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KOMATSU HB215LC-3 HYBRID HYDRAULIC EXCAVATOR SHOP MANUAL SEN06629-16 – PDF DOWNLOAD
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KOMATSU HB215LC-3 HYBRID HYDRAULIC EXCAVATOR SHOP MANUAL SEN06629-16 – PDF DOWNLOAD
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KOMATSU HB215LC-3 HYBRID HYDRAULIC EXCAVATOR SHOP MANUAL SEN06629-16 – PDF DOWNLOAD
Language : English
Pages : 3370
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU HB215LC-3 HYBRID HYDRAULIC EXCAVATOR SHOP MANUAL SEN06629-16 – PDF DOWNLOAD
Cover....................................................................................................................................... 1 00 Index and Foreword.................................................................................................................. 3 Index.............................................................................................................................. 4 Abbreviation List.................................................................................................................. 24 Foreword, Safety, Basic Information................................................................................................ 27 How to Read the Shop Manual.................................................................................................... 27 Safety Notice for Operation.................................................................................................... 29 Precautions Particularly for Hybrid Machines................................................................................... 37 Precautions to Prevent Fire.................................................................................................... 38 Procedures If Fire Occurs...................................................................................................... 40 Precautions for Disposing of Waste Materials................................................................................... 41 Procedures for Exhaust Gas Regulations......................................................................................... 42 Precautions for DEF............................................................................................................ 43 General Character and Precautions for Handling............................................................................. 43 Precautions for Adding..................................................................................................... 43 Precautions for Storage.................................................................................................... 43 Precautions for Fire Hazard and Leakage.................................................................................... 43 Other Precautions.......................................................................................................... 43 Store DEF...................................................................................................................... 44 Precautions When You Handle Hydraulic Equipment................................................................................ 45 Precautions When You Disconnect and Connect Pipings............................................................................ 48 Precautions When You Handle Electrical Equipment............................................................................... 55 Precautions for Maintenance of Hybrid System................................................................................... 57 Precautions Against High Voltage and High Temperature.......................................................................... 58 Precautions for Normal Check and Maintenance................................................................................... 59 Precautions for the Machine Not to be Tipped over and for Hybrid Components Not to be Damaged.................................. 60 Precautions for Machine Not to be Put in Water................................................................................. 61 In Cold Weather................................................................................................................ 62 Precautions When You Handle Fuel System Equipment.............................................................................. 63 Precautions When You Handle Intake System Equipment............................................................................ 64 Practical Use of KOMTRAX....................................................................................................... 65 Disconnect and Connect Push-Pull Type Coupler.................................................................................. 66 How to Disconnect and Connect Type 1 Push-Pull Type Coupler................................................................ 66 How to Disconnect and Connect Type 2 Push-Pull Type Coupler................................................................ 67 How to Disconnect and Connect Type 3 Push-Pull Type Coupler................................................................ 68 Precautions for Disconnection and Connection of Connectors..................................................................... 70 How to Disconnect and Connect Deutsch Connector................................................................................ 74 How to Disconnect and Connect Slide Lock Type Connector........................................................................ 75 How to Disconnect and Connect Connector with Lock to Pull...................................................................... 77 How to Disconnect and Connect Connector with Lock to Push...................................................................... 78 How to Disconnect and Connect Connector with Housing to Rotate................................................................. 80 How to Read the Codes for Electric Cable....................................................................................... 81 Explanation of Terms for Maintenance Standard.................................................................................. 85 Standard Tightening Torque Table............................................................................................... 88 Conversion Table............................................................................................................... 95 01 Specifications...................................................................................................................... 101 Table of Contents.................................................................................................................. 102 Specifications..................................................................................................................... 103 Specification Drawing.......................................................................................................... 103 Specification Drawing: HB215LC-3........................................................................................... 103 Working Range Drawings......................................................................................................... 105 Working Range Drawings: HB215LC-3.......................................................................................... 105 Specifications................................................................................................................. 106 Specification: HB215LC-3................................................................................................... 106 Weight Table................................................................................................................... 110 Weight Table: HB215LC-3.................................................................................................... 110 Fuel, Coolant, Lubricants (For North America).................................................................................. 112 How to Use Fuel, Coolant and Lubricants by Ambient Temperature............................................................. 112 10 Structure and Function.............................................................................................................. 115 Table of Contents.................................................................................................................. 116 Urea SCR System.................................................................................................................... 120 Layout Drawing of Urea SCR System.............................................................................................. 120 Urea SCR System Diagram........................................................................................................ 125 Function of Urea SCR System.................................................................................................... 126 Function of DEF System..................................................................................................... 126 Inducement Strategy........................................................................................................ 128 Component Parts of Urea SCR System............................................................................................. 137 DEF Mixing Tube............................................................................................................ 137 SCR Assembly............................................................................................................... 138 DEF Tank................................................................................................................... 140 DEF Pump................................................................................................................... 142 DEF Injector............................................................................................................... 143 DEF Hose................................................................................................................... 144 DEF Tank Heating Valve..................................................................................................... 145 Boot-up System..................................................................................................................... 146 Layout Drawing of Boot-up System............................................................................................... 146 System Operating Lamp System................................................................................................... 147 System Diagram of System Operating Lamp System............................................................................. 147 Function of Operation Lamp System.......................................................................................... 147 Operation of System Operating Lamp System.................................................................................. 147 Battery Disconnect Switch...................................................................................................... 148 Function of Battery Disconnect Switch...................................................................................... 148 Engine System...................................................................................................................... 149 Layout Drawing of Engine System................................................................................................ 149 Function of Engine System.................................................................................................. 150 Engine Control System.......................................................................................................... 151 System Diagram of Engine Control........................................................................................... 151 Operation of Engine Control System......................................................................................... 152 Auto-Deceleration System....................................................................................................... 154 System Diagram of Auto-Deceleration System................................................................................. 154 Function of Auto-Deceleration System....................................................................................... 155 Operation of Auto-Deceleration System...................................................................................... 155 Engine Automatic Warm-up System................................................................................................ 156 System Diagram of Engine Automatic Warm-up System.......................................................................... 156 Function of Engine Automatic Warm-up System................................................................................ 157 Overheat Prevention System..................................................................................................... 158 Overheat Prevention System Diagram......................................................................................... 158 Function of Overheat Prevention System..................................................................................... 159 Turbocharger Protection System................................................................................................. 162 System Diagram of Turbocharger Protection System........................................................................... 162 Function of Turbocharger Protection System................................................................................. 163 Automatic Idle Stop System..................................................................................................... 164 System Diagram of Automatic Idle Stop System............................................................................... 164 Function of Automatic Idle Stop System..................................................................................... 165 Component Parts of Engine System............................................................................................... 168 VGT........................................................................................................................ 168 EGR System................................................................................................................. 171 EGR Valve.................................................................................................................. 174 EGR Cooler................................................................................................................. 176 KCCV System................................................................................................................ 178 KCCV Ventilator............................................................................................................ 180 KDOC....................................................................................................................... 183 Cooling System..................................................................................................................... 186 Layout Drawing of Cooling System............................................................................................... 186 Specifications of Cooling System........................................................................................... 187 Fan Speed Control System of Fan Clutch......................................................................................... 188 Fan Speed Control System Diagram of Fan Clutch............................................................................. 188 Function of Fan Speed Control System of Fan Clutch......................................................................... 189 Engine Output Control System of Fan Clutch..................................................................................... 190 Engine Output Control System Diagram of Fan Clutch......................................................................... 190 Function of Engine Output Control System of Fan Clutch..................................................................... 191 Component Parts of Cooling System.............................................................................................. 193 Fan Clutch................................................................................................................. 193 Hybrid System...................................................................................................................... 194 Layout Drawing of Hybrid System................................................................................................ 194 System Diagram of Hybrid System................................................................................................ 195 Structure of Hybrid System..................................................................................................... 196 Hybrid Protection System....................................................................................................... 197 System Diagram of Hybrid Protection System................................................................................. 197 Function of Hybrid Protection System....................................................................................... 197 Cooling System of Hybrid Components............................................................................................ 199 System Diagram of Cooling System of Hybrid Components...................................................................... 199 Interlock System of Hybrid Components.......................................................................................... 200 System Diagram of Interlock System of Hybrid Components.................................................................... 200 Function of Interlock System of Hybrid Components.......................................................................... 200 Worker Protection System for When You Disassemble Hybrid Components............................................................ 201 System Diagram of Worker Protection System for When You Disassemble Hybrid Components...................................... 201 Function of Worker Protection System for When You Disassemble Hybrid Components............................................ 202 Component Parts of Hybrid System............................................................................................... 203 Motor-Generator............................................................................................................ 203 Electric Control Unit...................................................................................................... 204 High Voltage Wiring (Power Cable).......................................................................................... 205 Hybrid Water Pump.......................................................................................................... 206 Inverter (Hybrid Controller)............................................................................................... 207 Control System..................................................................................................................... 210 Layout Drawing of Control System............................................................................................... 210 Machine Monitor System......................................................................................................... 213 System Diagram of Machine Monitor System................................................................................... 213 Function of Machine Monitor System......................................................................................... 214 KomVision System............................................................................................................... 215 Layout Drawing of KomVision System......................................................................................... 215 System Diagram of KomVision System......................................................................................... 217 Function of KomVision System............................................................................................... 218 KOMTRAX System................................................................................................................. 220 System Diagram of KOMTRAX System........................................................................................... 220 Function of KOMTRAX System................................................................................................. 220 Component Parts of Control System.............................................................................................. 221 Machine Monitor............................................................................................................ 221 KomVision Controller....................................................................................................... 238 KomVision Camera........................................................................................................... 242 KOMTRAX Terminal........................................................................................................... 243 Gateway Function Controller................................................................................................ 245 Communication Terminal..................................................................................................... 248 Pump Controller............................................................................................................ 250 Resistor for PC-EPC Valve.................................................................................................. 255 CAN Terminating Resistor................................................................................................... 256 Engine Controller.......................................................................................................... 257 Fuel Control Dial.......................................................................................................... 264 Hydraulic System................................................................................................................... 266 Layout Drawing of Hydraulic System............................................................................................. 266 CLSS........................................................................................................................... 271 Structure of CLSS.......................................................................................................... 271 Operation of Unload Valve and LS Pressure.................................................................................. 273 Pump Swash Plate Angle (Oil Flow) Control.................................................................................. 274 Pressure Compensation Control.............................................................................................. 292 Engine and Pump Combined Control System........................................................................................ 293 Engine and Pump Combined Control System Diagram............................................................................ 293 Function of Engine and Pump Combined Control System........................................................................ 294 Pump and Valve Control System.................................................................................................. 299 Pump and Valve Control System Diagram...................................................................................... 299 Function of Pump and Valve Control System.................................................................................. 301 Component Parts of Hydraulic System............................................................................................ 302 Hydraulic Tank............................................................................................................. 302 Main Pump.................................................................................................................. 304 Control Valve.............................................................................................................. 330 Work Equipment System.............................................................................................................. 389 Layout Drawing of Work Equipment System........................................................................................ 389 One-Touch Power Maximizing System.............................................................................................. 393 System Diagram of One-Touch Power Maximizing System........................................................................ 393 Function of One-Touch Power Maximizing System.............................................................................. 394 PPC Lock System................................................................................................................ 395 System Diagram of PPC Lock................................................................................................. 395 Function of PPC Lock System................................................................................................ 395 Work Equipment and Travel Automatic Lock System................................................................................ 396 System Diagram of Lock Lever Automatic Lock System......................................................................... 396 Function of Work Equipment and Travel Automatic Lock System................................................................ 396 Operation of Lock Lever Automatic Lock System.............................................................................. 