Komatsu HB215LC-3 Hydraulic Excavator Shop Manual UENBM00463 PDF

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Komatsu HB215LC-3 Hydraulic Excavator Shop Manual UENBM00463 – PDF DOWNLOAD

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Komatsu HB215LC-3 Hydraulic Excavator Shop Manual UENBM00463 – PDF DOWNLOAD 

Language : English
Pages : 3150
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu HB215LC-3 Hydraulic Excavator Shop Manual UENBM00463 – PDF DOWNLOAD 

SERIAL NUMBERS

70009 and up
K70001 and up

00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 24
FOREWORD, SAFETY, BASIC INFORMATION 30
HOW TO READ THE SHOP MANUAL 30
SAFETY NOTICE FOR OPERATION 32
PRECAUTIONS PARTICULARLY FOR HYBRID MACHINES 40
PRECAUTIONS TO PREVENT FIRE 41
ACTIONS IF FIRE OCCURS 43
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 44
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 45
PRECAUTIONS FOR DEF 46
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 46
PRECAUTIONS FOR ADDING 46
PRECAUTIONS FOR STORING 46
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 46
THE OTHER PRECAUTIONS 46
STORE AdBlue/DEF 47
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 48
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 51
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 58
PRECAUTIONS FOR MAINTENANCE OF HYBRID SYSTEM 60
PRECAUTIONS AGAINST HIGH VOLTAGE AND HIGH TEMPERATURE 61
PRECAUTIONS FOR NORMAL CHECK AND MAINTENANCE 62
PRECAUTIONS FOR THE MACHINE NOT TO BE TIPPED OVER AND FOR HYBRID COMPONENTS NOT TO BE DAMAGED 63
PRECAUTIONS FOR THE MACHINE NOT TO BE SUBMERGED 64
PRECAUTIONS FOR THE COLD SEASON 65
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 66
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 67
PRACTICAL USE OF KOMTRAX 68
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 69
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 69
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 70
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 71
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 73
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 77
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 78
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 80
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 81
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 83
HOW TO READ THE CODES (SYMBOLS) FOR ELECTRIC CABLE 84
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 90
STANDARD TIGHTENING TORQUE TABLE 93
CONVERSION TABLE 100
01 SPECIFICATIONS 105
CONTENTS 106
ABBREVIATION LIST 107
SPECIFICATIONS 113
SPECIFICATION DRAWING 113
SPECIFICATION DRAWING: HB215LC-3 113
WORKING RANGE DRAWINGS 115
WORKING RANGE DRAWINGS: HB215LC-3 115
SPECIFICATIONS 116
SPECIFICATIONS: HB215LC-3 116
WEIGHT TABLE 120
WEIGHT TABLE: HB215LC-3 120
FUEL, COOLANT, LUBRICANTS (FOR EUROPEAN UNION) 122
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE 122
10 STRUCTURE AND FUNCTION 125
CONTENTS 126
ABBREVIATION LIST 130
UREA SCR SYSTEM 136
LAYOUT DRAWING OF UREA SCR SYSTEM 136
UREA SCR SYSTEM DIAGRAM 141
FUNCTION OF UREA SCR SYSTEM 142
FUNCTION OF AdBlue/DEF SYSTEM 142
INDUCEMENT STRATEGY 144
COMPONENT PARTS OF UREA SCR SYSTEM 154
AdBlue/DEF MIXING TUBE 154
SCR ASSEMBLY 154
AdBlue/DEF TANK 157
AdBlue/DEF PUMP 159
AdBlue/DEF INJECTOR 160
AdBlue/DEF HOSE 161
AdBlue/DEF TANK HEATING VALVE 162
BOOT-UP SYSTEM 163
LAYOUT DRAWING OF BOOT-UP SYSTEM 163
SYSTEM OPERATING LAMP SYSTEM 164
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 164
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 164
