Komatsu HB365LC-3E0,HB365NLC-3E0 Hydraulic Excavator Shop Manual UENBM00642 PDF

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Komatsu HB365LC-3E0,HB365NLC-3E0 Hydraulic Excavator Shop Manual UENBM00642  – PDF DOWNLOAD

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Komatsu HB365LC-3E0,HB365NLC-3E0 Hydraulic Excavator Shop Manual UENBM00642  – PDF DOWNLOAD

Language : English
Pages : 3238
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu HB365LC-3E0,HB365NLC-3E0 Hydraulic Excavator Shop Manual UENBM00642  – PDF DOWNLOAD

SERIAL NUMBERS

• HB365LC-3E0 K75222 and up
• HB365NLC-3E0 K75222 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
METHOD FOR CHECKING ENGINE TYPE . 46
PRECAUTIONS FOR DEF . 48
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 48
PRECAUTIONS FOR ADDING 48
PRECAUTIONS FOR STORING . 48
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 48
THE OTHER PRECAUTIONS . 48
STORE AdBlue/DEF 49
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 50
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 53
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 60
PRECAUTIONS FOR MAINTENANCE OF HYBRID SYSTEM 62
PRECAUTIONS AGAINST HIGH VOLTAGE AND HIGH TEMPERATURE . 63
PRECAUTIONS FOR NORMAL CHECK AND MAINTENANCE 64
PRECAUTIONS FOR THE MACHINE NOT TO BE TIPPED OVER AND FOR HYBRID COMPONENTS NOT TO BE DAMAGED . 65
PRECAUTIONS FOR THE MACHINE NOT TO BE SUBMERGED . 66
PRECAUTIONS FOR THE COLD SEASON . 67
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 68
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 69
PRACTICAL USE OF KOMTRAX 70
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 71
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 71
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 72
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 73
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 75
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 79
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 80
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 82
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 83
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 85
HOW TO READ THE CODES (SYMBOLS) FOR ELECTRIC CABLE 86
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 92
STANDARD TIGHTENING TORQUE TABLE 95
CONVERSION TABLE 102
01 SPECIFICATIONS . 107
CONTENTS 108
ABBREVIATION LIST . 109
SPECIFICATIONS 115
SPECIFICATION DRAWING . 115
SPECIFICATION DRAWING: HB365LC-3E0, HB365NLC-3E0 115
WORKING RANGE DRAWINGS 116
WORKING RANGE: HB365LC-3E0, HB365NLC-3E0 116
SPECIFICATIONS 117
SPECIFICATIONS: HB365LC-3E0, HB365NLC-3E0 . 117
WEIGHT TABLE 121
WEIGHT TABLE: HB365LC-3E0, HB365NLC-3E0 . 121
TABLE OF FUEL, COOLANT, AND LUBRICANTS 123
10 STRUCTURE AND FUNCTION . 125
CONTENTS 126
ABBREVIATION LIST . 130
UREA SCR SYSTEM . 136
LAYOUT DRAWING OF UREA SCR SYSTEM . 136
UREA SCR SYSTEM DIAGRAM . 140
FUNCTION OF UREA SCR SYSTEM . 141
FUNCTION OF AdBlue/DEF SYSTEM . 141
INDUCEMENT STRATEGY . 143
COMPONENT PARTS OF UREA SCR SYSTEM 167
AdBlue/DEF MIXING TUBE 167
SCR ASSEMBLY 167
AdBlue/DEF TANK . 170
AdBlue/DEF PUMP . 172
AdBlue/DEF INJECTOR . 173
AdBlue/DEF HOSE . 174
AdBlue/DEF TANK HEATING VALVE . 175
BOOT-UP SYSTEM 176
LAYOUT DRAWING OF BOOT-UP SYSTEM 176
SYSTEM OPERATING LAMP SYSTEM 178
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 178
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 178
BATTERY DISCONNECT SWITCH . 180
FUNCTION OF BATTERY DISCONNECT SWITCH . 180
ENGINE SYSTEM . 181
LAYOUT DRAWING OF ENGINE SYSTEM . 181
FUNCTION OF ENGINE SYSTEM . 182
ENGINE CONTROL SYSTEM . 183
ENGINE CONTROL SYSTEM DIAGRAM . 183
OPERATION OF ENGINE CONTROL SYSTEM 184
AUTO-DECELERATION SYSTEM 186
AUTO-DECELERATION SYSTEM DIAGRAM 186
FUNCTION OF AUTO-DECELERATION SYSTEM 186
OPERATION OF AUTO-DECELERATION SYSTEM . 187
ENGINE AUTOMATIC WARM-UP SYSTEM . 188
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 188
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 189
OVERHEAT PREVENTION SYSTEM 190
OVERHEAT PREVENTION SYSTEM DIAGRAM 190
FUNCTION OF OVERHEAT PREVENTION SYSTEM 191
TURBOCHARGER PROTECTION SYSTEM 193
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 193
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 194
AUTOMATIC IDLE STOP SYSTEM 195
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 195
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 195
COMPONENT PARTS OF ENGINE SYSTEM 199
VGT . 199
EGR SYSTEM 202
EGR VALVE . 204
EGR COOLER 206
KCCV SYSTEM . 207
KCCV VENTILATOR . 209
KDPF 210
COOLING SYSTEM 215
LAYOUT DRAWING OF COOLING SYSTEM 215
SPECIFICATIONS OF COOLING SYSTEM 216
HYBRID SYSTEM . 217
LAYOUT DRAWING OF HYBRID SYSTEM . 217
SYSTEM DIAGRAM OF HYBRID SYSTEM . 218
STRUCTURE OF HYBRID SYSTEM 219
HYBRID PROTECTION SYSTEM 220
SYSTEM DIAGRAM OF HYBRID PROTECTION SYSTEM 220
FUNCTION OF HYBRID PROTECTION SYSTEM 220
COOLING SYSTEM OF HYBRID COMPONENTS . 222
SYSTEM DIAGRAM OF COOLING SYSTEM OF HYBRID COMPONENTS . 222
INTERLOCK SYSTEM OF HYBRID COMPONENTS . 223
SYSTEM DIAGRAM OF INTERLOCK SYSTEM OF HYBRID COMPONENTS . 223
FUNCTION OF INTERLOCK SYSTEM OF HYBRID COMPONENTS . 223
WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID COMPONENTS . 224
SYSTEM DIAGRAM OF WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID COMPONENTS . 224
FUNCTION OF WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID COMPONENTS . 225
COMPONENT PARTS OF HYBRID SYSTEM 226
MOTOR-GENERATOR . 226
ELECTRIC CONTROL UNIT . 227
HIGH VOLTAGE WIRING (POWER CABLE) . 228
HYBRID WATER PUMP . 229
INVERTER (HYBRID CONTROLLER) 230
CONTROL SYSTEM 233
LAYOUT DRAWING OF CONTROL SYSTEM 233
MACHINE MONITOR SYSTEM 236
MACHINE MONITOR SYSTEM DIAGRAM 236
FUNCTION OF MACHINE MONITOR SYSTEM 236
KomVision SYSTEM 237
LAYOUT DRAWING OF KOMVISION SYSTEM 237
KomVision SYSTEM DIAGRAM 239
FUNCTION OF KomVision SYSTEM 239
KOMTRAX SYSTEM 241
KOMTRAX SYSTEM DIAGRAM 241
FUNCTION OF KOMTRAX SYSTEM 241
PPC LEVERS 242
LH PPC LEVER 242
RH PPC LEVER 243
AUTOMATIC GREASE SYSTEM . 244
OUTLINE OF AUTO GREASE SYSTEM . 244
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 258
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 258
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 258
COMPONENT PARTS OF CONTROL SYSTEM . 259
MACHINE MONITOR . 259
KomVision CAMERA 273
GATEWAY FUNCTION CONTROLLER . 274
COMMUNICATION TERMINAL 277
KomVision CONTROLLER 278
PUMP CONTROLLER . 283
RESISTOR FOR PC-EPC VALVE . 287
CAN TERMINATING RESISTOR 287
ENGINE CONTROLLER . 289
FUEL CONTROL DIAL . 295
HYDRAULIC SYSTEM 297
LAYOUT DRAWING OF HYDRAULIC SYSTEM 297
CLSS 300
STRUCTURE OF CLSS . 300
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 302
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 303
PRESSURE COMPENSATION CONTROL . 316
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 320
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 320
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 321
PUMP AND VALVE CONTROL SYSTEM . 326
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 326
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 327
COMPONENT PARTS OF HYDRAULIC SYSTEM . 329
HYDRAULIC TANK 329
MAIN PUMP . 331
CONTROL VALVE . 358
WORK EQUIPMENT SYSTEM . 412
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 412
STRUCTURE OF VALVE CONTROL 418
ONE-TOUCH POWER MAXIMIZING SYSTEM . 419
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 419
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 420
MACHINE PUSH-UP SYSTEM 421
MACHINE PUSH-UP SYSTEM DIAGRAM 421
FUNCTION OF MACHINE PUSH-UP SYSTEM 422
PPC LOCK SYSTEM . 423
PPC LOCK SYSTEM DIAGRAM . 423
FUNCTION OF PPC LOCK SYSTEM . 423
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 424
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 424
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 424
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 425
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 426