397 Attachment Oil Flow Adjuster System............................................................................................ 398 Attachment Oil Flow Adjuster System Diagram................................................................................ 398 Function of Attachment Oil Flow Adjuster System............................................................................ 399 Tool Control System............................................................................................................ 400 Tool Control System Diagram................................................................................................ 400 Component Parts of Work Equipment System....................................................................................... 402 Work Equipment and Swing PPC Valve......................................................................................... 402 1st-Line Attachment PPC Valve (with EPC Valve)............................................................................. 409 2nd-Line Attachment PPC Valve.............................................................................................. 417 Solenoid Valve............................................................................................................. 418 Attachment Circuit Selector Valve (For High Pressure)...................................................................... 422 Attachment Circuit Selector Valve (For Low Pressure)....................................................................... 424 1st-Line Attachment Variable Relief Valve.................................................................................. 426 Attachment Bypass Solenoid Valve........................................................................................... 429 Pilot Circuit Accumulator.................................................................................................. 431 Attachment Circuit Accumulator............................................................................................. 432 Swing System....................................................................................................................... 433 Layout Drawing of Swing System................................................................................................. 433 Swing Control System Diagram................................................................................................... 436 Function of Swing Control System........................................................................................... 437 Component Parts of Swing System................................................................................................ 440 Electric Swing Motor....................................................................................................... 440 Swing Machinery with Swing Parking Brake................................................................................... 441 Swing Circle............................................................................................................... 443 Travel System...................................................................................................................... 444 Layout Drawing of Travel System................................................................................................ 444 System Diagram of Travel Control System........................................................................................ 448 Function of Travel Control System.......................................................................................... 448 Component Parts of Travel System............................................................................................... 450 Travel Motor............................................................................................................... 450 Final Drive................................................................................................................ 463 Travel PPC Valve........................................................................................................... 466 Center Swivel Joint........................................................................................................ 470 Undercarriage and Frame............................................................................................................ 472 Layout Drawing of Undercarriage................................................................................................ 472 Specifications of Undercarriage............................................................................................ 473 Work Equipment..................................................................................................................... 474 Structure of Work Equipment.................................................................................................... 474 Function of Work Equipment..................................................................................................... 475 Work Equipment Clearance Adjustment Shim....................................................................................... 476 Function of Work Equipment Clearance Adjustment Shim....................................................................... 476 Bucket Clearance Adjustment Shim............................................................................................... 477 Function of Bucket Clearance Adjustment Shim............................................................................... 477 CAB Related Parts.................................................................................................................. 478 ROPS CAB....................................................................................................................... 478 Structure of ROPS CAB...................................................................................................... 478 Function of ROPS CAB....................................................................................................... 478 CAB Mount...................................................................................................................... 479 Structure of CAB Mount..................................................................................................... 479 Function of CAB Mount...................................................................................................... 479 CAB Tipping Stopper............................................................................................................ 480 Structure of CAB Tipping Stopper........................................................................................... 480 Function of CAB Tipping Stopper............................................................................................ 480 20 Standard Value Table................................................................................................................ 481 Table of Contents.................................................................................................................. 482 Standard Value Table for Engine.................................................................................................... 483 Standard Value Table for Engine: HB215LC-3..................................................................................... 483 Standard Value Table for Machine................................................................................................... 488 Standard Value Table for Machine: HB215LC-3.................................................................................... 488 Machine Posture and Procedures to Measure Performance.......................................................................... 504 30 Testing and Adjusting............................................................................................................... 509 Table of Contents.................................................................................................................. 510 Precautions Before Work............................................................................................................ 513 Related Information on Testing and Adjusting....................................................................................... 514 Tools for Testing and Adjusting................................................................................................ 514 Sketch of Tools for Testing and Adjusting...................................................................................... 521 Engine and Cooling System.......................................................................................................... 523 Examine Engine Speed........................................................................................................... 523 How to Examine Engine Speed................................................................................................ 523 Examine Boost Pressure......................................................................................................... 526 How to Examine Boost Pressure on Machine Monitor........................................................................... 526 How to Examine Boost Pressure by Testing Tool.............................................................................. 527 Examine Exhaust Gas Color...................................................................................................... 528 How to Examine Exhaust Gas Color with the Handy Smoke Checker.............................................................. 528 How to Examine Exhaust Gas Color with Smoke Meter.......................................................................... 529 Examine and Adjust Valve Clearance............................................................................................. 530 How to Examine Valve Clearance............................................................................................. 530 How to Adjust Valve Clearance.............................................................................................. 531 Examine Compression Pressure................................................................................................... 533 How to Examine Compression Pressure........................................................................................ 533 Examine Blowby Pressure........................................................................................................ 538 How to Examine Blowby Pressure............................................................................................. 538 Examine Engine Oil Pressure.................................................................................................... 540 How to Examine Engine Oil Pressure......................................................................................... 540 Examine Fuel Pressure.......................................................................................................... 541 How to Examine Fuel Pressure............................................................................................... 542 Examine Fuel Discharge, Return and Leakage..................................................................................... 546 How to Examine Fuel Discharge, Return, and Leakage......................................................................... 547 Bleed Air from Fuel System..................................................................................................... 551 How to Bleed Air from Fuel System.......................................................................................... 551 Examine Fuel Circuit for Leakage............................................................................................... 552 How to Examine Fuel System for Leakage..................................................................................... 552 Handle Cylinder Cut-out Mode Operation......................................................................................... 554 Handle No-Injection Cranking Operation......................................................................................... 555 Examine and Adjust Air Conditioner Compressor Belt Tension..................................................................... 556 How to Examine Air Conditioner Compressor Belt............................................................................. 556 How to Adjust Air Conditioner Compressor Belt.............................................................................. 556 Examine Fan Belt and Alternator Belt........................................................................................... 558 How to Examine Fan Belt and Alternator Belt................................................................................ 558 Examine Automatic Tensioner.................................................................................................... 559 How to Examine Automatic Tensioner......................................................................................... 559 Examine Cooling Fan Speed...................................................................................................... 560 How to Examine Cooling Fan Speed........................................................................................... 560 Examine SCR Related Functions.................................................................................................. 561 Examine DEF Pump Raised Pressure........................................................................................... 565 Examine Injection Volume from DEF Injector................................................................................. 568 Examine DEF Line Heater Relay 1............................................................................................ 572 Examine DEF Line Heater Relay 2............................................................................................ 575 Examine DEF Pump Heater Relay.............................................................................................. 578 Examine DEF Tank Heater Valve.............................................................................................. 582 Examine SCR Denitration Efficiency......................................................................................... 585 Clean DEF Tank................................................................................................................. 588 How to Clean DEF Tank...................................................................................................... 588 Clean DEF Pump................................................................................................................. 592 How to Clean DEF Pump...................................................................................................... 592 Bleed Air from Coolant Circuit of DEF Tank..................................................................................... 599 How to Bleed Air from Coolant Circuit of DEF Tank.......................................................................... 599 Hybrid System...................................................................................................................... 601 Precautions When You Use Hybrid Systems........................................................................................ 601 Drain, Refilling, Air Bleeding of Hybrid System Coolant........................................................................ 602 How to Drain the Hybrid System Coolant..................................................................................... 602 How to Refill Coolant and Bleed Air in Hybrid System....................................................................... 604 Water Pressure Test of the Hybrid System Coolant............................................................................... 606 How to Examine the Water Pressure of the Hybrid System Coolant............................................................. 606 Examine Lubrication Circuit Oil Pressure of Hybrid System...................................................................... 608 How to Examine Lubrication Circuit Oil Pressure of Electric Swing Motor Case............................................... 608 How to Examine Lubrication Circuit Oil Pressure of Motor-Generator Oil Case................................................ 608 Examine Swing Parking Brake.................................................................................................... 610 How to Examine Swing Parking Brake......................................................................................... 610 Examine and Clean Swing Motor Cooling Oil Delivery Filter...................................................................... 612 How to Examine and Clean Swing Motor Cooling Oil Delivery Filter........................................................... 612 Power Train........................................................................................................................ 613 Examine Swing Circle Bearing Clearance......................................................................................... 613 How to Examine Swing Circle Bearing Clearance.............................................................................. 613 Undercarriage and Frame............................................................................................................ 614 Examine and Adjust Track Tension............................................................................................... 614 How to Examine Track Tension............................................................................................... 614 How to Adjust Track Tension................................................................................................ 614 Hydraulic System................................................................................................................... 616 Release Remained Pressure in Hydraulic Circuit................................................................................. 616 How to Release Remained Pressure from Hydraulic Tank....................................................................... 616 How to Release Remained Pressure in Hydraulic Cylinder Circuit............................................................. 616 How to Release Remained Pressure from Travel Motor Circuit................................................................. 620 Examine and Adjust Oil Pressure in Work Equipment and Travel Circuits.......................................................... 622 How to Examine Oil Pressure in Work Equipment and Travel Circuits.......................................................... 623 How to Adjust Oil Pressure in Work Equipment and Travel Circuits........................................................... 626 Examine Oil Pressure of Control Circuit........................................................................................ 628 How to Examine Oil Pressure in Control Circuit............................................................................. 628 Examine and adjust oil pressure in pump PC control circuit..................................................................... 630 How to Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure)...................................................... 630 How to Examine PC-EPC Valve Outlet Pressure................................................................................ 631 How to Adjust Oil Pressure in Pump PC Control Circuit...................................................................... 632 Examine and Adjust Oil Pressure in Pump LS Control Circuit..................................................................... 634 How to Examine LS Differential Pressure with Machine Monitor............................................................... 634 How to Examine LS Differential Pressure by Testing Tool.................................................................... 635 How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure)...................................................... 637 How to Examine LS-EPC Valve Outlet Pressure................................................................................ 638 How to Adjust LS Valve..................................................................................................... 639 Examine Outlet Pressure of Solenoid Valve...................................................................................... 640 How to Examine Outlet Pressure of Solenoid Valve........................................................................... 640 Operating Condition of Solenoid Valve...................................................................................... 642 Examine PPC Valve Outlet Pressure.............................................................................................. 644 How to Examine Outlet Pressure in PPC Valve................................................................................ 644 Examine Attachment Circuit Oil Pressure........................................................................................ 646 How to Examine Attachment Circuit Oil Pressure............................................................................. 646 Adjust Play of Work Equipment and Swing PPC Valves............................................................................. 647 How to Adjust Play of Work Equipment and Swing PPC Valves.................................................................. 647 Examine Pump Swash Plate Sensor................................................................................................ 648 How to Examine pump swash plate sensor..................................................................................... 648 Examine Parts Which Cause Hydraulic Drift of Work Equipment.................................................................... 649 How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder...................................... 649 How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder....................................................... 649 How to Examine Parts that Cause Hydraulic Drift of PPC Valve............................................................... 650 Examine Oil Leakage............................................................................................................ 651 How to Examine Oil Leakage from Boom Cylinder.............................................................................. 651 How to Examine Oil Leakage from Arm Cylinder............................................................................... 651 How to Examine Oil Leakage from Bucket Cylinder............................................................................ 652 How to Examine Oil Leakage from Travel Motor............................................................................... 652 Bleed Air from Hydraulic System................................................................................................ 654 How to Bleed Air from Hydraulic System..................................................................................... 655 CAB Related Parts.................................................................................................................. 657 Examine CAB Tipping Stopper.................................................................................................... 657 How to Examine Cab Tipping Stopper......................................................................................... 657 How to Adjust Mirrors.......................................................................................................... 658 Procedure to Adjust Machine Left Front Mirror (A).......................................................................... 658 Procedure to Adjust Regular Position of Machine Left Front Mirror (A)...................................................... 659 Procedure to Adjust Machine Right Front Mirror (B)......................................................................... 660 Procedure to Adjust Regular Position of Machine Right Front Mirror (B)..................................................... 661 Procedure to Adjust Machine Right Side Mirror (C).......................................................................... 662 Electrical System.................................................................................................................. 663 Set and Operate Machine Monitor................................................................................................ 663 Operator Mode.............................................................................................................. 667 Function to Show Technician Identification Status Screen................................................................... 667 Function to Show Operator Identification Input Screen...................................................................... 667 Examine Function by LCD (Liquid Crystal Display)........................................................................... 668 Examine Function of Service Meter.......................................................................................... 668 Usage Limitation and Maintenance Password Change Function.................................................................. 668 Service Mode............................................................................................................... 671 How to Operate Service Mode................................................................................................ 671 How to See Pre-defined Monitoring Information.............................................................................. 673 How to Examine Self-Define Monitor Information............................................................................. 