BATTERY DISCONNECT SWITCH 166
FUNCTION OF BATTERY DISCONNECT SWITCH 166
ENGINE SYSTEM 167
LAYOUT DRAWING OF ENGINE SYSTEM 167
FUNCTION OF ENGINE SYSTEM 168
ENGINE CONTROL SYSTEM 169
ENGINE CONTROL SYSTEM DIAGRAM 169
FUNCTION OF ENGINE CONTROL SYSTEM 170
AUTO-DECELERATION SYSTEM 172
AUTO-DECELERATION SYSTEM DIAGRAM 172
FUNCTION OF AUTO-DECELERATION SYSTEM 172
OPERATION OF AUTO-DECELERATION SYSTEM 173
ENGINE AUTOMATIC WARM-UP SYSTEM 174
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 174
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 175
OVERHEAT PREVENTION SYSTEM 176
OVERHEAT PREVENTION SYSTEM DIAGRAM 176
FUNCTION OF OVERHEAT PREVENTION SYSTEM 177
TURBOCHARGER PROTECTION SYSTEM 180
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 180
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 181
AUTOMATIC IDLE STOP SYSTEM 182
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 182
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 182
COMPONENT PARTS OF ENGINE SYSTEM 186
VGT 186
EGR SYSTEM 188
EGR VALVE 190
EGR COOLER 192
KCCV SYSTEM 193
KCCV VENTILATOR 195
KDOC 197
COOLING SYSTEM 201
LAYOUT DRAWING OF COOLING SYSTEM 201
SPECIFICATIONS OF COOLING SYSTEM 202
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 203
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 203
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 204
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 205
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 205
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 206
COMPONENT PARTS OF COOLING SYSTEM 208
FAN CLUTCH 208
HYBRID SYSTEM 209
LAYOUT DRAWING OF HYBRID SYSTEM 209
SYSTEM DIAGRAM OF HYBRID SYSTEM 210
STRUCTURE OF HYBRID SYSTEM 211
HYBRID PROTECTION SYSTEM 212
SYSTEM DIAGRAM OF HYBRID PROTECTION SYSTEM 212
FUNCTION OF HYBRID PROTECTION SYSTEM 212
COOLING SYSTEM OF HYBRID COMPONENTS 214
SYSTEM DIAGRAM OF COOLING SYSTEM OF HYBRID COMPONENTS 214
INTERLOCK SYSTEM OF HYBRID COMPONENTS 215
SYSTEM DIAGRAM OF INTERLOCK SYSTEM OF HYBRID COMPONENTS 215
FUNCTION OF INTERLOCK SYSTEM OF HYBRID COMPONENTS 215
WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID COMPONENTS 216
SYSTEM DIAGRAM OF WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID COMPONENTS 216
FUNCTION OF WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID COMPONENTS 217
COMPONENT PARTS OF HYBRID SYSTEM 218
MOTOR-GENERATOR 218
ELECTRIC CONTROL UNIT 219
HIGH VOLTAGE WIRING (POWER CABLE) 220
HYBRID WATER PUMP 221
INVERTER (HYBRID CONTROLLER) 222
CONTROL SYSTEM 225
LAYOUT DRAWING OF CONTROL SYSTEM 225
MACHINE MONITOR SYSTEM 228
MACHINE MONITOR SYSTEM DIAGRAM 228
FUNCTION OF MACHINE MONITOR SYSTEM 229
KomVision SYSTEM 230
LAYOUT DRAWING OF KOMVISION SYSTEM 230
KomVision SYSTEM DIAGRAM 232
FUNCTION OF KomVision SYSTEM 232
KOMTRAX SYSTEM 234
KOMTRAX SYSTEM DIAGRAM 234
FUNCTION OF KOMTRAX SYSTEM 234
COMPONENT PARTS OF CONTROL SYSTEM 235
MACHINE MONITOR 235
KomVision CONTROLLER 249
KomVision CAMERA 253
KOMTRAX TERMINAL 254
PUMP CONTROLLER 256
RESISTOR FOR PC-EPC VALVE 260
CAN TERMINATING RESISTOR 260
ENGINE CONTROLLER 262
FUEL CONTROL DIAL 268
HYDRAULIC SYSTEM 270
LAYOUT DRAWING OF HYDRAULIC SYSTEM 270
CLSS 275
STRUCTURE OF CLSS 275
OPERATION OF UNLOAD VALVE AND LS PRESSURE 277
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 278
PRESSURE COMPENSATION CONTROL 291
ENGINE AND PUMP COMBINED CONTROL SYSTEM 292
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 292
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 293
PUMP AND VALVE CONTROL SYSTEM 298