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT . 426
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 427
TOOL CONTROL SYSTEM . 428
TOOL CONTROL SYSTEM DIAGRAM . 428
FUNCTION OF TOOL CONTROL SYSTEM . 429
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 430
WORK EQUIPMENT AND SWING PPC VALVE 430
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 435
2ND-LINE ATTACHMENT PPC VALVE . 439
SOLENOID VALVE 441
ANTI-DROP VALVE FOR BOOM 444
ANTI-DROP VALVE FOR ARM . 447
ATTACHMENT CIRCUIT SELECTOR VALVE . 451
ATT EPC VALVE ASSEMBLY 454
PILOT CIRCUIT ACCUMULATOR . 455
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE . 456
2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE . 459
ATTACHMENT BYPASS SOLENOID VALVE 461
SWING SYSTEM 463
LAYOUT DRAWING OF SWING SYSTEM 463
SWING CONTROL SYSTEM DIAGRAM 466
FUNCTION OF SWING CONTROL SYSTEM 467
COMPONENT PARTS OF SWING SYSTEM . 469
ELECTRIC SWING MOTOR 469
SWING MACHINERY WITH SWING PARKING BRAKE 470
SWING CIRCLE 472
TRAVEL SYSTEM . 473
LAYOUT DRAWING OF TRAVEL SYSTEM . 473
TRAVEL CONTROL SYSTEM DIAGRAM . 477
FUNCTION OF TRAVEL CONTROL SYSTEM . 478
COMPONENT PARTS OF TRAVEL SYSTEM 479
TRAVEL MOTOR 479
FINAL DRIVE . 492
TRAVEL PPC VALVE 493
CENTER SWIVEL JOINT . 498
UNDERCARRIAGE AND FRAME . 500
LAYOUT DRAWING OF UNDERCARRIAGE . 500
SPECIFICATIONS OF UNDERCARRIAGE . 500
WORK EQUIPMENT 502
STRUCTURE OF WORK EQUIPMENT . 502
FUNCTION OF WORK EQUIPMENT 503
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 504
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 504
BUCKET CLEARANCE ADJUSTMENT SHIM 505
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 505
CAB AND ITS ATTACHMENTS . 506
ROPS CAB 506
STRUCTURE OF ROPS CAB . 506
FUNCTION OF ROPS CAB 506
CAB MOUNT . 507
STRUCTURE OF CAB MOUNT 507
FUNCTION OF CAB MOUNT . 507
CAB TIPPING STOPPER . 508
STRUCTURE OF CAB TIPPING STOPPER 508
FUNCTION OF CAB TIPPING STOPPER . 508
20 STANDARD VALUE TABLE . 509
CONTENTS 510
ABBREVIATION LIST . 511
STANDARD VALUE TABLE FOR ENGINE . 517
STANDARD VALUE TABLE FOR ENGINE:HB365LC-3E0, HB365NLC-3E0 . 517
STANDARD VALUE TABLE FOR MACHINE 523
STANDARD VALUE TABLE FOR MACHINE: HB365LC-3E0, HB365NLC-3E0 . 523
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 540
30 TESTING AND ADJUSTING 545
CONTENTS 546
ABBREVIATION LIST . 549
RELATED INFORMATION ON TESTING AND ADJUSTING 555
TOOLS FOR TESTING AND ADJUSTING . 555
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 562
ENGINE AND COOLING SYSTEM . 564
TEST ENGINE SPEED . 564
METHOD FOR TESTING ENGINE SPEED . 564
TEST BOOST PRESSURE . 567
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 567
METHOD FOR TESTING BOOST PRESSURE . 568
TEST EXHAUST GAS COLOR 569
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 569
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 570
TEST AND ADJUST VALVE CLEARANCE . 572
METHOD FOR TESTING VALVE CLEARANCE 572
METHOD FOR ADJUSTING VALVE CLEARANCE 574
TEST COMPRESSION PRESSURE . 575
METHOD FOR TESTING COMPRESSION PRESSURE . 575
TEST BLOWBY PRESSURE 578
METHOD FOR TESTING BLOWBY PRESSURE 578
TEST ENGINE OIL PRESSURE 580
METHOD FOR TESTING ENGINE OIL PRESSURE 580
TEST EGR VALVE AND VGT OIL PRESSURE . 582
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 582
TEST FUEL PRESSURE 584
METHOD FOR TESTING FUEL PRESSURE 585
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 592
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 593
BLEED AIR FROM FUEL SYSTEM 600
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 600
TEST FUEL CIRCUIT FOR LEAKAGE . 601
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 601
HANDLE CYLINDER CUT-OUT MODE OPERATION 603
HANDLE NO-INJECTION CRANKING OPERATION 604
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 605
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 605
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 605
TEST COOLING FAN SPEED 607
METHOD FOR TESTING COOLING FAN SPEED 607
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 608
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 608
TEST SCR RELATED FUNCTIONS 609
TEST AdBlue/DEF PUMP RAISED PRESSURE 612
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 615
TEST AdBlue/DEF LINE HEATER RELAY 1 . 619
TEST AdBlue/DEF LINE HEATER RELAY 2 . 621
TEST AdBlue/DEF PUMP HEATER RELAY . 624
TEST AdBlue/DEF TANK HEATER VALVE . 627
TEST DENITRATION EFFICIENCY OF SCR 630
CLEAN AdBlue/DEF TANK . 634
METHOD FOR CLEANING AdBlue/DEF TANK . 634
HYBRID SYSTEM . 639
PRECAUTIONS FOR USING HYBRID SYSTEMS 639
DRAIN, REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT . 640
METHOD FOR DRAINING THE HYBRID SYSTEM COOLANT . 641
REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT 644
WATER PRESSURE TEST OF THE HYBRID SYSTEM COOLANT 646
METHOD FOR TESTING THE WATER PRESSURE OF THE HYBRID SYSTEM COOLANT 646
TEST LUBRICATION CIRCUIT OIL PRESSURE OF HYBRID SYSTEM 648
TEST LUBRICATION CIRCUIT OIL PRESSURE OF ELECTRIC SWING MOTOR CASE 648
TEST LUBRICATION CIRCUIT OIL PRESSURE OF MOTOR-GENERATOR OIL CASE . 648
TEST SWING PARKING BRAKE PRESSURE . 650
METHOD FOR TESTING THE SWING PARKING BRAKE PRESSURE . 650
TEST AND CLEAN DELIVERY FILTER OF SWING MOTOR . 652
METHOD FOR CHECKING AND CLEANING ELECTRIC SWING MOTOR COOLING OIL DELIVERY FILTER . 652
POWER TRAIN . 653
TEST SWING CIRCLE BEARING CLEARANCE . 653
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 653
UNDERCARRIAGE AND FRAME . 654
TEST AND ADJUST TRACK TENSION . 654
METHOD FOR TESTING TRACK TENSION 654
METHOD FOR ADJUSTING TRACK TENSION 654
HYDRAULIC SYSTEM 656
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 656
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK . 656
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT . 656
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT . 661
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUITS 662
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, AND TRAVEL CIRCUITS 663
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,AND TRAVEL CIRCUITS . 668
TEST OIL PRESSURE OF CONTROL CIRCUIT 671
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 671
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 673
METHOD FOR TESTING PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 673
METHOD FOR TESTING PC-EPC VALVE OUTLET PRESSURE . 674
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 675
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 677
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR 677
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE . 678
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 680
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 682
METHOD FOR ADJUSTING LS VALVE . 682
TEST OUTLET PRESSURE OF SOLENOID VALVE 684
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 684
OPERATING CONDITION OF SOLENOID VALVE . 685
TEST PPC VALVE OUTPUT PRESSURE 688
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 688
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 690
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 690
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 691
TEST PUMP SWASH PLATE SENSOR 693
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 693
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 694
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 694
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 694
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 695
TEST OIL LEAKAGE 696
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 696
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 697
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 697
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 698
BLEED AIR FROM HYDRAULIC CIRCUIT 699
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 699
CAB AND ITS ATTACHMENTS . 702
TEST CAB TIPPING STOPPER 702
METHOD FOR TESTING CAB TIPPING STOPPER 702
METHOD FOR ADJUSTING MIRRORS 703
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 703