682 Abnormality Record Menu.................................................................................................... 696 How to See Maintenance Record.............................................................................................. 700 Maintenance Mode Setting................................................................................................... 701 How to Set Phone Number Entry.............................................................................................. 705 Default Menu............................................................................................................... 707 Diagnostic Tests Menu...................................................................................................... 719 Adjustment Menu............................................................................................................ 733 No-Injection Cranking Operation............................................................................................ 756 KOMTRAX Settings Menu...................................................................................................... 758 How to Show Service Message................................................................................................ 762 How to Start Up KOMTRAX Terminal (Machine with KOMTRAX Terminal)............................................................... 764 How to Stop Use of KOMTRAX Terminal (Machine with KOMTRAX Terminal)............................................................ 769 How to Start Up KOMTRAX System (Machine with Gateway Function Controller)...................................................... 771 How to Stop Use of KOMTRAX System (Machine with Gateway Function Controller)................................................... 777 Adjust Rearview Camera Angle................................................................................................... 779 How to Adjust Rearview Camera Angle........................................................................................ 779 Adjust KomVision Camera Angle.................................................................................................. 782 How to Adjust KomVision Camera Angle....................................................................................... 783 Adjust KomVision Related Function.............................................................................................. 787 Setting of KomVision (Main Setting)........................................................................................ 788 Setting of KomVision (Camera Setting)...................................................................................... 791 Setting of KomVision (Camera Calibration).................................................................................. 794 KomVision screen - Check 12 m visibility................................................................................... 807 Set Region of Bluetooth(R) Compatible Radio.................................................................................... 810 How to Set Region of Bluetooth(R) Compatible Radio......................................................................... 810 Handle Voltage Circuit of Engine Controller.................................................................................... 812 Handle Battery Disconnect Switch............................................................................................... 813 Examine Diodes................................................................................................................. 814 How to Examine Diodes by Digital Tester.................................................................................... 814 How to Examine Diodes by Analog Tester..................................................................................... 814 Pm Clinic.......................................................................................................................... 815 Pm Clinic Service.............................................................................................................. 815 Pm Clinic Check Sheet: HB215LC-3........................................................................................... 817 40 Troubleshooting..................................................................................................................... 829 Table of Contents.................................................................................................................. 830 Precautions Before Work............................................................................................................ 843 Related Information to Troubleshooting............................................................................................. 844 General Troubleshooting Points................................................................................................. 844 Troubleshooting Points for Urea SCR System..................................................................................... 845 Sequence of Events in Troubleshooting.......................................................................................... 857 Precautions When You Use Hybrid Systems, Troubleshooting for High-Voltage Equipment............................................ 859 Table of Self-Define Monitoring Items and Check Sheet for Hybrid Components.................................................... 866 Checks Before Troubleshooting.................................................................................................. 872 Inspection Procedure Before Troubleshooting.................................................................................... 874 Walk-Around Check.......................................................................................................... 874 Test in Accordance with Testing Procedure...................................................................................... 876 Examine Fuel Level and Type................................................................................................ 876 Examine for Impure Ingredient in Fuel...................................................................................... 876 Examine Fuel Prefilter..................................................................................................... 877 Examine Water Separator, Drain Water and Sediment.......................................................................... 877 How to Replace Fuel Prefilter Cartridge.................................................................................... 878 Examine Fuel Main Filter................................................................................................... 879 Examine Engine Oil Level (Oil Quantity in Oil Pan)......................................................................... 881 Examine Oil Level in Motor-Generator Case.................................................................................. 882 Examine Coolant Level (Reservoir Tank)..................................................................................... 882 Examine Air Cleaner Clogging............................................................................................... 883 Clean Outer Element........................................................................................................ 883 Replace Element............................................................................................................ 886 Examine Hydraulic Oil Strainer............................................................................................. 887 Examine Hydraulic Oil Filter............................................................................................... 888 Examine Capacitor.......................................................................................................... 888 Examine Oil Level in Electric Swing Motor Case............................................................................. 889 Examine Oil Level in Swing Machinery Case.................................................................................. 890 Examine Oil Level in Final Drive Case...................................................................................... 891 Bleed Air from Fuel System................................................................................................. 892 Bleed Air from Hydraulic System............................................................................................ 892 How to Examine Electric Equipment.......................................................................................... 892 Preparation for Troubleshooting of Electrical System........................................................................... 898 Preparation for Troubleshooting of Machine Monitor......................................................................... 898 Preparation for Troubleshooting of Engine Controller....................................................................... 898 Preparation for Troubleshooting of Pump Controller......................................................................... 899 Preparation for Troubleshooting of KOMTRAX Terminal........................................................................ 899 Preparation for Troubleshooting of Gateway Function Controller............................................................. 899 Preparation for Troubleshooting of KomVision Controller.................................................................... 899 Preparation for Troubleshooting of Inverter (Hybrid Controller)............................................................ 900 How to Disconnect and Connect Connector with a Special Lock................................................................ 900 Procedure for Troubleshooting.................................................................................................. 904 Symptom and Troubleshooting Numbers............................................................................................ 907 Information Shown in Troubleshooting Table..................................................................................... 911 How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness................................................ 913 Connector List and Layout (Machine with KOMTRAX Terminal)...................................................................... 916 Connector List and Layout (Machine with Gateway Function Controller)........................................................... 929 Connector Contact Connection Table............................................................................................. 942 T-Branch Box and T-Branch Adapter Table........................................................................................ 982 Fuse Location Table (Machine with KOMTRAX Terminal)............................................................................ 988 Fuse Location Table (Machine with Gateway Function Controller)................................................................. 990 Precautions When You Replace KDOC.............................................................................................. 993 Failure Code Table............................................................................................................. 994 Troubleshooting by Failure Code (Display of Code)..................................................................................1019 Failure Code [879AKA]..........................................................................................................1019 Failure Code [879AKB]..........................................................................................................1020 Failure Code [879BKA]..........................................................................................................1021 Failure Code [879BKB]..........................................................................................................1023 Failure Code [879CKA]..........................................................................................................1025 Failure Code [879CKB]..........................................................................................................1026 Failure Code [879DKZ]..........................................................................................................1027 Failure Code [879EMC]..........................................................................................................1029 Failure Code [879FMC]..........................................................................................................1030 Failure Code [879GKX]..........................................................................................................1031 Failure Code [989L00]..........................................................................................................1033 Failure Code [989M00]..........................................................................................................1034 Failure Code [989N00]..........................................................................................................1035 Failure Code [A1U0N3]..........................................................................................................1036 Failure Code [A1U0N4]..........................................................................................................1038 Failure Code [A900FR]..........................................................................................................1040 Failure Code [A900N6]..........................................................................................................1041 Failure Code [A900NY]..........................................................................................................1042 Failure Code [AA10NX]..........................................................................................................1043 Failure Code [AB00KE]..........................................................................................................1045 Failure Code [AQ10MB]..........................................................................................................1047 Failure Code [AQ10N3]..........................................................................................................1049 Failure Code [AS00R2]..........................................................................................................1051 Failure Code [AS00R3]..........................................................................................................1052 Failure Code [AS00R4]..........................................................................................................1053 Failure Code [AS00R5]..........................................................................................................1054 Failure Code [AS00R6]..........................................................................................................1055 Failure Code [AS00ZK]..........................................................................................................1056 Failure Code [AS10KM]..........................................................................................................1057 Failure Code [AS10NR]..........................................................................................................1058 Failure Code [AS10NT]..........................................................................................................1059 Failure Code [B@BAZG]..........................................................................................................1060 Failure Code [B@BAZK]..........................................................................................................1061 Failure Code [B@BCNS]..........................................................................................................1063 Failure Code [B@BCQA]..........................................................................................................1064 Failure Code [B@BCZK]..........................................................................................................1066 Failure Code [B@HANS]..........................................................................................................1067 Failure Code [CA115]...........................................................................................................1068 Failure Code [CA122]...........................................................................................................1069 Failure Code [CA123]...........................................................................................................1071 Failure Code [CA131]...........................................................................................................1073 Failure Code [CA132]...........................................................................................................1075 Failure Code [CA144]...........................................................................................................1077 Failure Code [CA145]...........................................................................................................1079 Failure Code [CA153]...........................................................................................................1081 Failure Code [CA154]...........................................................................................................1083 Failure Code [CA187]...........................................................................................................1085 Failure Code [CA221]...........................................................................................................1087 Failure Code [CA222]...........................................................................................................1089 Failure Code [CA227]...........................................................................................................1091 Failure Code [CA234]...........................................................................................................1093 Failure Code [CA238]...........................................................................................................1094 Failure Code [CA239]...........................................................................................................1095 Failure Code [CA249]...........................................................................................................1096 Failure Code [CA256]...........................................................................................................1098 Failure Code [CA271]...........................................................................................................1100 Failure Code [CA272]...........................................................................................................1102 Failure Code [CA295]...........................................................................................................1104 Failure Code [CA322]...........................................................................................................1105 Failure Code [CA324]...........................................................................................................1107 Failure Code [CA331]...........................................................................................................1109 Failure Code [CA332]...........................................................................................................1111 Failure Code [CA343]...........................................................................................................1113 Failure Code [CA351]...........................................................................................................1114 Failure Code [CA352]...........................................................................................................1115 Failure Code [CA356]...........................................................................................................1117 Failure Code [CA357]...........................................................................................................1119 Failure Code [CA386]...........................................................................................................1121 Failure Code [CA428]...........................................................................................................1122 Failure Code [CA429]...........................................................................................................1124 Failure Code [CA435]...........................................................................................................1126 Failure Code [CA441]...........................................................................................................1128 Failure Code [CA442]...........................................................................................................1130 Failure Code [CA451]...........................................................................................................1131 Failure Code [CA452]...........................................................................................................1133 Failure Code [CA488]...........................................................................................................1135 Failure Code [CA515]...........................................................................................................1136 Failure Code [CA516]...........................................................................................................1138 Failure Code [CA553]...........................................................................................................1140 Failure Code [CA555]...........................................................................................................1141 Failure Code [CA556]...........................................................................................................1142 Failure Code [CA559]...........................................................................................................1143 Failure Code [CA595]...........................................................................................................1146 Failure Code [CA687]...........................................................................................................1148 Failure Code [CA689]...........................................................................................................1150 Failure Code [CA691]...........................................................................................................1153 Failure Code [CA692]...........................................................................................................1155 Failure Code [CA697]...........................................................................................................1157 Failure Code [CA698]...........................................................................................................1158 Failure Code [CA731]...........................................................................................................1159 Failure Code [CA778]...........................................................................................................1161 Failure Code [CA1117]..........................................................................................................1165 Failure Code [CA1664]..........................................................................................................1167 Failure Code [CA1669]..........................................................................................................1169 Failure Code [CA1673]..........................................................................................................1170 Failure Code [CA1677]..........................................................................................................1171 Failure Code [CA1678]..........................................................................................................1172 Failure Code [CA1682]..........................................................................................................1173 Failure Code [CA1683]..........................................................................................................1178 Failure Code [CA1684]..........................................................................................................1180 Failure Code [CA1686]..........................................................................................................1182 Failure Code [CA1691]..........................................................................................................1183 Failure Code [CA1694]..........................................................................................................1185 Failure Code [CA1695]..........................................................................................................1187 Failure Code [CA1696]..........................................................................................................1188 Failure Code [CA1712]..........................................................................................................1190 Failure Code [CA1713]..........................................................................................................1193 Failure Code [CA1714]..........................................................................................................1195 Failure Code [CA1715]..........................................................................................................1196 Failure Code [CA1776]..........................................................................................................1197 Failure Code [CA1777]..........................................................................................................1200 