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 298
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 299
COMPONENT PARTS OF HYDRAULIC SYSTEM 301
HYDRAULIC TANK 301
MAIN PUMP 303
CONTROL VALVE 328
WORK EQUIPMENT SYSTEM 384
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 384
ONE-TOUCH POWER MAXIMIZING SYSTEM 388
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 388
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 389
PPC LOCK SYSTEM 390
PPC LOCK SYSTEM DIAGRAM 390
FUNCTION OF PPC LOCK SYSTEM 390
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 391
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 391
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 391
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 392
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 393
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 393
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 394
TOOL CONTROL SYSTEM 395
TOOL CONTROL SYSTEM DIAGRAM 395
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 397
WORK EQUIPMENT AND SWING PPC VALVE 397
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 402
2ND-LINE ATTACHMENT PPC VALVE 408
SOLENOID VALVE 410
ANTI-DROP VALVE FOR BOOM 413
ANTI-DROP VALVE FOR ARM 417
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 421
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 423
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE 426
2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE 428
ATTACHMENT BYPASS SOLENOID VALVE 431
PILOT CIRCUIT ACCUMULATOR 433
ATTACHMENT CIRCUIT ACCUMULATOR 434
SWING SYSTEM 435
LAYOUT DRAWING OF SWING SYSTEM 435
SWING CONTROL SYSTEM DIAGRAM 438
FUNCTION OF SWING CONTROL SYSTEM 439
COMPONENT PARTS OF SWING SYSTEM 442
ELECTRIC SWING MOTOR 442
SWING MACHINERY WITH SWING PARKING BRAKE 443
SWING CIRCLE 445
TRAVEL SYSTEM 446
LAYOUT DRAWING OF TRAVEL SYSTEM 446
TRAVEL CONTROL SYSTEM DIAGRAM 450
FUNCTION OF TRAVEL CONTROL SYSTEM 450
COMPONENT PARTS OF TRAVEL SYSTEM 452
TRAVEL MOTOR 452
FINAL DRIVE 464
TRAVEL PPC VALVE 466
CENTER SWIVEL JOINT 471
UNDERCARRIAGE AND FRAME 473
LAYOUT DRAWING OF UNDERCARRIAGE 473
SPECIFICATIONS OF UNDERCARRIAGE 474
WORK EQUIPMENT 475
STRUCTURE OF WORK EQUIPMENT 475
FUNCTION OF WORK EQUIPMENT 476
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 477
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 477
BUCKET CLEARANCE ADJUSTMENT SHIM 478
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 478
CAB AND ITS ATTACHMENTS 479
ROPS CAB 479
STRUCTURE OF ROPS CAB 479
FUNCTION OF ROPS CAB 479
CAB MOUNT 480
STRUCTURE OF CAB MOUNT 480
FUNCTION OF CAB MOUNT 480
CAB TIPPING STOPPER 481
STRUCTURE OF CAB TIPPING STOPPER 481
FUNCTION OF CAB TIPPING STOPPER 481
20 STANDARD VALUE TABLE 483
CONTENTS 484
ABBREVIATION LIST 485
STANDARD VALUE TABLE FOR ENGINE 491
STANDARD VALUE TABLE FOR ENGINE:HB215LC-3 491
STANDARD VALUE TABLE FOR MACHINE 496
STANDARD VALUE TABLE FOR MACHINE: HB215LC-3 496
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 512
30 TESTING AND ADJUSTING 517
CONTENTS 518
ABBREVIATION LIST 521
RELATED INFORMATION ON TESTING AND ADJUSTING 527
TOOLS FOR TESTING AND ADJUSTING 527
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 534
ENGINE AND COOLING SYSTEM 536
TEST ENGINE SPEED 536
METHOD FOR TESTING ENGINE SPEED 536
TEST BOOST PRESSURE 539
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 539
METHOD FOR TESTING BOOST PRESSURE 540
TEST EXHAUST GAS COLOR 541
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 541
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 542