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 704
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 705
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 706
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 707
ELECTRICAL SYSTEM . 709
SET AND OPERATE MACHINE MONITOR . 709
OPERATOR MODE . 712
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 713
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 713
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 714
CHECKING FUNCTION OF SERVICE METER 714
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 714
SERVICE MODE 717
METHOD FOR OPERATING SERVICE MODE . 717
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 719
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 728
ABNORMALITY RECORD MENU . 741
METHOD FOR CONFIRMING MAINTENANCE RECORD 746
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 747
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 750
DEFAULT MENU 751
DIAGNOSTIC TESTS MENU . 763
ADJUSTMENT MENU . 777
METHOD FOR PERFORMING NO-INJECTION CRANKING . 797
KOMTRAX SETTINGS MENU . 798
METHOD FOR DISPLAYING SERVICE MESSAGE . 800
METHOD FOR STARTING UP KOMTRAX TERMINAL . 802
ADJUST REARVIEW CAMERA ANGLE 807
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE . 807
ADJUST KomVision CAMERA ANGLE . 810
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 811
ADJUST KomVision RELATED ITEMS 815
SETTING OF KomVision (MAIN SETTING) . 815
SETTING OF KomVision (CAMERA SETTING) . 817
SETTING OF KomVision (CAMERA CALIBRATION) . 819
KomVision screen – Check 12 m visibility 832
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 835
HANDLE BATTERY DISCONNECT SWITCH 836
TEST DIODES . 837
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 837
METHOD FOR TESTING DIODE USING ANALOG TESTER 837
Pm CLINIC . 838
Pm CLINIC SERVICE . 838
Pm CLINIC CHECK SHEET:HB365LC-3E0, HB365NLC-3E0 . 839
40 TROUBLESHOOTING 851
CONTENTS 852
ABBREVIATION LIST . 865
RELATED INFORMATION ON TROUBLESHOOTING 871
GENERAL TROUBLESHOOTING POINTS 871
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 872
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 884
PRECAUTIONS FOR USING HYBRID SYSTEMS, TROUBLESHOOTING FOR HIGH-VOLTAGE EQUIPMENT 886
TABLE OF SELF-DEFINE MONITORING ITEMS AND CHECK SHEET FOR HYBRID COMPONENTS . 893
CHECKS BEFORE TROUBLESHOOTING . 899
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 901
WALK-AROUND CHECK . 901
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 903
CHECK FUEL LEVEL AND TYPE . 903
CHECK IMPURE INGREDIENT IN FUEL . 904
CHECK FUEL PREFILTER 904
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 904
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 905
CHECK MAIN FILTER . 908
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 910
CHECK OIL LEVEL IN MOTOR-GENERATOR CASE . 911
CHECK COOLANT LEVEL (RESERVOIR TANK) 912
CHECK CLOGGING OF AIR CLEANER . 913
OUTER ELEMENT – CLEAN . 914
ELEMENTS – REPLACE 916
CHECK HYDRAULIC OIL LEVEL . 918
CHECK HYDRAULIC OIL STRAINER 919
CHECK HYDRAULIC FILTER 920
CHECK CAPACITOR . 921
CHECK OIL LEVEL IN ELECTRIC SWING MOTOR CASE 921
CHECK OIL LEVEL IN SWING MACHINERY CASE . 922
CHECK OIL LEVEL IN FINAL DRIVE CASE . 923
BLEED AIR FROM FUEL SYSTEM 924
BLEED AIR FROM HYDRAULIC SYSTEM . 924
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod 924
AUTOMATIC GREASE SYSTEM . 929
FINDING MALFUNCTIONS 929
MALFUNCTION FINDING PROCEDURES 933
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 935
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 935
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 935
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 936
PREPARATION FOR TROUBLESHOOTING OF GATEWAY TERMINAL . 936
PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER . 936
PREPARATION FOR TROUBLESHOOTING OF INVERTER (HYBRID CONTROLLER) . 937
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 937
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 941
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 944
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 948
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 950
CONNECTOR LIST AND LAYOUT . 953
CONNECTOR CONTACT IDENTIFICATION 967
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE .1007
FUSE LOCATION TABLE (MACHINE WITH KOMTRAX TERMINAL) .1013
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) .1016
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) .1020
FAILURE CODES TABLE .1022
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .1044
FAILURE CODE [879AKA] .1044
FAILURE CODE [879AKB] .1045
FAILURE CODE [879BKA] .1046
FAILURE CODE [879BKB] .1048
FAILURE CODE [879CKA] .1050
FAILURE CODE [879CKB] .1051
FAILURE CODE [879DKZ] .1052
FAILURE CODE [879EMC] .1054
FAILURE CODE [879FMC] .1055
FAILURE CODE [879GKX] .1056
FAILURE CODE [989L00] .1058
FAILURE CODE [989M00] .1059
FAILURE CODE [989N00] .1060
FAILURE CODE [A1U0N3] .1061
FAILURE CODE [A1U0N4] .1063
FAILURE CODE [A900FR] .1065
FAILURE CODE [A900N6] .1066
FAILURE CODE [A900NY] .1067
FAILURE CODE [AA10NX] .1068
FAILURE CODE [AB00KE] .1070
FAILURE CODE [AQ10N3] .1072
FAILURE CODE [AS00N3] .1074
FAILURE CODE [AS00R2] .1076
FAILURE CODE [AS00R3] .1077
FAILURE CODE [AS00R4] .1078
FAILURE CODE [AS00R5] .1079
FAILURE CODE [AS00R6] .1080
FAILURE CODE [AS00ZK] .1081
FAILURE CODE [AS10KM] .1082
FAILURE CODE [AS10NR] .1083
FAILURE CODE [AS10NT] .1084
FAILURE CODE [B@BAZG] .1085
FAILURE CODE [B@BAZK] .1086
FAILURE CODE [B@BCNS] .1088
FAILURE CODE [B@BCQA] .1089
FAILURE CODE [B@BCZK] .1091
FAILURE CODE [B@HANS] .1092
FAILURE CODE [CA115] 1093
FAILURE CODE [CA122] 1094
FAILURE CODE [CA123] 1096
FAILURE CODE [CA131] 1098
FAILURE CODE [CA132] 1100
FAILURE CODE [CA144] 1102
FAILURE CODE [CA145] 1104
FAILURE CODE [CA153] 1106
FAILURE CODE [CA154] 1109
FAILURE CODE [CA187] 1112
FAILURE CODE [CA221] 1114
FAILURE CODE [CA222] 1116
FAILURE CODE [CA227] 1118
FAILURE CODE [CA234] 1119
FAILURE CODE [CA238] 1120
FAILURE CODE [CA239] 1122
FAILURE CODE [CA249] 1124
FAILURE CODE [CA256] 1126
FAILURE CODE [CA271] 1128
FAILURE CODE [CA272] 1130
FAILURE CODE [CA281] 1132
FAILURE CODE [CA322] 1133
FAILURE CODE [CA323] 1135
FAILURE CODE [CA324] 1137
FAILURE CODE [CA325] 1139
FAILURE CODE [CA331] 1141
FAILURE CODE [CA332] 1143
FAILURE CODE [CA343] 1145
FAILURE CODE [CA351] 1146
FAILURE CODE [CA352] 1147
FAILURE CODE [CA356] 1150
FAILURE CODE [CA357] 1152
FAILURE CODE [CA386] 1154
FAILURE CODE [CA428] 1155
FAILURE CODE [CA429] 1157
FAILURE CODE [CA435] 1159
FAILURE CODE [CA441] 1161
FAILURE CODE [CA442] 1163
FAILURE CODE [CA449] 1164
FAILURE CODE [CA451] 1167
FAILURE CODE [CA452] 1170
FAILURE CODE [CA488] 1172
FAILURE CODE [CA515] 1173
FAILURE CODE [CA516] 1175
FAILURE CODE [CA553] 1177
FAILURE CODE [CA555] 1178
FAILURE CODE [CA556] 1179
FAILURE CODE [CA559] 1180
FAILURE CODE [CA595] 1184
FAILURE CODE [CA687] 1185
FAILURE CODE [CA689] 1187
FAILURE CODE [CA691] 1192
FAILURE CODE [CA692] 1194
FAILURE CODE [CA697] 1196
FAILURE CODE [CA698] 1197
FAILURE CODE [CA731] 1198
FAILURE CODE [CA778] 1200
FAILURE CODE [CA1117] .1205
FAILURE CODE [CA1664] .1206
FAILURE CODE [CA1669] .1208
FAILURE CODE [CA1673] .1209
FAILURE CODE [CA1677] .1210
FAILURE CODE [CA1678] .1211
FAILURE CODE [CA1682] .1212
FAILURE CODE [CA1683] .1214
FAILURE CODE [CA1684] .1216
FAILURE CODE [CA1686] .1218
FAILURE CODE [CA1691] .1219
FAILURE CODE [CA1694] .1222
FAILURE CODE [CA1695] .1225
FAILURE CODE [CA1696] .1226
FAILURE CODE [CA1712] .1228
FAILURE CODE [CA1713] .1231
FAILURE CODE [CA1714] .1233
FAILURE CODE [CA1715] .1234
FAILURE CODE [CA1776] .1235
FAILURE CODE [CA1777] .1238
FAILURE CODE [CA1843] .1241
FAILURE CODE [CA1844] .1243
FAILURE CODE [CA1879] .1245
FAILURE CODE [CA1881] .1248
FAILURE CODE [CA1883] .1250
FAILURE CODE [CA1885] .1253
FAILURE CODE [CA1887] .1255
FAILURE CODE [CA1921] .1257
FAILURE CODE [CA1922] .1260
FAILURE CODE [CA1942] .1265
FAILURE CODE [CA1993] .1266
FAILURE CODE [CA2185] .1269