Failure Code [CA1843]..........................................................................................................1203 Failure Code [CA1844]..........................................................................................................1205 Failure Code [CA1885]..........................................................................................................1208 Failure Code [CA1887]..........................................................................................................1210 Failure Code [CA1896]..........................................................................................................1212 Failure Code [CA1898]..........................................................................................................1213 Failure Code [CA1938]..........................................................................................................1215 Failure Code [CA1942]..........................................................................................................1217 Failure Code [CA1961]..........................................................................................................1218 Failure Code [CA1962]..........................................................................................................1219 Failure Code [CA2185]..........................................................................................................1220 Failure Code [CA2186]..........................................................................................................1221 Failure Code [CA2198]..........................................................................................................1223 Failure Code [CA2272]..........................................................................................................1225 Failure Code [CA2288]..........................................................................................................1227 Failure Code [CA2311]..........................................................................................................1228 Failure Code [CA2349]..........................................................................................................1229 Failure Code [CA2353]..........................................................................................................1231 Failure Code [CA2357]..........................................................................................................1233 Failure Code [CA2373]..........................................................................................................1234 Failure Code [CA2374]..........................................................................................................1236 Failure Code [CA2375]..........................................................................................................1238 Failure Code [CA2376]..........................................................................................................1240 Failure Code [CA2387]..........................................................................................................1243 Failure Code [CA2554]..........................................................................................................1244 Failure Code [CA2555]..........................................................................................................1246 Failure Code [CA2556]..........................................................................................................1249 Failure Code [CA2634]..........................................................................................................1251 Failure Code [CA2635]..........................................................................................................1253 Failure Code [CA2636]..........................................................................................................1254 Failure Code [CA2637]..........................................................................................................1256 Failure Code [CA2771]..........................................................................................................1258 Failure Code [CA2961]..........................................................................................................1262 Failure Code [CA2973]..........................................................................................................1263 Failure Code [CA2976]..........................................................................................................1264 Failure Code [CA3142]..........................................................................................................1266 Failure Code [CA3143]..........................................................................................................1267 Failure Code [CA3144]..........................................................................................................1268 Failure Code [CA3146]..........................................................................................................1270 Failure Code [CA3147]..........................................................................................................1271 Failure Code [CA3148]..........................................................................................................1272 Failure Code [CA3151]..........................................................................................................1274 Failure Code [CA3165]..........................................................................................................1280 Failure Code [CA3228]..........................................................................................................1282 Failure Code [CA3229]..........................................................................................................1285 Failure Code [CA3231]..........................................................................................................1287 Failure Code [CA3232]..........................................................................................................1289 Failure Code [CA3235]..........................................................................................................1293 Failure Code [CA3239]..........................................................................................................1295 Failure Code [CA3241]..........................................................................................................1298 Failure Code [CA3242]..........................................................................................................1301 Failure Code [CA3251]..........................................................................................................1304 Failure Code [CA3313]..........................................................................................................1306 Failure Code [CA3314]..........................................................................................................1307 Failure Code [CA3315]..........................................................................................................1308 Failure Code [CA3419]..........................................................................................................1310 Failure Code [CA3421]..........................................................................................................1312 Failure Code [CA3497]..........................................................................................................1314 Failure Code [CA3498]..........................................................................................................1315 Failure Code [CA3545]..........................................................................................................1316 Failure Code [CA3547]..........................................................................................................1318 Failure Code [CA3558]..........................................................................................................1319 Failure Code [CA3559]..........................................................................................................1321 Failure Code [CA3562]..........................................................................................................1323 Failure Code [CA3563]..........................................................................................................1325 Failure Code [CA3567]..........................................................................................................1328 Failure Code [CA3568]..........................................................................................................1332 Failure Code [CA3571]..........................................................................................................1337 Failure Code [CA3572]..........................................................................................................1339 Failure Code [CA3574]..........................................................................................................1341 Failure Code [CA3575]..........................................................................................................1344 Failure Code [CA3577]..........................................................................................................1346 Failure Code [CA3578]..........................................................................................................1348 Failure Code [CA3582]..........................................................................................................1350 Failure Code [CA3583]..........................................................................................................1357 Failure Code [CA3596]..........................................................................................................1359 Failure Code [CA3649]..........................................................................................................1362 Failure Code [CA3681]..........................................................................................................1364 Failure Code [CA3682]..........................................................................................................1368 Failure Code [CA3713]..........................................................................................................1372 Failure Code [CA3717]..........................................................................................................1375 Failure Code [CA3718]..........................................................................................................1376 Failure Code [CA3724]..........................................................................................................1377 Failure Code [CA3725]..........................................................................................................1378 Failure Code [CA3741]..........................................................................................................1381 Failure Code [CA3748]..........................................................................................................1382 Failure Code [CA3755]..........................................................................................................1385 Failure Code [CA3866]..........................................................................................................1387 Failure Code [CA3868]..........................................................................................................1390 Failure Code [CA4152]..........................................................................................................1393 Failure Code [CA4155]..........................................................................................................1397 Failure Code [CA4156]..........................................................................................................1400 Failure Code [CA4157]..........................................................................................................1403 Failure Code [CA4159]..........................................................................................................1405 Failure Code [CA4164]..........................................................................................................1406 Failure Code [CA4165]..........................................................................................................1408 Failure Code [CA4166]..........................................................................................................1410 Failure Code [CA4168]..........................................................................................................1411 Failure Code [CA4169]..........................................................................................................1414 Failure Code [CA4171]..........................................................................................................1416 Failure Code [CA4249]..........................................................................................................1418 Failure Code [CA4251]..........................................................................................................1420 Failure Code [CA4261]..........................................................................................................1422 Failure Code [CA4277]..........................................................................................................1425 Failure Code [CA4459]..........................................................................................................1429 Failure Code [CA4461]..........................................................................................................1431 Failure Code [CA4533]..........................................................................................................1434 Failure Code [CA4534]..........................................................................................................1435 Failure Code [CA4731]..........................................................................................................1436 Failure Code [CA4732]..........................................................................................................1437 Failure Code [CA4739]..........................................................................................................1438 Failure Code [CA4768]..........................................................................................................1439 Failure Code [CA4769]..........................................................................................................1441 Failure Code [CA4842]..........................................................................................................1443 Failure Code [CA4952] (Machine with KOMTRAX Terminal)..........................................................................1446 Failure Code [CA4952] (Machine with Gateway Function Controller)...............................................................1448 Failure Code [CA5115]..........................................................................................................1450 Failure Code [CA5179]..........................................................................................................1453 Failure Code [CA5181]..........................................................................................................1455 Failure Code [CA5387]..........................................................................................................1457 Failure Code [CA5388]..........................................................................................................1459 Failure Code [CA5389]..........................................................................................................1462 Failure Code [CA5391]..........................................................................................................1464 Failure Code [CA5392]..........................................................................................................1468 Failure Code [CA5393]..........................................................................................................1470 Failure Code [CA5394]..........................................................................................................1472 Failure Code [CA5395]..........................................................................................................1474 Failure Code [CA5396]..........................................................................................................1477 Failure Code [CA5631]..........................................................................................................1478 Failure Code [CA5938]..........................................................................................................1480 Failure Code [D110KB]..........................................................................................................1482 Failure Code [D19JKZ]..........................................................................................................1484 Failure Code [D811MC] (Machine with KOMTRAX Terminal)..........................................................................1487 Failure Code [D811MC] (Machine with Gateway Function Controller)...............................................................1488 Failure Code [D862KA] (Machine with KOMTRAX Terminal)..........................................................................1489 Failure Code [D862KA] (Machine with Gateway Function Controller)...............................................................1491 Failure Code [D8ALKA] (Machine with KOMTRAX Terminal)..........................................................................1493 Failure Code [D8ALKA] (Machine with Gateway Function Controller)...............................................................1496 Failure Code [D8ALKB] (Machine with KOMTRAX Terminal)..........................................................................1499 Failure Code [D8ALKB] (Machine with Gateway Function Controller)...............................................................1501 Failure Code [D8AQKR] (Machine with KOMTRAX Terminal)..........................................................................1503 Failure Code [D8AQKR] (Machine with Gateway Function Controller)...............................................................1510 Failure Code [D8ARKR]..........................................................................................................1517 Failure Code [D8G1KT]..........................................................................................................1522 Failure Code [D8G6KT]..........................................................................................................1523 Failure Code [DA20MC]..........................................................................................................1524 Failure Code [DA22KK]..........................................................................................................1525 Failure Code [DA25KP]..........................................................................................................1528 Failure Code [DA26KP]..........................................................................................................1531 Failure Code [DA29KQ]..........................................................................................................1534 Failure Code [DA2LKA] (Machine with KOMTRAX Terminal)..........................................................................1537 Failure Code [DA2LKA] (Machine with Gateway Function Controller)...............................................................1540 Failure Code [DA2LKB] (Machine with KOMTRAX Terminal)..........................................................................1543 Failure Code [DA2LKB] (Machine with Gateway Function Controller)...............................................................1545 Failure Code [DA2QKR] (Machine with KOMTRAX Terminal)..........................................................................1547 Failure Code [DA2QKR] (Machine with Gateway Function Controller)...............................................................1556 Failure Code [DA2RKR] (Machine with KOMTRAX Terminal)..........................................................................1565 Failure Code [DA2RKR] (Machine with Gateway Function Controller)...............................................................1570 Failure Code [DAF0KM]..........................................................................................................1575 Failure Code [DAF0MB]..........................................................................................................1576 Failure Code [DAF0MC]..........................................................................................................1577 Failure Code [DAF8KB]..........................................................................................................1578 Failure Code [DAF9KQ]..........................................................................................................1580 Failure Code [DAFGMC] (Machine with KOMTRAX Terminal)..........................................................................1581 Failure Code [DAFGMC] (Machine with Gateway Function Controller)...............................................................1582 Failure Code [DAFLKA] (Machine with KOMTRAX Terminal)..........................................................................1583 Failure Code [DAFLKA] (Machine with Gateway Function Controller)...............................................................1586 Failure Code [DAFLKB] (Machine with KOMTRAX Terminal)..........................................................................1589 Failure Code [DAFLKB] (Machine with Gateway Function Controller)...............................................................1591 Failure Code [DAFQKR] (Machine with KOMTRAX Terminal)..........................................................................1593 Failure Code [DAFQKR] (Machine with Gateway Function Controller)...............................................................1601 Failure Code [DAZ9KQ]..........................................................................................................1609 Failure Code [DAZQKR] (Machine with KOMTRAX Terminal)..........................................................................1610 Failure Code [DAZQKR] (Machine with Gateway Function Controller)...............................................................1617 Failure Code [DB2QKR] (Machine with KOMTRAX Terminal)..........................................................................1624 Failure Code [DB2QKR] (Machine with Gateway Function Controller)...............................................................1632 Failure Code [DB2RKR] (Machine with KOMTRAX Terminal)..........................................................................1640 Failure Code [DB2RKR] (Machine with Gateway Function Controller)...............................................................1646 Failure Code [DBP0KM]..........................................................................................................1652 Failure Code [DBP0KT]..........................................................................................................1653 Failure Code [DBP5KB]..........................................................................................................1654 Failure Code [DBP5KY]..........................................................................................................1657 Failure Code [DBPQKR] (Machine with KOMTRAX Terminal)..........................................................................1660 Failure Code [DBPQKR] (Machine with Gateway Function Controller)...............................................................1668 Failure Code [DDNRKA]..........................................................................................................1676 Failure Code [DDNRKY]..........................................................................................................1678 Failure Code [DDNS00]..........................................................................................................1680 Failure Code [DFB1KZ]..........................................................................................................1682 Failure Code [DFB2KZ]..........................................................................................................1684 Failure Code [DFB3L8]..........................................................................................................1686 Failure Code [DFB4L8]..........................................................................................................1688 Failure Code [DFB5KZ]..........................................................................................................1690 Failure Code [DFB6KZ]..........................................................................................................1692 Failure Code [DGH2KA]..........................................................................................................1694 Failure Code [DGH2KB]..........................................................................................................1696 Failure Code [DHA4KA]..........................................................................................................1698 Failure Code [DHAAMA]..........................................................................................................1700 Failure Code [DHACMA]..........................................................................................................1702 