TEST AND ADJUST VALVE CLEARANCE 543
METHOD FOR TESTING VALVE CLEARANCE 543
METHOD FOR ADJUSTING VALVE CLEARANCE 544
TEST COMPRESSION PRESSURE 546
METHOD FOR TESTING COMPRESSION PRESSURE 546
TEST BLOWBY PRESSURE 551
METHOD FOR TESTING BLOWBY PRESSURE 551
TEST ENGINE OIL PRESSURE 553
METHOD FOR TESTING ENGINE OIL PRESSURE 553
TEST FUEL PRESSURE 554
METHOD FOR TESTING FUEL PRESSURE 555
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 559
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 560
BLEEDING AIR FROM FUEL SYSTEM 564
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 564
TEST FUEL CIRCUIT FOR LEAKAGE 565
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 565
HANDLE CYLINDER CUT-OUT MODE OPERATION 567
HANDLE NO-INJECTION CRANKING OPERATION 568
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 569
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT 569
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 569
TEST COOLING FAN SPEED 571
METHOD FOR TESTING COOLING FAN SPEED 571
TEST SCR RELATED FUNCTIONS 572
TEST AdBlue/DEF PUMP RAISED PRESSURE 575
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 578
TEST AdBlue/DEF LINE HEATER RELAY 1 581
TEST AdBlue/DEF LINE HEATER RELAY 2 584
TEST AdBlue/DEF PUMP HEATER RELAY 587
TEST AdBlue/DEF TANK HEATER VALVE 591
TEST DENITRATION EFFICIENCY OF SCR 593
CLEAN AdBlue/DEF TANK 597
METHOD FOR CLEANING AdBlue/DEF TANK 597
BLEED AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 601
METHOD FOR BLEEDING AIR FROM COOLANT CIRCUIT OF AdBlue/DEF TANK 601
HYBRID SYSTEM 603
PRECAUTIONS FOR USING HYBRID SYSTEMS 603
DRAIN, REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT 604
METHOD FOR DRAINING THE HYBRID SYSTEM COOLANT 604
REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT 606
WATER PRESSURE TEST OF THE HYBRID SYSTEM COOLANT 608
METHOD FOR TESTING THE WATER PRESSURE OF THE HYBRID SYSTEM COOLANT 608
TEST LUBRICATION CIRCUIT OIL PRESSURE OF HYBRID SYSTEM 610
TEST LUBRICATION CIRCUIT OIL PRESSURE OF ELECTRIC SWING MOTOR CASE 610
TEST LUBRICATION CIRCUIT OIL PRESSURE OF MOTOR-GENERATOR OIL CASE 610
TEST SWING PARKING BRAKE PRESSURE 612
METHOD FOR TESTING THE SWING PARKING BRAKE PRESSURE 612
TEST AND CLEAN DELIVERY FILTER OF SWING MOTOR 614
METHOD FOR CHECKING AND CLEANING ELECTRIC SWING MOTOR COOLING OIL DELIVERY FILTER 614
POWER TRAIN 615
TEST SWING CIRCLE BEARING CLEARANCE 615
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 615
UNDERCARRIAGE AND FRAME 616
TEST AND ADJUST TRACK TENSION 616
METHOD FOR TESTING TRACK TENSION 616
METHOD FOR ADJUSTING TRACK TENSION 616
HYDRAULIC SYSTEM 618
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 618
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 618
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 618
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 623
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUITS 624
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, AND TRAVEL CIRCUITS 625
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,AND TRAVEL CIRCUITS 629
TEST OIL PRESSURE OF CONTROL CIRCUIT 631
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 631
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 633
METHOD FOR TESTING PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 633
METHOD FOR TESTING PC-EPC VALVE OUTLET PRESSURE 634
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 635
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 637
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR 637
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE 638
