK EQUIPMENTS OR TRAVEL DOES NOT OPERATE 2198
H-2 ALL WORK EQUIPMENT AND TRAVEL SPEED OR POWER IS LOW .2199
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 2201
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .2202
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2203
H-6 SPEED OR POWER OF BOOM IS LOW .2205
H-7 ARM SPEED OR POWER IS LOW .2211
H-8 BUCKET SPEED OR POWER IS LOW 2216
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 2220
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .2221
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 2223
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .2225
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .2226
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 2227
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .2228
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 2229
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED .2230
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .2231
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 2232
H-20 MACHINE DOES NOT TRAVEL STRAIGHT .2233
H-21 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .2235
H-22 TRAVEL SPEED IS LOW 2238
H-23 ONE OF TRACKS DOES NOT RUN .2240
H-24 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2242
H-25 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .2243
H-26 UNUSUAL NOISE IS HEARD FROM AROUND FAN .2244
H-27 Quick coupler cylinder will not extend .2245
H-28 Quick coupler cylinder will not retract (but buzzer doesnot sound) .2247
H-29 Buzzer does not sound (but quick coupler cylinder doesretract) .2249
H-30 Quick coupler cylinder extends and retracts slowly .2251
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .2252
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2253
TROUBLESHOOTING OF ENGINE (S-MODE) 2254
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .2254
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2255
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2256
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2257
S-4 ENGINE STARTABILITY IS POOR .2259
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2261
S-6 ENGINE STOPS DURING OPERATION .2263
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2265
S-8 ENGINE LACKS POWER 2266
S-9 KDPF GETS CLOGGED IN A SHORT TIME .2268
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2270
S-11 OIL BECOMES CONTAMINATED QUICKLY .2271
S-12 FUEL CONSUMPTION IS EXCESSIVE 2272
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2273
S-14 OIL PRESSURE DROPS .2274
S-15 FUEL MIXES INTO ENGINE OIL .2276
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2277
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2278
S-18 UNUSUAL NOISE IS HEARD .2279
S-19 VIBRATION IS EXCESSIVE .2280
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .2281
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2282
S-22 ACTIVE REGENERATION TAKES TIME .2284
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2285
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2286
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2288
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2289
TROUBLESHOOTING FOR HYBRID SYSTEMS (Y MODE) .2290
PRECAUTIONS FOR USING HYBRID SYSTEMS 2290
Y-1 HYBRID MONITOR DOES NOT GO OUT 2291
Y-2 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT .2293
Y-3 UPPER STRUCTURE SWINGS ONLY TO THE RIGHT OR LEFT 2294
Y-4 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 2295
Y-5 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS LOW IN ONLY ONE DIRECTION 2296
Y-6 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) .2297
Y-7 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (EITHER RIGHT OR LEFT) 2298
Y-8 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 2299
Y-9 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 2300
Y-10 SWING DRIFT ON A SLOPE IS LARGE (WHILE PARKING BRAKE IS APPLIED) .2301
Y-11 SWING DRIFT ON A SLOPE IS LARGE (WHILE PARKING BRAKE IS RELEASED) 2302
Y-12 ELECTRIC SWING MOTOR TEMPERATURE INCREASES ABNORMALLY 2303
Y-13 MOTOR-GENERATOR TEMPERATURE INCREASES ABNORMALLY .2306
Y-14 INVERTER TEMPERATURE INCREASES ABNORMALLY 2308
Y-15 CAPACITOR TEMPERATURE INCREASES ABNORMALLY .2310
50 DISASSEMBLY AND ASSEMBLY .2313
CONTENTS 2314
ABBREVIATION LIST .2319
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2325
HOW TO READ THIS MANUAL .2325
COATING MATERIALS LIST 2327
SPECIAL TOOLS LIST 2331
SKETCHES OF SPECIAL TOOLS .2350
ENGINE AND COOLING SYSTEM .2358
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2358
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2358
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2362
REMOVE AND INSTALL INJECTOR ASSEMBLY 2370
METHOD FOR REMOVING INJECTOR ASSEMBLY .2370
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2376
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2388
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2388
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2397
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2414
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2414
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2415
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2417