FAILURE CODE [CA2186] .1270
FAILURE CODE [CA2249] .1272
FAILURE CODE [CA2265] .1273
FAILURE CODE [CA2266] .1275
FAILURE CODE [CA2271] .1277
FAILURE CODE [CA2272] .1279
FAILURE CODE [CA2288] .1282
FAILURE CODE [CA2311] .1283
FAILURE CODE [CA2349] .1284
FAILURE CODE [CA2353] .1287
FAILURE CODE [CA2357] .1289
FAILURE CODE [CA2381] .1290
FAILURE CODE [CA2382] .1292
FAILURE CODE [CA2383] .1295
FAILURE CODE [CA2386] .1298
FAILURE CODE [CA2387] .1300
FAILURE CODE [CA2555] .1301
FAILURE CODE [CA2556] .1304
FAILURE CODE [CA2637] .1307
FAILURE CODE [CA2639] .1309
FAILURE CODE [CA2771] .1312
FAILURE CODE [CA2777] .1318
FAILURE CODE [CA2976] .1321
FAILURE CODE [CA3133] .1323
FAILURE CODE [CA3134] .1325
FAILURE CODE [CA3135] .1327
FAILURE CODE [CA3142] .1330
FAILURE CODE [CA3143] .1331
FAILURE CODE [CA3144] .1332
FAILURE CODE [CA3146] .1334
FAILURE CODE [CA3147] .1335
FAILURE CODE [CA3148] .1336
FAILURE CODE [CA3151] .1338
FAILURE CODE [CA3165] .1345
FAILURE CODE [CA3229] .1347
FAILURE CODE [CA3231] .1349
FAILURE CODE [CA3232] .1351
FAILURE CODE [CA3235] .1355
FAILURE CODE [CA3239] .1357
FAILURE CODE [CA3241] .1360
FAILURE CODE [CA3242] .1363
FAILURE CODE [CA3251] .1366
FAILURE CODE [CA3253] .1368
FAILURE CODE [CA3254] .1371
FAILURE CODE [CA3255] .1374
FAILURE CODE [CA3256] .1378
FAILURE CODE [CA3311] .1380
FAILURE CODE [CA3312] .1382
FAILURE CODE [CA3313] .1385
FAILURE CODE [CA3314] .1386
FAILURE CODE [CA3315] .1387
FAILURE CODE [CA3316] .1389
FAILURE CODE [CA3317] .1390
FAILURE CODE [CA3318] .1391
FAILURE CODE [CA3319] .1393
FAILURE CODE [CA3321] .1394
FAILURE CODE [CA3322] .1396
FAILURE CODE [CA3419] .1398
FAILURE CODE [CA3421] .1400
FAILURE CODE [CA3497] .1402
FAILURE CODE [CA3498] .1403
FAILURE CODE [CA3543] .1404
FAILURE CODE [CA3545] .1410
FAILURE CODE [CA3547] .1412
FAILURE CODE [CA3558] .1413
FAILURE CODE [CA3559] .1415
FAILURE CODE [CA3562] .1417
FAILURE CODE [CA3563] .1419
FAILURE CODE [CA3567] .1422
FAILURE CODE [CA3568] .1425
FAILURE CODE [CA3571] .1429
FAILURE CODE [CA3572] .1431
FAILURE CODE [CA3574] .1433
FAILURE CODE [CA3575] .1435
FAILURE CODE [CA3577] .1437
FAILURE CODE [CA3578] .1439
FAILURE CODE [CA3582] .1441
FAILURE CODE [CA3583] .1447
FAILURE CODE [CA3596] .1449
FAILURE CODE [CA3649] .1452
FAILURE CODE [CA3681] .1454
FAILURE CODE [CA3682] .1459
FAILURE CODE [CA3713] .1464
FAILURE CODE [CA3717] .1467
FAILURE CODE [CA3718] .1468
FAILURE CODE [CA3725] .1469
FAILURE CODE [CA3741] .1472
FAILURE CODE [CA3748] .1473
FAILURE CODE [CA3751] .1476
FAILURE CODE [CA3755] .1478
FAILURE CODE [CA3866] .1480
FAILURE CODE [CA3867] .1484
FAILURE CODE [CA3868] .1487
FAILURE CODE [CA3899] .1491
FAILURE CODE [CA3911] .1493
FAILURE CODE [CA3912] .1497
FAILURE CODE [CA3932] .1499
FAILURE CODE [CA3933] .1501
FAILURE CODE [CA3934] .1503
FAILURE CODE [CA3935] .1506
FAILURE CODE [CA3936] .1508
FAILURE CODE [CA4151] .1510
FAILURE CODE [CA4152] .1514
FAILURE CODE [CA4155] .1518
FAILURE CODE [CA4156] .1520
FAILURE CODE [CA4157] .1523
FAILURE CODE [CA4158] .1525
FAILURE CODE [CA4159] .1526
FAILURE CODE [CA4161] .1527
FAILURE CODE [CA4162] .1530
FAILURE CODE [CA4163] .1533
FAILURE CODE [CA4164] .1535
FAILURE CODE [CA4165] .1537
FAILURE CODE [CA4166] .1539
FAILURE CODE [CA4168] .1541
FAILURE CODE [CA4169] .1544
FAILURE CODE [CA4171] .1546
FAILURE CODE [CA4249] .1549
FAILURE CODE [CA4251] .1551
FAILURE CODE [CA4259] .1553
FAILURE CODE [CA4261] .1556
FAILURE CODE [CA4277] .1559
FAILURE CODE [CA4281] .1563
FAILURE CODE [CA4459] .1567
FAILURE CODE [CA4461] .1570
FAILURE CODE [CA4658] .1573
FAILURE CODE [CA4731] .1577
FAILURE CODE [CA4732] .1578
FAILURE CODE [CA4739] .1579
FAILURE CODE [CA4768] .1580
FAILURE CODE [CA4769] .1582
FAILURE CODE [CA4842] .1584
FAILURE CODE [CA4952] .1588
FAILURE CODE [CA5115] .1590
FAILURE CODE [CA5179] .1593
FAILURE CODE [CA5181] .1595
FAILURE CODE [CA5383] .1597
FAILURE CODE [D110KB] .1599
FAILURE CODE [D19JKZ] .1601
FAILURE CODE [D811MC] .1604
FAILURE CODE [D862KA] .1605
FAILURE CODE [D8ALKA] .1607
FAILURE CODE [D8ALKB] .1610
FAILURE CODE [D8AQKR] .1612
FAILURE CODE [D8G1KT] .1619
FAILURE CODE [DA20MC] .1620
FAILURE CODE [DA22KK] .1621
FAILURE CODE [DA25KP] .1624
FAILURE CODE [DA26KP] .1626
FAILURE CODE [DA29KQ] .1629
FAILURE CODE [DA2LKA] .1631
FAILURE CODE [DA2LKB] .1634
FAILURE CODE [DA2QKR] .1636
FAILURE CODE [DA2RKR] .1645
FAILURE CODE [DAF0KM] .1650
FAILURE CODE [DAF0MB] .1651
FAILURE CODE [DAF0MC] .1652
FAILURE CODE [DAF8KB] .1653
FAILURE CODE [DAF9KQ] .1655
FAILURE CODE [DAFGMC] .1656
FAILURE CODE [DAFLKA] .1657
FAILURE CODE [DAFLKB] .1660
FAILURE CODE [DAFQKR] .1662
FAILURE CODE [DAZ9KQ] .1670
FAILURE CODE [DAZQKR] .1671
FAILURE CODE [DB2QKR] .1678
FAILURE CODE [DB2RKR] .1686
FAILURE CODE [DBP0KM] .1691
FAILURE CODE [DBP0KT] .1692
FAILURE CODE [DBPQKR] .1693
FAILURE CODE [DDNRKA] .1701
FAILURE CODE [DDNRKY] .1703
FAILURE CODE [DDNS00] .1705
FAILURE CODE [DFB1KZ] .1707
FAILURE CODE [DFB2KZ] .1709
FAILURE CODE [DFB3L8] .1711
FAILURE CODE [DFB4L8] .1713
FAILURE CODE [DFB5KZ] .1715
FAILURE CODE [DFB6KZ] .1717
FAILURE CODE [DGH2KA] .1719
FAILURE CODE [DGH2KB] .1721
FAILURE CODE [DHA4KA] .1723
FAILURE CODE [DHAAMA] .1725
FAILURE CODE [DHACMA] .1727
FAILURE CODE [DHPAMA] .1729
FAILURE CODE [DHPBMA] .1731
FAILURE CODE [DHS3MA] .1733
FAILURE CODE [DHS4MA] .1735
FAILURE CODE [DHS8MA] .1737
FAILURE CODE [DHS9MA] .1739
FAILURE CODE [DHSAKZ] .1741
FAILURE CODE [DHSBKZ] .1743
FAILURE CODE [DHSCMA] .1745
FAILURE CODE [DHSDMA] .1747
FAILURE CODE [DHSFMA] .1749
FAILURE CODE [DHSGMA] .1751
FAILURE CODE [DHSHMA] .1753
FAILURE CODE [DHSJMA] .1755
FAILURE CODE [DHVAKZ] .1757
FAILURE CODE [DHVAL8] .1759
FAILURE CODE [DHVAMA] .1761
FAILURE CODE [DHVBKZ] .1762
FAILURE CODE [DHVBL8] .1764
FAILURE CODE [DHVBMA] .1766
FAILURE CODE [DHZAMA] .1767
FAILURE CODE [DHZCL8] .1771
FAILURE CODE [DKR0MA] .1772
FAILURE CODE [DKR1MA] .1774
FAILURE CODE [DKULKA] .1776
FAILURE CODE [DKULKB] .1778
FAILURE CODE [DKULKY] .1780
FAILURE CODE [DLM5KA] .1781
FAILURE CODE [DLM5MB] .1783
FAILURE CODE [DR10KA] .1785
FAILURE CODE [DR21KX] .1788
FAILURE CODE [DUMBKA] .1790
FAILURE CODE [DUMBKB] .1793
FAILURE CODE [DV00KA] .1795
FAILURE CODE [DV00KB] .1796
FAILURE CODE [DV20KB] .1797
FAILURE CODE [DW43KA] .1799
FAILURE CODE [DW43KB] .1801
FAILURE CODE [DW43KY] .1802
FAILURE CODE [DW45KA] .1803
FAILURE CODE [DW45KB] .1806
FAILURE CODE [DW45KK] .1809
FAILURE CODE [DW45KY] .1811
FAILURE CODE [DW4CKY] .1813
FAILURE CODE [DW91KA] .1814
FAILURE CODE [DW91KB] .1816
FAILURE CODE [DW91KY] .1817
FAILURE CODE [DWA2KA] .1818
FAILURE CODE [DWA2KB] .1820
FAILURE CODE [DWA2KY] .1821
FAILURE CODE [DWK0KA] .1822
FAILURE CODE [DWK0KB] .1824
FAILURE CODE [DWK0KY] .1826
FAILURE CODE [DWK2KA] .1827
FAILURE CODE [DWK2KB] .1829
FAILURE CODE [DWK2KY] .1831
FAILURE CODE [DWN5KA] .1832
FAILURE CODE [DWN5KB] .1835
FAILURE CODE [DWN5KY] .1837
FAILURE CODE [DWPUKA] .1838
FAILURE CODE [DWPUKB] .1840
FAILURE CODE [DWPUKY] .1842
FAILURE CODE [DXA8KA] .1844
FAILURE CODE [DXA8KB] .1847
FAILURE CODE [DXA9KA] .1849
FAILURE CODE [DXA9KB] .1852
FAILURE CODE [DXE0KA] .1854
FAILURE CODE [DXE0KB] .1856
FAILURE CODE [DXE4KA] .1857
FAILURE CODE [DXE4KB] .1859
FAILURE CODE [DXE4KY] .1860
FAILURE CODE [DXE5KA] .1861
FAILURE CODE [DXE5KB] .1863
FAILURE CODE [DXE6KA] .1865
FAILURE CODE [DXE6KB] .1867
FAILURE CODE [DXE7KA] .1869
FAILURE CODE [DXE7KB] .1871
FAILURE CODE [DXE7KY] .1873
FAILURE CODE [DXE8KA] .1875
FAILURE CODE [DXE8KB] .1877
FAILURE CODE [DXE8KY] .1879
FAILURE CODE [DXE9KA] .1881
FAILURE CODE [DXE9KB] .1883
FAILURE CODE [DXE9KY] .1885
FAILURE CODE [DXEAKA] .1887
FAILURE CODE [DXEAKB] .1889
FAILURE CODE [DXEAKY] .1891
FAILURE CODE [DXEKKA] .1893
FAILURE CODE [DXEKKB] .1895
FAILURE CODE [DXEKKY] .1897
FAILURE CODE [DXELKA] .1899
FAILURE CODE [DXELKB] .1901
FAILURE CODE [DXELKY] .1903
FAILURE CODE [DY20KA] .1905
FAILURE CODE [DY20MA] .1907
FAILURE CODE [DY2CKB] .1909
FAILURE CODE [DY2DKB] .1911
FAILURE CODE [DY2EKB] .1913
FAILURE CODE [F313KA] .1915
FAILURE CODE [F313KB] .1917