Failure Code [DHPAMA]..........................................................................................................1704 Failure Code [DHPBMA]..........................................................................................................1706 Failure Code [DHS3MA]..........................................................................................................1708 Failure Code [DHS4MA]..........................................................................................................1710 Failure Code [DHS8MA]..........................................................................................................1712 Failure Code [DHS9MA]..........................................................................................................1714 Failure Code [DHSAKZ]..........................................................................................................1716 Failure Code [DHSBKZ]..........................................................................................................1718 Failure Code [DHSCMA]..........................................................................................................1720 Failure Code [DHSDMA]..........................................................................................................1722 Failure Code [DHSFMA]..........................................................................................................1724 Failure Code [DHSGMA]..........................................................................................................1726 Failure Code [DHSHMA]..........................................................................................................1728 Failure Code [DHSJMA]..........................................................................................................1730 Failure Code [DHVAKZ]..........................................................................................................1732 Failure Code [DHVAL8]..........................................................................................................1734 Failure Code [DHVAMA]..........................................................................................................1736 Failure Code [DHVBKZ]..........................................................................................................1737 Failure Code [DHVBL8]..........................................................................................................1739 Failure Code [DHVBMA]..........................................................................................................1741 Failure Code [DHZAMA]..........................................................................................................1742 Failure Code [DHZCL8]..........................................................................................................1746 Failure Code [DKR0MA]..........................................................................................................1747 Failure Code [DKR1MA]..........................................................................................................1749 Failure Code [DKTKKX]..........................................................................................................1751 Failure Code [DKTLKX]..........................................................................................................1753 Failure Code [DKTMKX]..........................................................................................................1755 Failure Code [DKTNKX]..........................................................................................................1757 Failure Code [DKTPKX]..........................................................................................................1759 Failure Code [DKTQKX]..........................................................................................................1761 Failure Code [DKULKA]..........................................................................................................1763 Failure Code [DKULKB]..........................................................................................................1765 Failure Code [DKULKY]..........................................................................................................1767 Failure Code [DLM5KA]..........................................................................................................1769 Failure Code [DLM5MB]..........................................................................................................1771 Failure Code [DR10KA]..........................................................................................................1773 Failure Code [DR12KA]..........................................................................................................1776 Failure Code [DR20KA]..........................................................................................................1778 Failure Code [DR21KX]..........................................................................................................1780 Failure Code [DR30KA]..........................................................................................................1782 Failure Code [DR31KX]..........................................................................................................1784 Failure Code [DR40KA]..........................................................................................................1786 Failure Code [DUMBKA] (Machine with KOMTRAX Terminal)..........................................................................1788 Failure Code [DUMBKA] (Machine with Gateway Function Controller)...............................................................1791 Failure Code [DUMBKB] (Machine with KOMTRAX Terminal)..........................................................................1794 Failure Code [DUMBKB] (Machine with Gateway Function Controller)...............................................................1796 Failure Code [DV20KB]..........................................................................................................1798 Failure Code [DW43KA]..........................................................................................................1800 Failure Code [DW43KB]..........................................................................................................1802 Failure Code [DW43KY]..........................................................................................................1804 Failure Code [DW45KA]..........................................................................................................1806 Failure Code [DW45KB]..........................................................................................................1809 Failure Code [DW45KK]..........................................................................................................1812 Failure Code [DW45KY]..........................................................................................................1814 Failure Code [DW4CKY]..........................................................................................................1816 Failure Code [DW91KA]..........................................................................................................1818 Failure Code [DW91KB]..........................................................................................................1820 Failure Code [DW91KY]..........................................................................................................1822 Failure Code [DWA2KA]..........................................................................................................1824 Failure Code [DWA2KB]..........................................................................................................1826 Failure Code [DWA2KY]..........................................................................................................1828 Failure Code [DWK0KA]..........................................................................................................1830 Failure Code [DWK0KB]..........................................................................................................1832 Failure Code [DWK0KY]..........................................................................................................1834 Failure Code [DWK2KA]..........................................................................................................1836 Failure Code [DWK2KB]..........................................................................................................1838 Failure Code [DWK2KY]..........................................................................................................1840 Failure Code [DWN5KA]..........................................................................................................1842 Failure Code [DWN5KB]..........................................................................................................1845 Failure Code [DWN5KY]..........................................................................................................1847 Failure Code [DWPUKA]..........................................................................................................1849 Failure Code [DWPUKB]..........................................................................................................1851 Failure Code [DWPUKY]..........................................................................................................1853 Failure Code [DXA8KA]..........................................................................................................1855 Failure Code [DXA8KB]..........................................................................................................1858 Failure Code [DXA9KA]..........................................................................................................1860 Failure Code [DXA9KB]..........................................................................................................1863 Failure Code [DXE0KA]..........................................................................................................1865 Failure Code [DXE0KB]..........................................................................................................1867 Failure Code [DXE4KA]..........................................................................................................1869 Failure Code [DXE4KB]..........................................................................................................1871 Failure Code [DXE4KY]..........................................................................................................1873 Failure Code [DXE5KA]..........................................................................................................1874 Failure Code [DXE5KB]..........................................................................................................1876 Failure Code [DXE6KA]..........................................................................................................1878 Failure Code [DXE6KB]..........................................................................................................1880 Failure Code [DXE7KA]..........................................................................................................1882 Failure Code [DXE7KB]..........................................................................................................1884 Failure Code [DXE7KY]..........................................................................................................1886 Failure Code [DXE8KA]..........................................................................................................1888 Failure Code [DXE8KB]..........................................................................................................1890 Failure Code [DXE8KY]..........................................................................................................1892 Failure Code [DXE9KA]..........................................................................................................1894 Failure Code [DXE9KB]..........................................................................................................1896 Failure Code [DXE9KY]..........................................................................................................1898 Failure Code [DXEAKA]..........................................................................................................1900 Failure Code [DXEAKB]..........................................................................................................1902 Failure Code [DXEAKY]..........................................................................................................1904 Failure Code [DXEKKA]..........................................................................................................1906 Failure Code [DXEKKB]..........................................................................................................1908 Failure Code [DXEKKY]..........................................................................................................1910 Failure Code [DXELKA]..........................................................................................................1912 Failure Code [DXELKB]..........................................................................................................1914 Failure Code [DXELKY]..........................................................................................................1916 Failure Code [DY20KA]..........................................................................................................1918 Failure Code [DY20MA]..........................................................................................................1920 Failure Code [DY2CKB]..........................................................................................................1922 Failure Code [DY2DKB]..........................................................................................................1924 Failure Code [DY2EKB]..........................................................................................................1926 Failure Code [F311KA]..........................................................................................................1928 Failure Code [F311KB]..........................................................................................................1930 Failure Code [F312KA]..........................................................................................................1932 Failure Code [F312KB]..........................................................................................................1934 Failure Code [F313KA]..........................................................................................................1936 Failure Code [F313KB]..........................................................................................................1938 Failure Code [F314KA]..........................................................................................................1941 Failure Code [F314KB]..........................................................................................................1943 Failure Code [F315KB]..........................................................................................................1945 Failure Code [F315KY]..........................................................................................................1947 Failure Code [F316KB]..........................................................................................................1949 Failure Code [F316KY]..........................................................................................................1951 Failure Code [F318KB]..........................................................................................................1953 Failure Code [F318KY]..........................................................................................................1956 Failure Code [F31AKB]..........................................................................................................1958 Failure Code [F31AKY]..........................................................................................................1960 Failure Code [F31BKB]..........................................................................................................1962 Failure Code [F31BKY]..........................................................................................................1964 Failure Code [F31CKB]..........................................................................................................1966 Failure Code [F31CKY]..........................................................................................................1968 Failure Code [F31DKB]..........................................................................................................1970 Failure Code [F31DKY]..........................................................................................................1972 Failure Code [F31EKB]..........................................................................................................1974 Failure Code [F31EKY]..........................................................................................................1976 Failure Code [GA00NS]..........................................................................................................1978 Failure Code [GA01KA]..........................................................................................................1979 Failure Code [GA01KB]..........................................................................................................1981 Failure Code [GA02KZ]..........................................................................................................1983 Failure Code [GA04KG]..........................................................................................................1986 Failure Code [GA05KG]..........................................................................................................1989 Failure Code [GA05KP]..........................................................................................................1992 Failure Code [GA06KZ]..........................................................................................................1996 Failure Code [GA08KG]..........................................................................................................1997 Failure Code [GA09KG]..........................................................................................................2005 Failure Code [GA09KP]..........................................................................................................2013 Failure Code [GA0AKZ]..........................................................................................................2014 Failure Code [GA0BKZ]..........................................................................................................2015 Failure Code [GA10MA] (Machine with KOMTRAX Terminal)..........................................................................2022 Failure Code [GA10MA] (Machine with Gateway Function Controller)...............................................................2028 Failure Code [GA10MC]..........................................................................................................2034 Failure Code [GA12NK]..........................................................................................................2035 Failure Code [GA13KP]..........................................................................................................2042 Failure Code [GA13KY]..........................................................................................................2044 Failure Code [GA15KZ]..........................................................................................................2045 Failure Code [GA17KR]..........................................................................................................2053 Failure Code [GA17MB]..........................................................................................................2054 Failure Code [GA18MC]..........................................................................................................2055 Failure Code [GA19KR]..........................................................................................................2060 Failure Code [GA19KT]..........................................................................................................2061 Failure Code [GA1BMA]..........................................................................................................2062 Failure Code [GA1FKR]..........................................................................................................2064 Failure Code [GA1FMA]..........................................................................................................2065 Failure Code [GA1GKR]..........................................................................................................2068 Failure Code [GA1GKT]..........................................................................................................2069 Failure Code [GA1GMB]..........................................................................................................2070 Failure Code [GA1HKZ]..........................................................................................................2071 Failure Code [GA1JKZ]..........................................................................................................2072 Failure Code [GA1KKZ]..........................................................................................................2073 Failure Code [GA1LKZ]..........................................................................................................2074 Failure Code [GA1MKZ]..........................................................................................................2075 Failure Code [GA1NNS]..........................................................................................................2076 Failure Code [GA1SFS]..........................................................................................................2077 Failure Code [GA1SMC]..........................................................................................................2078 Failure Code [GA1TKP]..........................................................................................................2079 Failure Code [GA1TNS]..........................................................................................................2083 Failure Code [GA1UKZ]..........................................................................................................2086 Failure Code [GA1VFS]..........................................................................................................2089 Failure Code [GA1VMC]..........................................................................................................2090 Failure Code [GA1XKZ]..........................................................................................................2092 Failure Code [GA1YNS]..........................................................................................................2093 Failure Code [GA1ZKZ]..........................................................................................................2094 Failure Code [GA1ZNS]..........................................................................................................2095 Failure Code [GA22NS]..........................................................................................................2096 Failure Code [GA23KZ]..........................................................................................................2097 Failure Code [GA24KZ]..........................................................................................................2098 Failure Code [GA25MA]..........................................................................................................2099 Failure Code [GA25NS]..........................................................................................................2104 Failure Code [GA26MA]..........................................................................................................2105 Failure Code [GA26NS]..........................................................................................................2110 Failure Code [GA27KZ]..........................................................................................................2111 Failure Code [GA2QKR] (Machine with KOMTRAX Terminal)..........................................................................2112 Failure Code [GA2QKR] (Machine with Gateway Function Controller)...............................................................2119 Failure Code [GA2RKR] (Machine with KOMTRAX Terminal)..........................................................................2126 Failure Code [GA2RKR] (Machine with Gateway Function Controller)...............................................................2131 Failure Code [GA32KK]..........................................................................................................2136 Failure Code [GA60KZ]..........................................................................................................2138 Failure Code [GA60MC]..........................................................................................................2143 Failure Code [GA60N1]..........................................................................................................2145 Failure Code [GA61KZ]..........................................................................................................2146 Failure Code [GA61NS]..........................................................................................................2148 Failure Code [GA62KY]..........................................................................................................2149 Failure Code [GA62KZ]..........................................................................................................2153 Failure Code [GA62MA]..........................................................................................................2157 Failure Code [GA62MC]..........................................................................................................2158 Failure Code [GA63KY]..........................................................................................................2159 Failure Code [GA63KZ]..........................................................................................................2163 Failure Code [GA63MA]..........................................................................................................2167 Failure Code [GA63MC]..........................................................................................................2168 Failure Code [GA64KY]..........................................................................................................2169 Failure Code [GA64KZ]..........................................................................................................2173 Failure Code [GA64MA]..........................................................................................................2177 Failure Code [GA64MC]..........................................................................................................2178 Failure Code [GA70KB]..........................................................................................................2179 Failure Code [GA70MD]..........................................................................................................2182 Failure Code [GA70N1]..........................................................................................................2184 Failure Code [GA70NS]..........................................................................................................2185 Failure Code [GA71KZ]..........................................................................................................2186 Failure Code [GA72MA]..........................................................................................................2188 Failure Code [GA72MC]..........................................................................................................2190 Failure Code [GA81KZ]..........................................................................................................2192 Failure Code [GAA0KB]..........................................................................................................2195 Failure Code [GAA2KB]..........................................................................................................2197 Failure Code [GAA6KP]..........................................................................................................2199 Failure Code [GAA6KY]..........................................................................................................2201 Failure Code [GACLKA]..........................................................................................................2203 Failure Code [GACLKB]..........................................................................................................2205 Troubleshooting of Electrical System (E-Mode)......................................................................................2207 E-1 Engine Does Not Start (Engine Does Not Crank)..............................................................................2207 E-2 Manual Preheating System Does Not Operate..................................................................................2213 E-3 Automatic Preheating System Does Not Operate...............................................................................2216 E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On......................................................2218 E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing...............................................2220 E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow..........2223 E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow....2224 E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation...................................................2225 E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs......................................................2226 E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs.........................................................2227 E-11 Charge Level Monitor Comes On in Red While Engine is in Operation.........................................................2228 E-12 Fuel Level Monitor Comes On in Red While Engine Runs......................................................................2229 E-13 Water Separator Monitor Comes On in Red While Engine Runs.................................................................2230 E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation...........................................2231 E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation..................................................2232 E-16 Hybrid Temperature Monitor Comes On in Red Engine Runs....................................................................2233 E-17 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation............................................2235 E-18 Fuel Gauge Display Does Not Move from Minimum or Maximum..................................................................2236 E-19 Display of Fuel Gauge is Different from Actual Fuel Level.................................................................2238 E-20 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum...................................................2239 E-21 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature.........................................2240 E-22 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum.............................................2241 E-23 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature.......................................2243 E-24 Hybrid Temperature Gauge Does Not Move from Minimum or Maximum............................................................2244 E-25 Hybrid Temperature Gauge Shows Incorrect Temperature (Shows Neither Minimum Nor Maximum)..................................2246 E-26 Some Areas of Machine Monitor Screen are Not Shown........................................................................2248 E-27 Function Switch Does Not Operate..........................................................................................2249 E-28 Automatic Warm-up System Does Not Work (in Cold Weather)..................................................................2250 E-29 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out....................2251 E-30 Auto-Decelerator is Not Operated or Canceled with Lever...................................................................2252 E-31 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown..........................................2253 E-32 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed.........................................2254 E-33 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change................................................2255 E-34 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change...............................................2256 E-35 Alarm Buzzer Cannot be Canceled...........................................................................................2258 E-36 Service Meter is Not Shown, While Starting Switch is in OFF Position......................................................2259 E-37 Service Mode Cannot be Selected...........................................................................................2260 E-38 All of Work Equipment, Swing, and Travel Mechanism Do Not Move............................................................2261 E-39 All Work Equipment, Swing and Travel Do Not Lock..........................................................................2264 E-40 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing............................................2266 E-41 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate............................2269 E-42 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show...................................2271 E-43 One-Touch Power Maximizing Function is Not Cancelled......................................................................2273 E-44 Alarm Does Not Sound During Travel........................................................................................2274 E-45 Alarm Does Not Stop When Machine Stops....................................................................................2276 E-46 Horn Does Not Sound.......................................................................................................2277 E-47 Horn Does Not Stop........................................................................................................2280 E-48 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out...................................................2282 E-49 When Wiper Switch is Operated, Windshield Wiper Does Not Operate..........................................................2283 E-50 Window Washer Does Not Operate When Window Washer Switch is Operated......................................................2285 E-51 "Boom RAISE" is Not Shown Correctly with Monitoring Function..............................................................2286 E-52 "Boom LOWER" is Not Shown Correctly with Monitoring Function..............................................................2287 E-53 "Arm OUT" is Not Shown Correctly with Monitoring Function.................................................................2288 E-54 "Arm IN" is Not Shown Correctly with Monitoring Function..................................................................2289 E-55 "Bucket DUMP" is Not Shown Correctly with Monitoring Function.............................................................2290 E-56 "Bucket CURL" is Not Shown Correctly with Monitoring Function.............................................................2291 E-57 "Swing" is Not Shown Correctly with Monitoring Function...................................................................2292 E-58 "Travel" is Not Shown Correctly with Monitoring Function..................................................................2293 E-59 Service is Not Shown Correctly with Monitoring Function...................................................................2294 E-60 Attachment Hydraulic Circuit Cannot be Changed............................................................................2296 E-61 KOMTRAX System Does Not Operate Correctly.................................................................................2297 Troubleshooting for Hydraulic and Mechanical Systems (H Mode)......................................................................2298 Information Shown in Troubleshooting Table (H-Mode)............................................................................2298 System Chart of Hydraulic and Mechanical Systems...............................................................................2299 Failure Mode and Cause Table...................................................................................................2301 H-1 All Work Equipment, Swing and Travel Do Not Work...........................................................................2310 H-2 All Work Equipment, Swing and Travel Lack Speed and Power..................................................................2311 H-3 Fine Control Performance or Response is Unsatisfactory.....................................................................2313 H-4 Unusual Noise is Heard from Around Hydraulic Pump..........................................................................2314 H-5 Engine Speed Drops Largely or Engine Stops.................................................................................2315 H-6 Speed or Power of Boom is Low..............................................................................................2317 H-7 Arm Speed or Power is Low..................................................................................................2321 H-8 Bucket Speed or Power is Low...............................................................................................2326 H-9 Work Equipment Does Not Move in Single Operation...........................................................................2329 H-10 Hydraulic Drift of Boom is Large..........................................................................................2330 H-11 Hydraulic Drift of Arm is Large...........................................................................................2332 H-12 Hydraulic Drift of Bucket is Large........................................................................................2334 H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves..........................................2335 H-14 Time Lag of Work Equipment is Large.......................................................................................2336 H-15 One-Touch Power Maximizing Function Does Not Operate......................................................................2338 H-16 Attachment Circuit Cannot be Changed......................................................................................2339 H-17 Oil Flow in Attachment Circuit Cannot be Changed..........................................................................2340 H-18 The Set Pressure of Attachment is Not Output..............................................................................2341 H-19 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower.......................................2342 H-20 Machine Does Not Travel Straight..........................................................................................2343 H-21 Machine is Not Steered Correctly or Steering Power is Low.................................................................2346 H-22 Travel Speed is Low.......................................................................................................2349 H-23 One of Tracks Does Not Run................................................................................................2351 H-24 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast.........................................................2352 H-25 Upper Structure Does Not Swing to Right and Left..........................................................................2353 H-26 Upper Structure Swings Only to Right or Left..............................................................................2354 H-27 Swing Acceleration or Swing Speed is Low in Right and Left Directions.....................................................2355 H-28 Swing Acceleration or Swing Speed is Low in Only One Direction............................................................2356 H-29 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)..........................................2357 H-30 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction)......................................2358 H-31 Shock is Large When Upper Structure Stops Swing Operation.................................................................2359 H-32 Large Unusual Noise is Heard When Upper Structure Stops Swing Operation...................................................2360 H-33 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied)....................................................2361 H-34 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)...................................................2362 H-35 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate)...............................................................2363 H-36 Unusual Noise is Heard from Around Fan....................................................................................2364 Troubleshooting of Engine (S-Mode).................................................................................................2365 Information Shown in Troubleshooting Table (S-Mode)............................................................................2365 S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position.....................................................2366 S-2 Engine Cranks but No Exhaust Smoke Comes Out...............................................................................2367 S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)...................................2368 S-4 Engine Startability is Unsatisfactory......................................................................................2370 S-5 Engine Does Not Pick Up Smoothly...........................................................................................2372 S-6 Engine Stops During Operation..............................................................................................2374 S-7 Engine Runs Rough or is Not Stable.........................................................................................2376 S-8 Engine Lacks Power.........................................................................................................2377 S-9 Exhaust Smoke is Black.....................................................................................................2379 S-10 Engine Oil Consumption is Excessive.......................................................................................2381 S-11 Oil Becomes Dirty Quickly.................................................................................................2382 S-12 Fuel Consumption is Excessive.............................................................................................2383 S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant......................................................................2384 S-14 Oil Pressure Drops........................................................................................................2385 S-15 Fuel Mixes Into Engine Oil................................................................................................2387 S-16 Water Mixes Into Engine Oil (Milky).......................................................................................2388 S-17 Coolant Temperature Increases Too High (Overheating)......................................................................2389 S-18 Unusual Noise is Heard....................................................................................................2390 S-19 Vibration is Excessive....................................................................................................2391 S-20 Air Cannot be Bled from Fuel Circuit......................................................................................2392 S-21 Active Regeneration is Done Frequently....................................................................................2393 S-22 Active Regeneration Continues Long........................................................................................2394 S-23 White Smoke is Exhausted During Active Regeneration.......................................................................2395 S-24 DEF Consumption is Excessive..............................................................................................2396 S-25 There is Unusual Smell (Irritating Odor)..................................................................................2398 S-26 Foreign Materials Enter DEF (DEF Increases)...............................................................................2399 Troubleshooting for Hybrid Systems (Y Mode)........................................................................................2400 Precautions When You Use Hybrid Systems........................................................................................2400 Y-1 Hybrid Monitor Does Not Go Out.............................................................................................2401 Y-2 Upper Structure Does Not Swing to Right and Left...........................................................................2403 Y-3 Upper Structure Swings Only to the Right or Left...........................................................................2404 Y-4 Swing Acceleration Performance is Unsatisfactory or Swing Speed is Low in Both Directions (Right and Left).................2405 Y-5 Swing Acceleration Performance is Unsatisfactory or Swing Speed is Low in Only One Direction...............................2406 Y-6 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)...........................................2407 Y-7 Upper Structure Overruns Too Much When It Stops Swing Operation (Right or Left)............................................2408 Y-8 Shock is Large When Upper Structure Stops Swing Operation..................................................................2409 Y-9 There is Large Unusual Noise When It Stops Swing Operation.................................................................2410 Y-10 Swing Drift on a Slope is Large (While Parking Brake is Applied)..........................................................2411 Y-11 Swing Drift on a Slope is Large (While Parking Brake is Released).........................................................2412 Y-12 Electric Swing Motor Temperature Increases Abnormally.....................................................................2413 Y-13 Motor-Generator Temperature Increases Abnormally..........................................................................2416 Y-14 Inverter Temperature Increases Abnormally.................................................................................2418 Y-15 Capacitor Temperature Increases Abnormally................................................................................2420 50 Disassembly and Assembly............................................................................................................2423 Table of Contents..................................................................................................................2424 Precautions Before Work............................................................................................................2429 Related Information on Disassembly and Assembly....................................................................................2430 How to Read This Manual........................................................................................................2430 Coating Materials List.........................................................................................................2431 Special Tool List..............................................................................................................2436 Sketches of Special Tools......................................................................................................2451 Engine and Cooling System..........................................................................................................2456 Remove and Install Supply Pump Assembly........................................................................................2456 How to Remove Supply Pump Assembly.........................................................................................2456 How to Install Supply Pump Assembly........................................................................................2460 Remove and Install Injector Assembly...........................................................................................2464 How to Remove Injector Assembly............................................................................................2464 How to Install Injector Assembly...........................................................................................2467 Remove and Install Cylinder Head Assembly......................................................................................2473 How to Remove Cylinder Head Assembly.......................................................................................2473 How to Install Cylinder Head Assembly......................................................................................2483 Remove and Install EGR Valve Assembly..........................................................................................2500 How to Remove EGR Valve Assembly...........................................................................................2500 How to Install EGR Valve Assembly..........................................................................................2501 Remove and Install EGR Cooler Assembly.........................................................................................2503 How to Remove EGR Cooler Assembly..........................................................................................2503 How to Install EGR Cooler Assembly.........................................................................................2506 Remove and Install Starter Assembly............................................................................................2509 How to Remove Starting Motor Assembly......................................................................................2509 How to Install Starting Motor Assembly.....................................................................................2512 Remove and Install Alternator Belt.............................................................................................2515 How to Remove Alternator Belt..............................................................................................2515 How to Install Alternator Belt.............................................................................................2517 Remove and Install Radiator Assembly...........................................................................................2519 