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2417
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2418
REMOVE AND INSTALL STARTER ASSEMBLY .2420
METHOD FOR REMOVING STARTER ASSEMBLY 2420
METHOD FOR INSTALLING STARTER ASSEMBLY 2421
REMOVE AND INSTALL ALTERNATOR BELT 2422
METHOD FOR REMOVING ALTERNATOR BELT .2422
METHOD FOR INSTALLING ALTERNATOR BELT .2425
REMOVE AND INSTALL RADIATOR ASSEMBLY 2428
METHOD FOR REMOVING RADIATOR ASSEMBLY .2428
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2431
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2434
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2434
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2438
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2441
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2441
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2443
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 2445
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY .2445
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY .2449
REMOVE AND INSTALL FAN 2452
METHOD FOR INSTALLING FAN .2452
METHOD FOR REMOVING FAN .2452
REMOVE AND INSTALL ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY 2453
METHOD FOR REMOVING ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY .2454
METHOD FOR INSTALLING ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY .2463
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2475
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2475
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2477
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2479
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2479
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2480
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2488
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2488
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2490
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2493
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2493
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2496
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2499
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2499
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2505
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2510
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2510
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2517
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2521
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2521
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2521
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2528
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2528
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2528
REMOVE AND INSTALL KDPF ASSEMBLY 2529
METHOD FOR REMOVING KDPF ASSEMBLY .2529
METHOD FOR INSTALLING KDPF ASSEMBLY .2532
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2535
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2536
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2539
REMOVE AND INSTALL SCR ASSEMBLY .2544
METHOD FOR REMOVING SCR ASSEMBLY 2544
METHOD FOR INSTALLING SCR ASSEMBLY 2547
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2550
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2551
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2557
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2562
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2562
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2565
REMOVE AND INSTALL KCCV ASSEMBLY 2569
METHOD FOR REMOVING KCCV ASSEMBLY .2569
METHOD FOR INSTALLING KCCV ASSEMBLY .2570
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2572
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2573
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2576
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2580
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2580
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2583
REMOVE AND INSTALL AdBlue/DEF PUMP 2587
METHOD FOR REMOVING AdBlue/DEF PUMP .2587
METHOD FOR INSTALLING AdBlue/DEF PUMP .2590
REMOVE AND INSTALL AdBlue/DEF HOSE 2593
METHOD FOR REMOVING AdBlue/DEF HOSE .2594
METHOD FOR INSTALLING AdBlue/DEF HOSE .2600
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2608
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2608
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2610
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2613
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2613
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2614
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2616
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2616
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2617
HYBRID SYSTEM .2620
REMOVE AND INSTALL HYBRID RADIATOR ASSEMBLY .2620
METHOD FOR REMOVING HYBRID RADIATOR ASSEMBLY 2620
METHOD FOR INSTALLING HYBRID RADIATOR ASSEMBLY 2622
REMOVE AND INSTALL HYBRID WATER PUMP ASSEMBLY .2624
METHOD FOR REMOVING HYBRID WATER PUMP ASSEMBLY 2624
METHOD FOR INSTALLING HYBRID WATER PUMP ASSEMBLY 2626
REMOVE AND INSTALL INVERTER ASSEMBLY 2629
METHOD FOR REMOVING INVERTER ASSEMBLY .2629
METHOD FOR INSTALLING INVERTER ASSEMBLY .2633
REMOVE AND INSTALL INVERTER AND CAPACITOR ASSEMBLY 2638