FAILURE CODE [F318KB] .1920
FAILURE CODE [F318KY] .1923
FAILURE CODE [GA00NS] .1925
FAILURE CODE [GA01KA] .1926
FAILURE CODE [GA02KZ] .1928
FAILURE CODE [GA04KG] .1931
FAILURE CODE [GA05KG] .1934
FAILURE CODE [GA05KP] .1937
FAILURE CODE [GA06KZ] .1940
FAILURE CODE [GA08KG] .1941
FAILURE CODE [GA09KG] .1949
FAILURE CODE [GA09KP] .1957
FAILURE CODE [GA0AKZ] .1958
FAILURE CODE [GA0BKZ] .1959
FAILURE CODE [GA10MA] .1966
FAILURE CODE [GA10MC] .1973
FAILURE CODE [GA12NK] .1974
FAILURE CODE [GA13KP] .1980
FAILURE CODE [GA13KY] .1982
FAILURE CODE [GA15KZ] .1984
FAILURE CODE [GA17KR] .1992
FAILURE CODE [GA17MB] .1993
FAILURE CODE [GA18MC] .1994
FAILURE CODE [GA19KR] .1999
FAILURE CODE [GA19KT] .2000
FAILURE CODE [GA1BMA] .2001
FAILURE CODE [GA1FKR] .2003
FAILURE CODE [GA1FMA] .2004
FAILURE CODE [GA1GKR] .2007
FAILURE CODE [GA1GKT] .2008
FAILURE CODE [GA1GMB] .2009
FAILURE CODE [GA1HKZ] .2010
FAILURE CODE [GA1JKZ] .2011
FAILURE CODE [GA1KKZ] .2012
FAILURE CODE [GA1LKZ] .2013
FAILURE CODE [GA1MKZ] .2014
FAILURE CODE [GA1NNS] .2015
FAILURE CODE [GA1SFS] .2016
FAILURE CODE [GA1SMC] .2017
FAILURE CODE [GA1TKP] .2018
FAILURE CODE [GA1TNS] .2021
FAILURE CODE [GA1UKZ] .2024
FAILURE CODE [GA1VFS] .2027
FAILURE CODE [GA1VMC] .2028
FAILURE CODE [GA1XKZ] .2029
FAILURE CODE [GA1YNS] .2030
FAILURE CODE [GA1ZKZ] .2031
FAILURE CODE [GA1ZNS] .2032
FAILURE CODE [GA22NS] .2033
FAILURE CODE [GA23KZ] .2034
FAILURE CODE [GA24KZ] .2035
FAILURE CODE [GA25MA] .2036
FAILURE CODE [GA25NS] .2041
FAILURE CODE [GA26MA] .2042
FAILURE CODE [GA26NS] .2047
FAILURE CODE [GA27KZ] .2048
FAILURE CODE [GA2QKR] .2049
FAILURE CODE [GA2RKR] .2054
FAILURE CODE [GA60MC] .2059
FAILURE CODE [GA60N1] .2061
FAILURE CODE [GA61KZ] .2063
FAILURE CODE [GA61NS] .2065
FAILURE CODE [GA62KY] .2066
FAILURE CODE [GA62KZ] .2071
FAILURE CODE [GA62MA] .2075
FAILURE CODE [GA63KY] .2076
FAILURE CODE [GA63KZ] .2081
FAILURE CODE [GA63MA] .2085
FAILURE CODE [GA64KY] .2086
FAILURE CODE [GA64KZ] .2091
FAILURE CODE [GA64MA] .2095
FAILURE CODE [GA70KB] .2096
FAILURE CODE [GA70MD] .2099
FAILURE CODE [GA70NS] .2101
FAILURE CODE [GA71KZ] .2102
FAILURE CODE [GA72MA] .2104
FAILURE CODE [GA72MC] .2106
FAILURE CODE [GA81KZ] .2108
FAILURE CODE [GAA0KB] .2111
FAILURE CODE [GAA2KB] .2113
FAILURE CODE [GAA6KP] .2115
FAILURE CODE [GAA6KY] .2117
FAILURE CODE [GACA00] .2119
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .2120
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .2120
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 2126
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .2129
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .2131
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .2133
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 2136
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 2137
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .2138
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 2139
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .2140
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2141
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2142
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2143
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2144
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2145
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2146
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .2147
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .2149
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .2150
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 2151
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2152
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .2154
E-23 MONITOR TEMPERATURE GAUGE OF HYBRID SYSTEMS DOES NOT INDICATE CORRECT TEMPERATURE 2155
E-24 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .2156
E-25 FUNCTION SWITCH DOES NOT OPERATE .2157
E-26 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .2158
E-27 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 2159
E-28 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 2160
E-29 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .2161
E-30 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 2162
E-31 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .2163
E-32 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 2164
E-33 ALARM BUZZER CANNOT BE CANCELED 2165
E-34 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .2166
E-35 SERVICE MODE CANNOT BE SELECTED 2167
E-36 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 2168
E-37 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .2170
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .2171
E-39 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .2174
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .2176
E-41 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .2178
E-42 ALARM DOES NOT SOUND DURING TRAVEL .2179
E-43 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 2181
E-44 HORN DOES NOT SOUND 2182
E-45 HORN DOES NOT STOP SOUNDING 2185
E-46 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .2187
E-47 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .2188
E-48 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 2190
E-49 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2191
E-50 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2192
E-51 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .2193
E-52 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2194
E-53 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .2195
E-54 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .2196
E-55 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .2197
E-56 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2198
E-57 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .2199
E-58 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .2201
E-59 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .2202
E-60 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED 2203
E-61 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 2205
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .2206
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .2206
FAILURE MODE AND CAUSE TABLE 2207
H-1 ALL WORK EQUIPMENTS OR TRAVEL DOES NOT OPERATE 2218
H-2 ALL WORK EQUIPMENT AND TRAVEL SPEED OR POWER IS LOW .2219
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 2221
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .2222
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2223
H-6 SPEED OR POWER OF BOOM IS LOW .2225
H-7 ARM SPEED OR POWER IS LOW .2231
H-8 BUCKET SPEED OR POWER IS LOW 2236
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 2240
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .2241
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 2243
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .2245
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .2246
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 2247
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .2248
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 2249
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED .2250
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .2251
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 2252
H-20 MACHINE DOES NOT TRAVEL STRAIGHT .2253
H-21 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .2255
H-22 TRAVEL SPEED IS LOW 2258
H-23 ONE OF TRACKS DOES NOT RUN .2260
H-24 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2262
H-25 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .2263
H-26 UNUSUAL NOISE IS HEARD FROM AROUND FAN .2264
H-27 Quick coupler cylinder will not extend .2265
H-28 Quick coupler cylinder will not retract (but buzzer doesnot sound) .2267
H-29 Buzzer does not sound (but quick coupler cylinder doesretract) .2269
H-30 Quick coupler cylinder extends and retracts slowly .2271
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .2272