How to Remove Radiator Assembly............................................................................................2519 How to Install Radiator Assembly...........................................................................................2523 Remove and Install Hydraulic Oil Cooler Assembly...............................................................................2527 How to Remove Hydraulic Oil Cooler Assembly................................................................................2527 How to Install Hydraulic Oil Cooler Assembly...............................................................................2530 Remove and Install Aftercooler Assembly........................................................................................2533 How to Remove Aftercooler Assembly.........................................................................................2533 How to Install Aftercooler Assembly........................................................................................2536 Remove and Install Fan Clutch Assembly.........................................................................................2540 Remove Fan Clutch Assembly.................................................................................................2540 Install Fan Clutch Assembly................................................................................................2541 Remove and Install Fan.........................................................................................................2544 How to Remove Fan..........................................................................................................2544 How to Install Fan.........................................................................................................2544 Remove and Install Engine, Motor-Generator, and Main Pump Assembly.............................................................2545 How to Remove Engine, Motor-Generator, and Main Pump Assembly..............................................................2545 How to Install Engine, Motor-Generator, and Main Pump Assembly.............................................................2566 Remove and Install Engine Front Oil Seal.......................................................................................2589 How to Remove Engine Front Oil Seal........................................................................................2589 How to Install Engine Front Oil Seal.......................................................................................2592 Remove and Install Engine Rear Oil Seal........................................................................................2596 How to Remove Engine Rear Oil Seal.........................................................................................2596 How to Install Engine Rear Oil Seal........................................................................................2597 Remove and Install Engine Hood Assembly........................................................................................2601 How to Remove Engine Hood Assembly.........................................................................................2601 How to Install Engine Hood Assembly........................................................................................2603 Remove and Install KDOC Assembly...............................................................................................2606 How to Remove KDOC Assembly................................................................................................2606 How to Install KDOC Assembly...............................................................................................2608 Remove and Install KDOC and SCR Assembly.......................................................................................2611 How to Remove KDOC and SCR Assembly........................................................................................2612 How to Install KDOC and SCR Assembly.......................................................................................2617 Remove and Install Bellows Pipe Assembly.......................................................................................2622 How to Remove Bellows Pipe Assembly........................................................................................2622 How to Install Bellows Pipe Assembly.......................................................................................2625 Remove and Install Fuel Tank Assembly..........................................................................................2630 How to Remove Fuel Tank Assembly...........................................................................................2630 How to Install Fuel Tank Assembly..........................................................................................2634 Remove and Install DEF Tank Assembly...........................................................................................2638 How to Remove DEF Tank Assembly............................................................................................2638 How to Install DEF Tank Assembly...........................................................................................2645 Remove and Install DEF Tank Sensor Flange Assembly.............................................................................2650 How to Remove DEF Tank Sensor Flange Assembly..............................................................................2650 How to Install DEF Tank Sensor Flange Assembly.............................................................................2651 Remove and Install DEF Tank Sensor.............................................................................................2653 How to Remove DEF Tank Sensor..............................................................................................2653 How to Install DEF Tank Sensor.............................................................................................2654 Remove and Install DEF Tank Strainer...........................................................................................2657 How to Remove DEF Tank Strainer............................................................................................2657 How to Install DEF Tank Strainer...........................................................................................2657 Remove and Install DEF Tank Filler Port Filter.................................................................................2658 How to Remove DEF Tank Filler Port Filter..................................................................................2658 How to Install DEF Tank Filler Port Filter.................................................................................2660 Remove and Install SCR Assembly................................................................................................2663 How to Remove SCR Assembly.................................................................................................2663 How to Install SCR Assembly................................................................................................2665 Remove and Install KCCV Assembly...............................................................................................2669 How to Remove KCCV Assembly................................................................................................2669 How to Install KCCV Assembly...............................................................................................2670 Remove and Install DEF Mixing Tube.............................................................................................2673 How to Remove DEF Mixing Tube..............................................................................................2673 How to Install DEF Mixing Tube.............................................................................................2679 Remove and Install DEF Injector................................................................................................2686 How to Remove DEF Injector.................................................................................................2686 How to Install DEF Injector................................................................................................2690 Remove and Install DEF Pump....................................................................................................2694 How to Remove DEF Pump.....................................................................................................2694 How to Install DEF Pump....................................................................................................2697 Remove and Install DEF Hose....................................................................................................2700 How to Remove DEF Hose.....................................................................................................2701 How to Install DEF Hose....................................................................................................2715 Remove and Install Air Cleaner Assembly........................................................................................2727 How to Remove Air Cleaner Assembly.........................................................................................2727 How to Install Air Cleaner Assembly........................................................................................2730 Remove and Install Air Conditioner Compressor Assembly.........................................................................2734 How to Remove Air Conditioner Compressor Assembly..........................................................................2734 How to Install Air Conditioner Compressor Assembly.........................................................................2736 Remove and Install Air Conditioner Condenser Assembly..........................................................................2739 How to Remove Air Conditioner Condenser Assembly...........................................................................2739 How to Install Air Conditioner Condenser Assembly..........................................................................2740 Hybrid System......................................................................................................................2743 Remove and Install Hybrid Radiator Assembly....................................................................................2743 How to Remove Hybrid Radiator Assembly.....................................................................................2743 How to Install Hybrid Radiator Assembly....................................................................................2746 Remove and Install Hybrid Water Pump Assembly..................................................................................2751 How to Remove Hybrid Water Pump Assembly...................................................................................2751 How to Install Hybrid Water Pump Assembly..................................................................................2755 Remove and Install Inverter Assembly...........................................................................................2759 How to Remove Inverter Assembly............................................................................................2759 How to Install Inverter Assembly...........................................................................................2763 Remove and Install Inverter and Capacitor Assembly.............................................................................2770 How to Remove Inverter and Capacitor Assembly..............................................................................2770 How to Install Inverter and Capacitor Assembly.............................................................................2779 Remove and Install Motor-Generator and Housing Assembly........................................................................2790 How to Remove Motor-Generator and Housing Assembly.........................................................................2790 How to Install Motor-Generator and Housing Assembly........................................................................2798 Remove and Install Tandem Pump Assembly........................................................................................2809 How to Remove Tandem Pump Assembly.........................................................................................2809 How to Remove Tandem Pump Assembly.........................................................................................2810 Remove and Install Electric Swing Motor........................................................................................2812 How to Remove Electric Swing Motor.........................................................................................2812 How to Install Electric Swing Motor........................................................................................2816 Power Train........................................................................................................................2822 Remove and Install Travel Motor and Final Drive Assembly.......................................................................2822 How to Remove Travel Motor and Final Drive Assembly........................................................................2822 How to Install Travel Motor and Final Drive Assembly.......................................................................2823 Disassemble and Assemble Final Drive Assembly..................................................................................2825 How to Disassemble Final Drive Assembly....................................................................................2825 How to Assemble Final Drive Assembly.......................................................................................2829 Remove and Install Electric Swing Motor and Swing Machinery Assembly...........................................................2838 How to Remove Electric Swing Motor and Swing Machinery Assembly............................................................2838 How to Install Electric Swing Motor and Swing Machinery Assembly...........................................................2844 Disassemble and Assemble Swing Machinery Assembly..............................................................................2850 How to Disassemble Swing Machinery Assembly................................................................................2851 How to Assemble Swing Machinery Assembly...................................................................................2859 Remove and Install Swing Circle Assembly.......................................................................................2870 How to Remove Swing Circle Assembly........................................................................................2870 How to Install Swing Circle Assembly.......................................................................................2870 Undercarriage and Frame............................................................................................................2872 Separate and Connect Track Assembly............................................................................................2872 How to Separate Track Assembly.............................................................................................2872 How to Install Track Assembly..............................................................................................2874 Remove and Install Sprocket....................................................................................................2877 How to Remove Sprocket.....................................................................................................2877 How to Install Sprocket....................................................................................................2877 Remove and Install Idler and Idler Cushion Assembly............................................................................2879 How to Remove Idler and Idler Cushion Assembly.............................................................................2879 How to Install Idler and Idler Cushion Assembly............................................................................2880 Disassemble and Assemble Idler Assembly........................................................................................2881 How to Disassemble Idler Assembly..........................................................................................2881 How to Assemble Idler Assembly.............................................................................................2882 Disassemble and Assemble Idler Cushion Assembly................................................................................2886 How to Disassemble Idler Cushion Assembly..................................................................................2887 How to Assemble Idler Cushion Assembly.....................................................................................2887 Disassemble and Assemble Track Roller Assembly.................................................................................2889 How to Disassemble Track Roller Assembly...................................................................................2889 How to Assemble Track Roller Assembly......................................................................................2890 Disassemble and Assemble Carrier Roller Assembly...............................................................................2892 How to Disassemble Carrier Roller Assembly.................................................................................2892 How to Assemble Carrier Roller Assembly....................................................................................2894 Remove and Install Revolving Frame Assembly....................................................................................2896 How to Remove Revolving Frame Assembly.....................................................................................2896 How to Install Revolving Frame Assembly....................................................................................2898 Remove and Install Counterweight Assembly......................................................................................2900 How to Remove Counterweight Assembly.......................................................................................2900 How to Install Counterweight Assembly......................................................................................2901 Hydraulic System...................................................................................................................2904 Remove and Install Center Swivel Joint Assembly................................................................................2904 How to Remove Center Swivel Joint Assembly.................................................................................2904 How to Install Center Swivel Joint Assembly................................................................................2906 Disassemble and Assemble Center Swivel Joint Assembly..........................................................................2909 How to Disassemble Center Swivel Joint Assembly............................................................................2909 How to Assemble Center Swivel Joint Assembly...............................................................................2910 Remove and Install Hydraulic Tank Assembly.....................................................................................2912 How to Remove Hydraulic Tank Assembly......................................................................................2912 How to Install Hydraulic Tank Assembly.....................................................................................2914 Remove and Install Main Pump Assembly..........................................................................................2918 How to Remove Main Pump Assembly...........................................................................................2918 How to Install Main Pump Assembly..........................................................................................2924 Remove and Install Control Valve Assembly......................................................................................2932 How to Remove Control Valve Assembly.......................................................................................2932 How to Install Control Valve Assembly......................................................................................2943 Disassemble and Assemble Control Valve Assembly................................................................................2955 How to Replace Pressure Compensation Valve Seal Ring.......................................................................2955 How to Assemble Control Valve Assembly.....................................................................................2956 Disassemble and Assemble Work Equipment PPC Valve Assembly.....................................................................2961 How to Disassemble Work Equipment PPC Valve Assembly.......................................................................2961 How to Assemble Work Equipment PPC Valve Assembly..........................................................................2961 Disassemble and Assemble Travel PPC Valve Assembly.............................................................................2963 How to Disassemble Travel PPC Valve Assembly...............................................................................2963 How to Assemble Travel PPC Valve Assembly..................................................................................2964 Work Equipment.....................................................................................................................2966 Remove and Install Work Equipment Assembly.....................................................................................2966 How to Remove Work Equipment Assembly......................................................................................2966 How to Install Work Equipment Assembly.....................................................................................2970 Remove and Install Boom Anti-drop Valve Assembly...............................................................................2975 How to Remove Boom Anti-drop Valve Assembly................................................................................2975 How to Install Boom Anti-drop Valve Assembly...............................................................................2977 Remove and Install Arm Anti-Drop Valve Assembly................................................................................2978 How to Remove Arm Anti-Drop Valve Assembly.................................................................................2978 How to Install Arm Anti-Drop Valve Assembly................................................................................2980 Disassemble and Assemble Anti-Drop Valve Assembly..............................................................................2981 How to Disassemble Anti-Drop Valve Assembly................................................................................2981 How to Assemble Anti-Drop Valve Assembly...................................................................................2981 Disassemble and Assemble Work Equipment Cylinder Assembly......................................................................2982 How to Disassemble Work Equipment Cylinder Assembly........................................................................2982 How to Assemble Work Equipment Cylinder Assembly...........................................................................2985 CAB Related Parts..................................................................................................................2991 Remove and Install Operator Cab Assembly.......................................................................................2991 How to Remove Operator Cab Assembly........................................................................................2991 How to Install Operator Cab Assembly.......................................................................................2999 Remove and Install Operator Cab Glass (Adhered Glass)..........................................................................3007 How to Remove Operator Cab Glass (Adhered Glass)...........................................................................3009 How to Install Operator Cab Glass (Adhered Glass)..........................................................................3009 Remove and Install Front Window Assembly.......................................................................................3019 How to Remove Front Window Assembly........................................................................................3019 How to Install Front Window Assembly.......................................................................................3022 Remove and Install Floor Frame Assembly........................................................................................3028 How to Remove Floor Frame Assembly.........................................................................................3028 How to Install Floor Frame Assembly........................................................................................3032 Remove and Install Air Conditioner Unit Assembly...............................................................................3037 How to Remove Air Conditioner Unit Assembly................................................................................3037 