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) 640
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE 641
METHOD FOR ADJUSTING LS VALVE 642
TEST OUTLET PRESSURE OF SOLENOID VALVE 643
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 643
OPERATING CONDITION OF SOLENOID VALVE 645
TEST PPC VALVE OUTLET PRESSURE 647
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 647
TEST ATTACHMENT CIRCUIT OIL PRESSURE 649
METHOD FOR TESTING ATTACHMENT CIRCUIT OIL PRESSURE 649
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 651
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 651
TEST PUMP SWASH PLATE SENSOR 652
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 652
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 653
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 653
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 653
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 654
TEST OIL LEAKAGE 655
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 655
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 655
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 656
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 656
BLEED AIR FROM HYDRAULIC CIRCUIT 658
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 659
CAB AND ITS ATTACHMENTS 661
TEST CAB TIPPING STOPPER 661
METHOD FOR TESTING CAB TIPPING STOPPER 661
METHOD FOR ADJUSTING MIRRORS 662
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 662
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 663
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 664
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 665
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 666
ELECTRICAL SYSTEM 668
SET AND OPERATE MACHINE MONITOR 668
OPERATOR MODE 672
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 672
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 672
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 673
CHECKING FUNCTION OF SERVICE METER 674
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 674
SERVICE MODE 676
METHOD FOR OPERATING SERVICE MODE 676
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 680
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 689
ABNORMALITY RECORD MENU 702
METHOD FOR CONFIRMING MAINTENANCE RECORD 707
METHOD FOR OPERATING MAINTENANCE MODE SETTING 708
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 711
DEFAULT MENU 712
DIAGNOSTIC TESTS MENU 724
ADJUSTMENT MENU 737
METHOD FOR PERFORMING NO-INJECTION CRANKING 771
KOMTRAX SETTINGS MENU 772
METHOD FOR DISPLAYING SERVICE MESSAGE 775
METHOD FOR STARTING UP KOMTRAX TERMINAL 777
ADJUST KomVision CAMERA ANGLE 782
METHOD FOR ADJUSTING KomVision CAMERA ANGLE 783
ADJUST KomVision RELATED ITEMS 787
SETTING OF KomVision (MAIN SETTING) 787
SETTING OF KomVision (CAMERA SETTING) 789
SETTING OF KomVision (CAMERA CALIBRATION) 791
KomVision screen – Check 12 m visibility 804
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 807
HANDLE BATTERY DISCONNECT SWITCH 808
TEST DIODES 809
METHOD FOR TESTING DIODE USING DIGITAL TESTER 809
METHOD FOR TESTING DIODE USING ANALOG TESTER 809
Pm CLINIC 810
Pm CLINIC SERVICE 810
Pm CLINIC CHECK SHEET:HB215LC-3 811
40 TROUBLESHOOTING 823
CONTENTS 824
ABBREVIATION LIST 837
RELATED INFORMATION ON TROUBLESHOOTING 843
GENERAL TROUBLESHOOTING POINTS 843
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 844
SEQUENCE OF EVENTS IN TROUBLESHOOTING 856
PRECAUTIONS FOR USING HYBRID SYSTEMS, TROUBLESHOOTING FOR HIGH-VOLTAGE EQUIPMENT 858