METHOD FOR REMOVING INVERTER AND CAPACITOR ASSEMBLY .2638
METHOD FOR INSTALLING INVERTER AND CAPACITOR ASSEMBLY .2643
REMOVE AND INSTALL MOTOR-GENERATOR AND HOUSING ASSEMBLY .2648
METHOD FOR REMOVING MOTOR-GENERATOR AND HOUSING ASSEMBLY 2648
METHOD FOR INSTALLING MOTOR-GENERATOR AND HOUSING ASSEMBLY 2652
REMOVE AND INSTALL ELECTRIC SWING MOTOR .2658
METHOD FOR REMOVING ELECTRIC SWING MOTOR 2658
METHOD FOR INSTALLING ELECTRIC SWING MOTOR 2662
POWER TRAIN .2668
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2668
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2668
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2669
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2671
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2672
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2676
REMOVE AND INSTALL ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY 2684
METHOD FOR REMOVING ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY .2684
METHOD FOR INSTALLING ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY .2688
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2693
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2693
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2700
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2713
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2713
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2713
UNDERCARRIAGE AND FRAME .2715
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2715
METHOD FOR SEPARATING TRACK ASSEMBLY 2715
METHOD FOR INSTALLING TRACK ASSEMBLY 2717
REMOVE AND INSTALL SPROCKET .2720
METHOD FOR REMOVING SPROCKET 2720
METHOD FOR INSTALLING SPROCKET 2721
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2722
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2722
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2723
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2724
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2724
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2725
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2729
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2730
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2730
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2732
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2733
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2734
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2736
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2736
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2738
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2741
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2741
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2743
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2746
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2746
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2747
HYDRAULIC SYSTEM 2750
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2750
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2750
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2752
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2755
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2756
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2757
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2758
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2758
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2761
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2765
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2765
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2768
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2771
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2771
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2778
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2785
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2785
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2787
REMOVE AND INSTALL ATT BYPASS SOLENOID 2792
REMOVE ATT BYPASS SOLENOID 2792
INSTALL ATT BYPASS SOLENOID .2795
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2797
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2797
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2798
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2800
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2800
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2801
REMOVE AND INSTALL QUICK COUPLER VALVE 2803
WORK EQUIPMENT 2805
REMOVE AND INSTALL BUCKET ASSEMBLY 2805
METHOD FOR REMOVING BUCKET ASSEMBLY .2805
METHOD FOR INSTALLING BUCKET ASSEMBLY .2805
REMOVE AND INSTALL ARM ASSEMBLY .2807
METHOD FOR REMOVING ARM ASSEMBLY 2807
METHOD FOR INSTALLING ARM ASSEMBLY 2808
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2810
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2810
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2812
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2815
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2815
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2818
CAB AND ITS ATTACHMENTS .2825
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2825
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY .2825