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2273
TROUBLESHOOTING OF ENGINE (S-MODE) 2274
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .2274
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2275
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2276
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2277
S-4 ENGINE STARTABILITY IS POOR .2279
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2281
S-6 ENGINE STOPS DURING OPERATION .2283
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2285
S-8 ENGINE LACKS POWER 2286
S-9 KDPF GETS CLOGGED IN A SHORT TIME .2288
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2290
S-11 OIL BECOMES CONTAMINATED QUICKLY .2291
S-12 FUEL CONSUMPTION IS EXCESSIVE 2292
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2293
S-14 OIL PRESSURE DROPS .2294
S-15 FUEL MIXES INTO ENGINE OIL .2296
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2297
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2298
S-18 UNUSUAL NOISE IS HEARD .2299
S-19 VIBRATION IS EXCESSIVE .2300
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .2301
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2302
S-22 ACTIVE REGENERATION TAKES TIME .2304
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2305
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2306
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2308
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2309
TROUBLESHOOTING FOR HYBRID SYSTEMS (Y MODE) .2310
PRECAUTIONS FOR USING HYBRID SYSTEMS 2310
Y-1 HYBRID MONITOR DOES NOT GO OUT 2311
Y-2 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT .2313
Y-3 UPPER STRUCTURE SWINGS ONLY TO THE RIGHT OR LEFT 2314
Y-4 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 2315
Y-5 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS LOW IN ONLY ONE DIRECTION 2316
Y-6 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) .2317
Y-7 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (EITHER RIGHT OR LEFT) 2318
Y-8 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 2319
Y-9 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 2320
Y-10 SWING DRIFT ON A SLOPE IS LARGE (WHILE PARKING BRAKE IS APPLIED) .2321
Y-11 SWING DRIFT ON A SLOPE IS LARGE (WHILE PARKING BRAKE IS RELEASED) 2322
Y-12 ELECTRIC SWING MOTOR TEMPERATURE INCREASES ABNORMALLY 2323
Y-13 MOTOR-GENERATOR TEMPERATURE INCREASES ABNORMALLY .2326
Y-14 INVERTER TEMPERATURE INCREASES ABNORMALLY 2328
Y-15 CAPACITOR TEMPERATURE INCREASES ABNORMALLY .2330
50 DISASSEMBLY AND ASSEMBLY .2333
CONTENTS 2334
ABBREVIATION LIST .2339
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2345
HOW TO READ THIS MANUAL .2345
COATING MATERIALS LIST 2347
SPECIAL TOOLS LIST 2352
SKETCHES OF SPECIAL TOOLS .2371
ENGINE AND COOLING SYSTEM .2379
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2379
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2379
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2383
REMOVE AND INSTALL INJECTOR ASSEMBLY 2391
METHOD FOR REMOVING INJECTOR ASSEMBLY .2391
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2397
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2409
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2409
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2418
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2435
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2435
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2436
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2438
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2438
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2439
REMOVE AND INSTALL STARTER ASSEMBLY .2441
METHOD FOR REMOVING STARTER ASSEMBLY 2441
METHOD FOR INSTALLING STARTER ASSEMBLY 2442
REMOVE AND INSTALL ALTERNATOR BELT 2443
METHOD FOR REMOVING ALTERNATOR BELT .2443
METHOD FOR INSTALLING ALTERNATOR BELT .2446
REMOVE AND INSTALL RADIATOR ASSEMBLY 2449
METHOD FOR REMOVING RADIATOR ASSEMBLY .2449
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2452
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2455
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2455
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2459
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2462
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2462
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2464
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 2466
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY .2466
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY .2470
REMOVE AND INSTALL FAN 2473
METHOD FOR INSTALLING FAN .2473
METHOD FOR REMOVING FAN .2473
REMOVE AND INSTALL ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY 2474
METHOD FOR REMOVING ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY .2475
METHOD FOR INSTALLING ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY .2484
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2496
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2496
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2498
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2500
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2500
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2501
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2509
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2509
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2511
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2514
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2514
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2517
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2520
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2520
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2526
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2531
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2531
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2538
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2542
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2542
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2542
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2549
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2549
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2549
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2550
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2550
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2552
REMOVE AND INSTALL KDPF ASSEMBLY 2555
METHOD FOR REMOVING KDPF ASSEMBLY .2555
METHOD FOR INSTALLING KDPF ASSEMBLY .2558
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2561
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2562
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2565
REMOVE AND INSTALL SCR ASSEMBLY .2570
METHOD FOR REMOVING SCR ASSEMBLY 2570
METHOD FOR INSTALLING SCR ASSEMBLY 2573
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2576
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2577
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2583
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2588
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2588
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2591
REMOVE AND INSTALL KCCV ASSEMBLY 2595
METHOD FOR REMOVING KCCV ASSEMBLY .2595
METHOD FOR INSTALLING KCCV ASSEMBLY .2596
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2598
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2599
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2602
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2606
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2606
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2609
REMOVE AND INSTALL AdBlue/DEF PUMP 2613
METHOD FOR REMOVING AdBlue/DEF PUMP .2613
METHOD FOR INSTALLING AdBlue/DEF PUMP .2616
REMOVE AND INSTALL AdBlue/DEF HOSE 2619
METHOD FOR REMOVING AdBlue/DEF HOSE .2620
METHOD FOR INSTALLING AdBlue/DEF HOSE .2626
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2634