TABLE OF SELF-DEFINE MONITORING ITEMS AND CHECK SHEET FOR HYBRID COMPONENTS 865
CHECKS BEFORE TROUBLESHOOTING 871
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 873
WALK-AROUND CHECK 873
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 875
CHECK FUEL LEVEL AND TYPE 875
CHECK IMPURE INGREDIENT IN FUEL 875
CHECK FUEL PREFILTER 876
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 876
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE 877
CHECK MAIN FILTER 878
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 880
CHECK OIL LEVEL IN MOTOR-GENERATOR CASE 881
CHECK COOLANT LEVEL (RESERVOIR TANK) 881
CHECK CLOGGING OF AIR CLEANER 882
OUTER ELEMENT – CLEAN 882
ELEMENTS – REPLACE 885
CHECK HYDRAULIC OIL LEVEL 886
CHECK HYDRAULIC OIL STRAINER 887
CHECK HYDRAULIC FILTER 888
CHECK CAPACITOR 889
CHECK OIL LEVEL IN ELECTRIC SWING MOTOR CASE 889
CHECK OIL LEVEL IN SWING MACHINERY CASE 890
CHECK OIL LEVEL IN FINAL DRIVE CASE 891
BLEED AIR FROM FUEL SYSTEM 892
BLEED AIR FROM HYDRAULIC SYSTEM 892
ELECTRICAL EQUIPMENT – CHECK METHOD 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 KomVision CONTROLLER 899
PREPARATION FOR TROUBLESHOOTING OF INVERTER (HYBRID CONTROLLER) 899
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 900
PROCEDURE FOR TESTING AND TROUBLESHOOTING 904
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 907
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 911
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 913
CONNECTOR LIST AND LAYOUT 916
CONNECTOR CONTACT IDENTIFICATION 929
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 969
FUSE LOCATION TABLE 975
PRECAUTIONS FOR REPLACING KDOC 978
FAILURE CODES TABLE 979
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1000
FAILURE CODE [879AKA] 1000
FAILURE CODE [879AKB] 1001
FAILURE CODE [879BKA] 1002
FAILURE CODE [879BKB] 1004
FAILURE CODE [879CKA] 1006
FAILURE CODE [879CKB] 1007
FAILURE CODE [879DKZ] 1008
FAILURE CODE [879EMC] 1010
FAILURE CODE [879FMC] 1011
FAILURE CODE [879GKX] 1012
FAILURE CODE [989L00] 1014
FAILURE CODE [989M00] 1015
FAILURE CODE [989N00] 1016
FAILURE CODE [A1U0N3] 1017
FAILURE CODE [A1U0N4] 1019
FAILURE CODE [A900FR] 1021
FAILURE CODE [A900N6] 1022
FAILURE CODE [A900NY] 1023
FAILURE CODE [AA10NX] 1024
FAILURE CODE [AB00KE] 1026
FAILURE CODE [AQ10MB] 1028
FAILURE CODE [AQ10N3] 1030
FAILURE CODE [AS00R2] 1032
FAILURE CODE [AS00R3] 1033
FAILURE CODE [AS00R4] 1034
FAILURE CODE [AS00R5] 1035
FAILURE CODE [AS00R6] 1036
FAILURE CODE [AS00ZK] 1037
FAILURE CODE [AS10KM] 1038
FAILURE CODE [AS10NR] 1039
FAILURE CODE [AS10NT] 1040
FAILURE CODE [B@BAZG] 1041
FAILURE CODE [B@BAZK] 1042
FAILURE CODE [B@BCNS] 1044
FAILURE CODE [B@BCQA] 1045
FAILURE CODE [B@BCZK] 1047
FAILURE CODE [B@HANS] 1048
FAILURE CODE [CA115] 1049
FAILURE CODE [CA122] 1050
FAILURE CODE [CA123] 1052
FAILURE CODE [CA131] 1054
FAILURE CODE [CA132] 1056
FAILURE CODE [CA144] 1058
FAILURE CODE [CA145] 1060
FAILURE CODE [CA153] 1062
FAILURE CODE [CA154] 1064
FAILURE CODE [CA187] 1066
FAILURE CODE [CA221] 1068
FAILURE CODE [CA222] 1070
FAILURE CODE [CA227] 1072
FAILURE CODE [CA234] 1074
FAILURE CODE [CA238] 1075
FAILURE CODE [CA239] 1076
FAILURE CODE [CA249] 1077
FAILURE CODE [CA256] 1079
FAILURE CODE [CA271] 1082
FAILURE CODE [CA272] 1084
FAILURE CODE [CA295] 1086
FAILURE CODE [CA322] 1087
FAILURE CODE [CA324] 1089
FAILURE CODE [CA331] 1091
FAILURE CODE [CA332] 1093
FAILURE CODE [CA343] 1095
FAILURE CODE [CA351] 1096
FAILURE CODE [CA352] 1097
FAILURE CODE [CA356] 1099
FAILURE CODE [CA357] 1101
FAILURE CODE [CA386] 1103
FAILURE CODE [CA428] 1104