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY .2832
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2840
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2842
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2842
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2852
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2852
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2855
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2861
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2861
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2866
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2871
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2871
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2876
REMOVE AND INSTALL OPERATOR’S SEAT 2882
METHOD FOR REMOVING OPERATOR’S SEAT .2882
METHOD FOR INSTALLING OPERATOR’S SEAT .2884
REMOVE AND INSTALL SEAT BELT 2887
METHOD FOR REMOVING SEAT BELT .2887
METHOD FOR INSTALLING SEAT BELT .2887
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2889
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2889
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2894
ELECTRICAL SYSTEM .2903
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2903
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2903
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2905
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2909
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2909
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2912
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2915
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2915
METHOD FOR INSTALLING KomVision CONTROLLER 2916
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2917
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2917
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2919
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2923
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2923
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2923
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2925
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2925
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2926
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2928
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2928
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2928
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2930
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2930
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2931
REMOVE AND INSTALL KomVision CAMERA .2933
METHOD FOR REMOVING KomVision CAMERA 2933
METHOD FOR INSTALLING KomVision CAMERA 2934
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY .2936
METHOD FOR REMOVING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2936
METHOD FOR INSTALLING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2941
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 2946
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS .2946
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS .2954
REMOVE AND INSTALL COMMUNICATION TERMINAL .2963
METHOD FOR REMOVING COMMUNICATION TERMINAL 2963
METHOD FOR INSTALLING COMMUNICATION TERMINAL 2965
60 MAINTENANCE STANDARD .2969
CONTENTS 2970
ABBREVIATION LIST .2971
ENGINE AND COOLING SYSTEM .2977
MAINTENANCE STANDARD OF ENGINE MOUNT 2977
MAINTENANCE STANDARD OF COOLING SYSTEM 2979
POWER TRAIN .2981
MAINTENANCE STANDARD OF SWING CIRCLE 2981
MAINTENANCE STANDARD OF SWING MACHINERY WITH SWING PARKING BRAKE 2982
MAINTENANCE STANDARD OF FINAL DRIVE .2984
MAINTENANCE STANDARD OF SPROCKET 2986
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2987
UNDERCARRIAGE AND FRAME .2989
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2989
MAINTENANCE STANDARD OF IDLER .2991
MAINTENANCE STANDARD OF TRACK ROLLER 2993
MAINTENANCE STANDARD OF CARRIER ROLLER 2995
MAINTENANCE STANDARD OF TRACK SHOE 2996
MAINTENANCE STANDARD OF TRIPLE SHOE .2999
HYDRAULIC SYSTEM 3000
MAINTENANCE STANDARD OF HYDRAULIC TANK 3000
MAINTENANCE STANDARD OF MAIN PUMP .3001
MAINTENANCE STANDARD OF MAIN PUMP LS-EPC VALVE 3003
MAINTENANCE STANDARD OF MAIN PUMP PC-EPC VALVE 3004
MAINTENANCE STANDARD OF TRAVEL MOTOR 3005
MAINTENANCE STANDARD OF CONTROL VALVE .3008
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 3020
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM .3022
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 3024
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 3027
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 3030
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 3032
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE .3033
MAINTENANCE STANDARD OF SOLENOID VALVE 3035
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE .3036
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .3037
WORK EQUIPMENT 3038
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 3038
DIMENSION OF ARM 3043
DIMENSIONS OF BUCKET 3045
MAINTENANCE STANDARD OF BOOM CYLINDER .3047
MAINTENANCE STANDARD OF ARM CYLINDER 3048
MAINTENANCE STANDARD OF BUCKET CYLINDER .3049
80 APPENDIX .3051
CONTENTS 3052
ABBREVIATION LIST .3054
AIR CONDITIONER SYSTEM 3060
PRECAUTIONS FOR REFRIGERANT .3060
AIR CONDITIONER COMPONENT .3061