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2634
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2636
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2639
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2639
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2640
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2642
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2642
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2643
HYBRID SYSTEM .2646
REMOVE AND INSTALL HYBRID RADIATOR ASSEMBLY .2646
METHOD FOR REMOVING HYBRID RADIATOR ASSEMBLY 2646
METHOD FOR INSTALLING HYBRID RADIATOR ASSEMBLY 2648
REMOVE AND INSTALL HYBRID WATER PUMP ASSEMBLY .2650
METHOD FOR REMOVING HYBRID WATER PUMP ASSEMBLY 2650
METHOD FOR INSTALLING HYBRID WATER PUMP ASSEMBLY 2652
REMOVE AND INSTALL INVERTER ASSEMBLY 2655
METHOD FOR REMOVING INVERTER ASSEMBLY .2655
METHOD FOR INSTALLING INVERTER ASSEMBLY .2659
REMOVE AND INSTALL INVERTER AND CAPACITOR ASSEMBLY 2664
METHOD FOR REMOVING INVERTER AND CAPACITOR ASSEMBLY .2664
METHOD FOR INSTALLING INVERTER AND CAPACITOR ASSEMBLY .2669
REMOVE AND INSTALL MOTOR-GENERATOR AND HOUSING ASSEMBLY .2674
METHOD FOR REMOVING MOTOR-GENERATOR AND HOUSING ASSEMBLY 2674
METHOD FOR INSTALLING MOTOR-GENERATOR AND HOUSING ASSEMBLY 2678
REMOVE AND INSTALL ELECTRIC SWING MOTOR .2684
METHOD FOR REMOVING ELECTRIC SWING MOTOR 2684
METHOD FOR INSTALLING ELECTRIC SWING MOTOR 2688
POWER TRAIN .2694
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2694
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2694
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2695
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2697
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2698
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2702
REMOVE AND INSTALL ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY 2710
METHOD FOR REMOVING ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY .2710
METHOD FOR INSTALLING ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY .2714
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2719
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2719
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2726
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2739
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2739
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2739
UNDERCARRIAGE AND FRAME .2741
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2741
METHOD FOR SEPARATING TRACK ASSEMBLY 2741
METHOD FOR INSTALLING TRACK ASSEMBLY 2743
REMOVE AND INSTALL SPROCKET .2746
METHOD FOR REMOVING SPROCKET 2746
METHOD FOR INSTALLING SPROCKET 2747
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2748
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2748
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2749
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2750
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2750
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2751
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2755
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2756
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2756
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2758
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2759
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2760
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2762
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2762
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2764
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2767
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2767
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2769
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2772
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2772
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2773
HYDRAULIC SYSTEM 2776
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2776
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2776
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2778
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2781
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2782
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2783
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2784
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2784
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2787
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2791
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2791
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2794
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2797
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2797
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2804
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2811
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2811
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2813
REMOVE AND INSTALL ATT BYPASS SOLENOID 2818
REMOVE ATT BYPASS SOLENOID 2818
INSTALL ATT BYPASS SOLENOID .2821
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2823
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2823
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2824
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2826
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2826
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2827
REMOVE AND INSTALL QUICK COUPLER VALVE 2829
WORK EQUIPMENT 2831
REMOVE AND INSTALL BUCKET ASSEMBLY 2831
METHOD FOR REMOVING BUCKET ASSEMBLY .2831
METHOD FOR INSTALLING BUCKET ASSEMBLY .2831
REMOVE AND INSTALL ARM ASSEMBLY .2833
METHOD FOR REMOVING ARM ASSEMBLY 2833
METHOD FOR INSTALLING ARM ASSEMBLY 2834
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2836
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2836
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2838
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2841
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2841
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2844
CAB AND ITS ATTACHMENTS .2851
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2851
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY .2851
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY .2858
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2866
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2868
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2868
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2878
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2878
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2881
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2887
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2887
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2892
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2897
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2897
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2902
REMOVE AND INSTALL OPERATOR’S SEAT 2908
METHOD FOR REMOVING OPERATOR’S SEAT .2908
METHOD FOR INSTALLING OPERATOR’S SEAT .2910
REMOVE AND INSTALL SEAT BELT 2913
METHOD FOR REMOVING SEAT BELT .2913
METHOD FOR INSTALLING SEAT BELT .2913
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2915
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2915
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2920
ELECTRICAL SYSTEM .2929
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2929
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2929
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2931
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2935
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2935
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2938
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2941
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2941
METHOD FOR INSTALLING KomVision CONTROLLER 2942