How to Install Air Conditioner Unit Assembly...............................................................................3042 Remove and Install Operator Seat...............................................................................................3048 How to Remove Operator Seat................................................................................................3048 How to Install Operator Seat...............................................................................................3050 How to Remove and Install Seat Belt............................................................................................3053 How to Remove Seat Belt....................................................................................................3053 How to Install Seatbelt....................................................................................................3053 Remove and Install Work Equipment Control Lever Assembly.......................................................................3055 How to Remove Work Equipment Control Lever Assembly........................................................................3055 How to Install Work Equipment Control Lever Assembly.......................................................................3061 Remove and Install Front Wiper Assembly........................................................................................3070 How to Remove Front Wiper Assembly.........................................................................................3070 How to Install Front Wiper Assembly........................................................................................3075 Electrical System..................................................................................................................3084 Remove and Install Engine Controller Assembly..................................................................................3084 How to Remove Engine Controller Assembly...................................................................................3084 How to Install Engine Controller Assembly..................................................................................3086 Remove and Install Pump Controller Assembly....................................................................................3089 How to Remove Pump Controller Assembly.....................................................................................3089 How to Install Pump Controller Assembly....................................................................................3092 Remove and Install KomVision Controller Assembly...............................................................................3095 How to Remove KomVision Controller Assembly................................................................................3095 How to Install KomVision Controller Assembly...............................................................................3096 Remove and Install Machine Monitor Assembly....................................................................................3097 How to Remove Machine Monitor Assembly.....................................................................................3097 How to Install Machine Monitor Assembly....................................................................................3099 Remove and Install Pump Swash Plate Sensor.....................................................................................3103 How to Remove Pump Swash Plate Sensor......................................................................................3103 How to Install Pump Swash Plate Sensor.....................................................................................3104 Remove and Install Mass Air Flow and Temperature Sensor........................................................................3107 How to Remove Mass Air Flow and Temperature Sensor.........................................................................3107 How to Install Mass Air Flow and Temperature Sensor........................................................................3109 Remove and Install KCCV Crankcase Pressure Sensor..............................................................................3112 How to Remove KCCV Crankcase Pressure Sensor...............................................................................3112 How to Install KCCV Crankcase Pressure Sensor..............................................................................3113 Remove and Install SCR Temperature Sensor......................................................................................3115 How to Remove SCR Temperature Sensor.......................................................................................3115 How to Install SCR Temperature Sensor......................................................................................3116 Remove and Install KomVision Camera............................................................................................3118 How to Remove KomVision Camera.............................................................................................3118 How to Install KomVision Camera............................................................................................3119 Remove and Install KOMTRAX Terminal Assembly...................................................................................3121 How to Remove KOMTRAX Terminal Assembly....................................................................................3121 How to Install KOMTRAX Terminal Assembly...................................................................................3122 Remove and Install Gateway Function Controller Assembly........................................................................3124 How to Remove Gateway Function Controller Assembly.........................................................................3124 How to Install Gateway Function Controller Assembly........................................................................3129 Remove and Install Communication Terminal Wiring Harness.......................................................................3134 How to Remove Communication Terminal Wiring Harness........................................................................3134 How to Install Communication Terminal Wiring Harness.......................................................................3142 Remove and Install Communication Terminal......................................................................................3151 How to Remove Communication Terminal.......................................................................................3151 How to Install Communication Terminal......................................................................................3153 60 Maintenance Standard................................................................................................................3157 Table of Contents..................................................................................................................3158 Engine and Cooling System..........................................................................................................3159 Maintenance Standard for Engine Mount..........................................................................................3159 Maintenance Standard for Cooling System........................................................................................3160 Power Train........................................................................................................................3162 Maintenance Standard for Swing Circle..........................................................................................3162 Maintenance Standard for Swing Machinery with Swing Parking Brake..............................................................3163 Maintenance Standard for Final Drive...........................................................................................3165 Maintenance Standard for Sprocket..............................................................................................3167 Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing.............................................................3168 Undercarriage and Frame............................................................................................................3169 Maintenance Standard for Track Frame and Idler Cushion.........................................................................3169 Maintenance Standard for Idler.................................................................................................3170 Maintenance Standard for Track Roller..........................................................................................3172 Maintenance Standard for Carrier Roller........................................................................................3173 Maintenance Standard for Track Shoes...........................................................................................3174 Maintenance Standard for Triple Shoes..........................................................................................3177 Maintenance Standard for Swamp Shoes...........................................................................................3178 Maintenance Standard for Road Liner............................................................................................3179 Hydraulic System...................................................................................................................3180 Maintenance Standard for Hydraulic Tank........................................................................................3180 Maintenance Standard for Main Pump.............................................................................................3181 Maintenance Standard for LS-EPC Valve..........................................................................................3182 Maintenance Standard for PC-EPC Valve..........................................................................................3183 Maintenance Standard for Travel Motor..........................................................................................3184 Maintenance Standard for Control Valve.........................................................................................3187 Maintenance Standard for Work Equipment and Swing PPC Valve....................................................................3197 Maintenance Standard for Travel PPC Valve......................................................................................3200 Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve)........................................................3202 Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve........................................................3204 Maintenance Standard for 2nd-Line Attachment PPC Valve.........................................................................3205 Maintenance Standard for Solenoid Valve........................................................................................3207 Maintenance Standard for Bucket DUMP Operation Lock Solenoid Valve.............................................................3208 Maintenance Standard for Attachment Circuit Selector Valve (For High Pressure).................................................3209 Maintenance Standard for Attachment Circuit Selector Valve (For Low Pressure)..................................................3210 Maintenance Standard for Center Swivel Joint...................................................................................3211 Work Equipment.....................................................................................................................3212 Maintenance Standard for Work Equipment Linkage................................................................................3212 Dimensions of Arm..........................................................................................................3217 Dimensions of Bucket.......................................................................................................3219 Maintenance Standard for Boom Cylinder (Large Diameter Piston).................................................................3221 Maintenance Standard for Arm Cylinder..........................................................................................3222 Maintenance Standard for Bucket Cylinder.......................................................................................3223 80 Appendix............................................................................................................................3225 Table of Contents..................................................................................................................3226 Precautions Before Work............................................................................................................3228 Air Conditioner System.............................................................................................................3229 Precautions for Refrigerant....................................................................................................3229 Air Conditioner Component......................................................................................................3230 Specifications of Air Conditioner..............................................................................................3232 Structure and Function of Refrigeration Cycle..................................................................................3233 Outline of Refrigeration Cycle.................................................................................................3234 Component Parts of Air Conditioner System..........................................................................................3236 Air Conditioner Unit...........................................................................................................3236 Configuration Diagram of Air Conditioner Unit..............................................................................3236 Function of Air Conditioner Unit...........................................................................................3238 Component Parts of Air Conditioner Unit........................................................................................3240 Function of Evaporator as Air Conditioner Unit Component...................................................................3241 Function of Heater Core as Air Conditioner Unit Component..................................................................3241 Function of Evaporator Temperature Sensor as Air Conditioner Unit Component................................................3241 Function of Servo Motor as Air Conditioner Unit Component..................................................................3241 Structure of Expansion Valve as Air Conditioner Unit Component.............................................................3242 Function of Expansion Valve as Air Conditioner Unit Component..............................................................3242 Operate Expansion Valve as Air Conditioner Unit Component..................................................................3242 Function of Dual Pressure Switch...........................................................................................3243 Air Conditioner Controller.....................................................................................................3244 Structure of Air Conditioner Controller....................................................................................3244 Compressor.....................................................................................................................3245 Structure of Compressor....................................................................................................3245 Specifications of Compressor...............................................................................................3245 Function of Compressor.....................................................................................................3245 Condenser......................................................................................................................3246 Structure of Condenser.....................................................................................................3246 Specifications of Condenser................................................................................................3246 Function of Condenser......................................................................................................3246 Air Conditioner Related Sensors................................................................................................3248 Structure of Sunlight Sensor...............................................................................................3248 Function of Sunlight Sensor................................................................................................3248 Structure of Outside Temperature Sensor....................................................................................3248 Function of Outside Air Temperature Sensor.................................................................................3248 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner........................................................3250 Circuit Diagram and Configuration of Connector Pins of Air Conditioner.............................................................3252 System Diagram of Air Conditioner..................................................................................................3254 Input and Output Signals of Air Conditioner Controller.........................................................................3255 Function of Air Conditioner Controller.....................................................................................3256 Locations of Air Conditioner Parts and Layout of Connectors........................................................................3257 Examine Air Leakage (Duct).........................................................................................................3261 How to Examine Air Leakage (Duct)..............................................................................................3261 Examine Air Conditioner with Self-Diagnosis Function...............................................................................3263 Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor............................................3264 Examine Vent (Mode) Changeover.....................................................................................................3265 How to Examine Vent (Mode) Changeover..........................................................................................3265 Examine Fresh/Recirc Air Changeover................................................................................................3267 How to Examine Fresh/Recirc Air Changeover.....................................................................................3267 Examine Sunlight Sensor............................................................................................................3268 How to Examine Sunlight Sensor.................................................................................................3268 Examine Refrigerant (Dual) Pressure Switch.........................................................................................3269 How to Examine Refrigerant (Dual) Pressure Switch..............................................................................3269 Examine Relay......................................................................................................................3270 How to Examine Relay...........................................................................................................3270 Air Conditioner Troubleshooting Chart 1............................................................................................3271 Air Conditioner Troubleshooting Chart 2............................................................................................3272 Information Shown in Troubleshooting Table.........................................................................................3275 Failure Code [879AKA]..............................................................................................................3276 Failure Code [879AKB]..............................................................................................................3277 Failure Code [879BKA]..............................................................................................................3278 Failure Code [879BKB]..............................................................................................................3280 Failure Code [879CKA]..............................................................................................................3282 Failure Code [879CKB]..............................................................................................................3283 Failure Code [879DKZ]..............................................................................................................3284 Failure Code [879EMC]..............................................................................................................3286 Failure Code [879FMC]..............................................................................................................3287 Failure Code [879GKX]..............................................................................................................3288 A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate).....................................................3290 A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled)......................................................3292 A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal).............................................3295 A-4 Troubleshooting for Fresh/Recirc Air Changeover................................................................................3297 Troubleshooting by Gauge Pressure..................................................................................................3299 Connect Service Tool...............................................................................................................3302 How to Connect Service Tool....................................................................................................3302 Precautions for Disconnection and Connection of Air Conditioner Piping.............................................................3304 Handle Compressor Oil..............................................................................................................3306 How to Replace Desiccant...........................................................................................................3308 90 Circuit Diagrams....................................................................................................................3311 Table of Contents..................................................................................................................3312 Hydraulic Circuit Diagram..........................................................................................................3313 Symbols Used in Hydraulic Circuit Diagram......................................................................................3313 Hydraulic Circuit Diagram (1/2)................................................................................................3317 Hydraulic Circuit Diagram (2/2)................................................................................................3319 Electrical Circuit Diagram.........................................................................................................3321 Symbols Used in Electric Circuit Diagram.......................................................................................3321 Electrical Circuit Diagram (1/11)..............................................................................................3325 Electrical Circuit Diagram (2/11)..............................................................................................3327 Electrical Circuit Diagram (3/11)..............................................................................................3329 Electrical Circuit Diagram (4/11)..............................................................................................3331 Electrical Circuit Diagram (5/11)..............................................................................................3333 Electrical Circuit Diagram (6/11)..............................................................................................3335 Electrical Circuit Diagram (7/11)..............................................................................................3337 Electrical Circuit Diagram (8/11)..............................................................................................3339 Electrical Circuit Diagram (9/11)..............................................................................................3341 Electrical Circuit Diagram (10/11).............................................................................................3343 Electrical Circuit Diagram (11/11).............................................................................................3345 Index...................................................................................................................................3347
DESCRIPTION:
KOMATSU HB215LC-3 HYBRID HYDRAULIC EXCAVATOR SHOP MANUAL SEN06629-16 – PDF DOWNLOAD
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 Specification
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 Others
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.
S.S 29/12/24