SPECIFICATIONS OF AIR CONDITIONER .3063
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .3064
OUTLINE OF REFRIGERATION CYCLE 3065
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .3067
AIR CONDITIONER UNIT 3067
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .3067
FUNCTION OF AIR CONDITIONER UNIT 3069
COMPONENT PARTS OF AIR CONDITIONER UNIT .3071
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3072
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .3072
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .3072
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .3072
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3073
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .3073
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .3073
FUNCTION OF DUAL PRESSURE SWITCH 3074
AIR CONDITIONER CONTROLLER 3075
STRUCTURE OF AIR CONDITIONER CONTROLLER .3075
COMPRESSOR 3076
STRUCTURE OF COMPRESSOR .3076
SPECIFICATIONS OF COMPRESSOR 3076
FUNCTION OF COMPRESSOR 3076
CONDENSER .3077
STRUCTURE OF CONDENSER 3077
SPECIFICATIONS OF CONDENSER .3077
FUNCTION OF CONDENSER .3077
RECEIVER DRIER 3078
STRUCTURE OF RECEIVER DRIER .3078
SPECIFICATIONS OF RECEIVER DRIER 3078
FUNCTION OF RECEIVER DRIER 3078
SENSORS FOR AIR CONDITIONER SYSTEM 3079
STRUCTURE OF SUNLIGHT SENSOR 3079
FUNCTION OF SUNLIGHT SENSOR .3079
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .3079
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3079
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .3081
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .3083
AIR CONDITIONER SYSTEM DIAGRAM 3085
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3086
FUNCTION OF AIR CONDITIONER CONTROLLER 3087
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .3088
TESTING AIR LEAKAGE (DUCT) 3092
METHOD FOR TESTING AIR LEAKAGE (DUCT) .3092
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .3094
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3095
TEST VENT (MODE) CHANGEOVER .3096
METHOD FOR TESTING VENT (MODE) CHANGEOVER .3096
TESTING FRESH/RECIRC AIR CHANGEOVER .3098
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3098
TEST SUNLIGHT SENSOR 3099
METHOD FOR TESTING SUNLIGHT SENSOR 3099
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .3100
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .3100
TEST RELAYS .3101
METHOD FOR TESTING RELAYS .3101
AIR CONDITIONER TROUBLESHOOTING CHART 1 .3102
AIR CONDITIONER TROUBLESHOOTING CHART 2 .3103
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3106
FAILURE CODE [879AKA] .3108
FAILURE CODE [879AKB] .3109
FAILURE CODE [879BKA] .3110
FAILURE CODE [879BKB] .3112
FAILURE CODE [879CKA] .3114
FAILURE CODE [879CKB] .3115
FAILURE CODE [879DKZ] .3116
FAILURE CODE [879EMC] .3118
FAILURE CODE [879FMC] .3119
FAILURE CODE [879GKX] .3120
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3122
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .3124
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3127
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .3129
TROUBLESHOOTING USING GAUGE PRESSURE 3131
CONNECTION OF SERVICE TOOL 3134
METHOD FOR CONNECTING SERVICE TOOL 3134
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .3136
HANDLE COMPRESSOR OIL .3138
90 CIRCUIT DIAGRAMS .3141
CONTENTS 3142
ABBREVIATION LIST .3143
HYDRAULIC CIRCUIT DIAGRAM .3149
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .3149
HYDRAULIC CIRCUIT DIAGRAM (1/2) .3153
HYDRAULIC CIRCUIT DIAGRAM (2/2) .3155
ELECTRICAL CIRCUIT DIAGRAM 3157
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3157
ELECTRICAL CIRCUIT DIAGRAM (1/12) .3161
ELECTRICAL CIRCUIT DIAGRAM (2/12) .3163
ELECTRICAL CIRCUIT DIAGRAM (3/12) .3165
ELECTRICAL CIRCUIT DIAGRAM (4/12) .3167
ELECTRICAL CIRCUIT DIAGRAM (5/12) .3169
ELECTRICAL CIRCUIT DIAGRAM (6/12) .3171
ELECTRICAL CIRCUIT DIAGRAM (7/12) .3173
ELECTRICAL CIRCUIT DIAGRAM (8/12) .3175
ELECTRICAL CIRCUIT DIAGRAM (9/12) .3177
ELECTRICAL CIRCUIT DIAGRAM (10/12) 3179
ELECTRICAL CIRCUIT DIAGRAM (11/12) 3181
ELECTRICAL CIRCUIT DIAGRAM (12/12) 3183
HYDRAULIC CIRCUIT DIAGRAM GATEWAY .3185
HYDRAULIC CIRCUIT DIAGRAM (1/3) .3187
HYDRAULIC CIRCUIT DIAGRAM (2/3) .3189
HYDRAULIC CIRCUIT DIAGRAM (3/3) .3191
WIRING DIAGRAM (BEFORE GATEWAY) .3193
WIRING DIAGRAM (1/12) .3195
WIRING DIAGRAM (2/12) .3197
WIRING DIAGRAM (3/12) .3199
WIRING DIAGRAM (4/12) .3201
WIRING DIAGRAM (5/12) .3203
WIRING DIAGRAM (6/12) .3205
WIRING DIAGRAM (7/12) .3207
WIRING DIAGRAM (8/12) .3209
WIRING DIAGRAM (9/12) .3211
WIRING DIAGRAM (10/12) 3213
WIRING DIAGRAM (11/12) 3215
WIRING DIAGRAM (12/12) 3217
WIRING DIAGRAM (AFTER GATEWAY) 3219
WIRING DIAGRAM (1/13) .3221
WIRING DIAGRAM (2/13) .3223
WIRING DIAGRAM (3/13) .3225
WIRING DIAGRAM (4/13) .3227
WIRING DIAGRAM (5/13) .3229
WIRING DIAGRAM (6/13) .3231
WIRING DIAGRAM (7/13) .3233
WIRING DIAGRAM (8/13) .3235
WIRING DIAGRAM (9/13) .3237
WIRING DIAGRAM (10/13) 3239
WIRING DIAGRAM (11/13) 3241
WIRING DIAGRAM (12/13) 3243
WIRING DIAGRAM (13/13) 3245
INDEX 3247

DESCRIPTION:

Komatsu HB365LC-3E0,HB365NLC-3E0 Hydraulic Excavator Shop Manual UENBM00522 – PDF DOWNLOAD

SERIAL NUMBERS

• 5001 and up
• K70001 and up

FOREWORD, SAFETY, BASIC INFORMATION
HOW TO READ THE SHOP MANUAL
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

G.B 29/12/24