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2943
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2943
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2945
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2949
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2949
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2949
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2951
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2951
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2952
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2954
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2954
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2954
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2956
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2956
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2957
REMOVE AND INSTALL KomVision CAMERA .2959
METHOD FOR REMOVING KomVision CAMERA 2959
METHOD FOR INSTALLING KomVision CAMERA 2960
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY .2962
METHOD FOR REMOVING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2962
METHOD FOR INSTALLING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2967
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 2972
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS .2972
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS .2980
REMOVE AND INSTALL COMMUNICATION TERMINAL .2989
METHOD FOR REMOVING COMMUNICATION TERMINAL 2989
METHOD FOR INSTALLING COMMUNICATION TERMINAL 2991
60 MAINTENANCE STANDARD .2995
CONTENTS 2996
ABBREVIATION LIST .2997
ENGINE AND COOLING SYSTEM .3003
MAINTENANCE STANDARD OF ENGINE MOUNT 3003
MAINTENANCE STANDARD OF COOLING SYSTEM 3005
POWER TRAIN .3007
MAINTENANCE STANDARD OF SWING CIRCLE 3007
MAINTENANCE STANDARD OF SWING MACHINERY WITH SWING PARKING BRAKE 3008
MAINTENANCE STANDARD OF FINAL DRIVE .3010
MAINTENANCE STANDARD OF SPROCKET 3012
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .3013
UNDERCARRIAGE AND FRAME .3015
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .3015
MAINTENANCE STANDARD OF IDLER .3017
MAINTENANCE STANDARD OF TRACK ROLLER 3019
MAINTENANCE STANDARD OF CARRIER ROLLER 3021
MAINTENANCE STANDARD OF TRACK SHOE 3022
MAINTENANCE STANDARD OF TRIPLE SHOE .3025
HYDRAULIC SYSTEM 3026
MAINTENANCE STANDARD OF HYDRAULIC TANK 3026
MAINTENANCE STANDARD OF MAIN PUMP .3027
MAINTENANCE STANDARD OF MAIN PUMP LS-EPC VALVE 3029
MAINTENANCE STANDARD OF MAIN PUMP PC-EPC VALVE 3030
MAINTENANCE STANDARD OF TRAVEL MOTOR 3031
MAINTENANCE STANDARD OF CONTROL VALVE .3034
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 3046
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM .3048
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 3050
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 3053
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 3056
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 3058
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE .3059
MAINTENANCE STANDARD OF SOLENOID VALVE 3061
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE .3062
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .3063
WORK EQUIPMENT 3064
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 3064
DIMENSION OF ARM 3069
DIMENSIONS OF BUCKET 3071
MAINTENANCE STANDARD OF BOOM CYLINDER .3073
MAINTENANCE STANDARD OF ARM CYLINDER 3074
MAINTENANCE STANDARD OF BUCKET CYLINDER .3075
80 APPENDIX .3077
CONTENTS 3078
ABBREVIATION LIST .3080
AIR CONDITIONER SYSTEM 3086
PRECAUTIONS FOR REFRIGERANT .3086
AIR CONDITIONER COMPONENT .3087
SPECIFICATIONS OF AIR CONDITIONER .3089
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .3090
OUTLINE OF REFRIGERATION CYCLE 3091
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .3093
AIR CONDITIONER UNIT 3093
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .3093
FUNCTION OF AIR CONDITIONER UNIT 3095
COMPONENT PARTS OF AIR CONDITIONER UNIT .3097
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3098
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .3098
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .3098
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .3098
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3099
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .3099
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .3099
FUNCTION OF DUAL PRESSURE SWITCH 3100
AIR CONDITIONER CONTROLLER 3101
STRUCTURE OF AIR CONDITIONER CONTROLLER .3101
COMPRESSOR 3102
STRUCTURE OF COMPRESSOR .3102
SPECIFICATIONS OF COMPRESSOR 3102
FUNCTION OF COMPRESSOR 3102
CONDENSER .3103
STRUCTURE OF CONDENSER 3103
SPECIFICATIONS OF CONDENSER .3103
FUNCTION OF CONDENSER .3103
RECEIVER DRIER 3104
STRUCTURE OF RECEIVER DRIER .3104
SPECIFICATIONS OF RECEIVER DRIER 3104
FUNCTION OF RECEIVER DRIER 3104
SENSORS FOR AIR CONDITIONER SYSTEM 3105
STRUCTURE OF SUNLIGHT SENSOR 3105
FUNCTION OF SUNLIGHT SENSOR .3105
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .3105
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3105
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .3107
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .3109
AIR CONDITIONER SYSTEM DIAGRAM 3111
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3112
FUNCTION OF AIR CONDITIONER CONTROLLER 3113
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .3114
TESTING AIR LEAKAGE (DUCT) 3118
METHOD FOR TESTING AIR LEAKAGE (DUCT) .3118
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .3120
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3121
TEST VENT (MODE) CHANGEOVER .3122
METHOD FOR TESTING VENT (MODE) CHANGEOVER .3122
TESTING FRESH/RECIRC AIR CHANGEOVER .3124
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3124
TEST SUNLIGHT SENSOR 3125
METHOD FOR TESTING SUNLIGHT SENSOR 3125
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .3126
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .3126
TEST RELAYS .3127
METHOD FOR TESTING RELAYS .3127
AIR CONDITIONER TROUBLESHOOTING CHART 1 .3128
AIR CONDITIONER TROUBLESHOOTING CHART 2 .3129
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3132
FAILURE CODE [879AKA] .3134
FAILURE CODE [879AKB] .3135
FAILURE CODE [879BKA] .3136
FAILURE CODE [879BKB] .3138
FAILURE CODE [879CKA] .3140
FAILURE CODE [879CKB] .3141
FAILURE CODE [879DKZ] .3142
FAILURE CODE [879EMC] .3144
FAILURE CODE [879FMC] .3145
FAILURE CODE [879GKX] .3146
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3148
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .3150
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3153
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .3155
TROUBLESHOOTING USING GAUGE PRESSURE 3157
CONNECTION OF SERVICE TOOL 3160
METHOD FOR CONNECTING SERVICE TOOL 3160
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .3162
HANDLE COMPRESSOR OIL .3164
90 CIRCUIT DIAGRAMS .3167
CONTENTS 3168
ABBREVIATION LIST .3169
HYDRAULIC CIRCUIT DIAGRAM .3175
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .3175
HYDRAULIC CIRCUIT DIAGRAM (1/3) .3179
HYDRAULIC CIRCUIT DIAGRAM (2/3) .3181
HYDRAULIC CIRCUIT DIAGRAM (3/3) .3183
ELECTRICAL CIRCUIT DIAGRAM 3185
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3185
ELECTRICAL CIRCUIT DIAGRAM 3189
ELECTRICAL CIRCUIT DIAGRAM (1/13) .3191
ELECTRICAL CIRCUIT DIAGRAM (2/13) .3193
ELECTRICAL CIRCUIT DIAGRAM (3/13) .3195
ELECTRICAL CIRCUIT DIAGRAM (4/13) .3197
ELECTRICAL CIRCUIT DIAGRAM (5/13) .3199
ELECTRICAL CIRCUIT DIAGRAM (6/13) .3201
ELECTRICAL CIRCUIT DIAGRAM (7/13) .3203
ELECTRICAL CIRCUIT DIAGRAM (8/13) .3205
ELECTRICAL CIRCUIT DIAGRAM (9/13) .3207
ELECTRICAL CIRCUIT DIAGRAM (10/13) 3209
ELECTRICAL CIRCUIT DIAGRAM (11/13) 3211
ELECTRICAL CIRCUIT DIAGRAM (12/13) 3213
ELECTRICAL CIRCUIT DIAGRAM (13/13) 3215
INDEX 3217

DESCRIPTION:

Komatsu HB365LC-3E0,HB365NLC-3E0 Hydraulic Excavator Shop Manual UENBM00642  – PDF DOWNLOAD

SERIAL NUMBERS

• HB365LC-3E0 K75222 and up
• HB365NLC-3E0 K75222 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