FAILURE CODE [CA429] 1106
FAILURE CODE [CA435] 1108
FAILURE CODE [CA441] 1110
FAILURE CODE [CA442] 1112
FAILURE CODE [CA451] 1113
FAILURE CODE [CA452] 1115
FAILURE CODE [CA488] 1117
FAILURE CODE [CA515] 1118
FAILURE CODE [CA516] 1120
FAILURE CODE [CA553] 1122
FAILURE CODE [CA555] 1123
FAILURE CODE [CA556] 1124
FAILURE CODE [CA559] 1125
FAILURE CODE [CA595] 1128
FAILURE CODE [CA687] 1130
FAILURE CODE [CA689] 1132
FAILURE CODE [CA691] 1135
FAILURE CODE [CA692] 1137
FAILURE CODE [CA697] 1139
FAILURE CODE [CA698] 1140
FAILURE CODE [CA731] 1141
FAILURE CODE [CA778] 1143
FAILURE CODE [CA1117] 1147
FAILURE CODE [CA1664] 1149
FAILURE CODE [CA1669] 1151
FAILURE CODE [CA1673] 1152
FAILURE CODE [CA1677] 1153
FAILURE CODE [CA1678] 1154
FAILURE CODE [CA1682] 1155
FAILURE CODE [CA1683] 1159
FAILURE CODE [CA1684] 1161
FAILURE CODE [CA1686] 1163
FAILURE CODE [CA1691] 1164
FAILURE CODE [CA1694] 1166
FAILURE CODE [CA1695] 1168
FAILURE CODE [CA1696] 1169
FAILURE CODE [CA1712] 1171
FAILURE CODE [CA1713] 1174
FAILURE CODE [CA1714] 1177
FAILURE CODE [CA1715] 1178
FAILURE CODE [CA1776] 1179
FAILURE CODE [CA1777] 1182
FAILURE CODE [CA1843] 1185
FAILURE CODE [CA1844] 1187
FAILURE CODE [CA1885] 1190
FAILURE CODE [CA1887] 1192
FAILURE CODE [CA1896] 1194
FAILURE CODE [CA1898] 1195
FAILURE CODE [CA1938] 1197
FAILURE CODE [CA1942] 1199
FAILURE CODE [CA1961] 1200
FAILURE CODE [CA1962] 1201
FAILURE CODE [CA2185] 1202
FAILURE CODE [CA2186] 1204
FAILURE CODE [CA2198] 1206
FAILURE CODE [CA2272] 1208
FAILURE CODE [CA2288] 1210
FAILURE CODE [CA2311] 1211
FAILURE CODE [CA2349] 1212
FAILURE CODE [CA2353] 1214
FAILURE CODE [CA2357] 1216
FAILURE CODE [CA2373] 1217
FAILURE CODE [CA2374] 1219
FAILURE CODE [CA2375] 1221
FAILURE CODE [CA2376] 1223
FAILURE CODE [CA2387] 1226
FAILURE CODE [CA2554] 1227
FAILURE CODE [CA2555] 1228
FAILURE CODE [CA2556] 1231
FAILURE CODE [CA2634] 1233
FAILURE CODE [CA2635] 1235
FAILURE CODE [CA2636] 1236
FAILURE CODE [CA2637] 1238
FAILURE CODE [CA2771] 1240
FAILURE CODE [CA2961] 1244
FAILURE CODE [CA2973] 1245
FAILURE CODE [CA2976] 1246
FAILURE CODE [CA3142] 1248
FAILURE CODE [CA3143] 1249
FAILURE CODE [CA3144] 1250
FAILURE CODE [CA3146] 1252
FAILURE CODE [CA3147] 1253
FAILURE CODE [CA3148] 1254
FAILURE CODE [CA3151] 1256
FAILURE CODE [CA3165] 1263
FAILURE CODE [CA3228] 1265
FAILURE CODE [CA3229] 1268
FAILURE CODE [CA3231] 1270
FAILURE CODE [CA3232] 1272
FAILURE CODE [CA3235] 1276
FAILURE CODE [CA3239] 1278
FAILURE CODE [CA3241] 1281
FAILURE CODE [CA3242] 1284
FAILURE CODE [CA3251] 1287
FAILURE CODE [CA3313] 1289
FAILURE CODE [CA3314] 1290
FAILURE CODE [CA3315] 1291
FAILURE CODE [CA3419] 1293
FAILURE CODE [CA3421] 1295
FAILURE CODE [CA3497] 1297
FAILURE CODE [CA3498] 1298
FAILURE CODE [CA3545] 1299
FAILURE CODE [CA3547] 1301
FAILURE CODE [CA3558] 1302
FAILURE CODE [CA3559] 1304
FAILURE CODE [CA3562] 1306
FAILURE CODE [CA3563] 1308
FAILURE CODE [CA3567] 1311
FAILURE CODE [CA3568] 1315
FAILURE CODE [CA3571] 1320
FAILURE CODE [CA3572] 1322
FAILURE CODE [CA3574] 1324
FAILURE CODE [CA3575] 1327
FAILURE CODE [CA3577] 1329
FAILURE CODE [CA3578] 1331
FAILURE CODE [CA3582] 1333
FAILURE CODE [CA3583] 1340
FAILURE CODE [CA3596] 1342
FAILURE CODE [CA3649] 1345
FAILURE CODE [CA3681] 1347
FAILURE CODE [CA3682] 1351
FAILURE CODE [CA3713] 1355
FAILURE CODE [CA3717] 1358
FAILURE CODE [CA3718] 1359
FAILURE CODE [CA3724] 1360
FAILURE CODE [CA3725] 1361
FAILURE CODE [CA3741] 1364
FAILURE CODE [CA3748] 1365
FAILURE CODE [CA3755] 1368
FAILURE CODE [CA3866] 1370
FAILURE CODE [CA3868] 1373
FAILURE CODE [CA4152] 1376
FAILURE CODE [CA4155] 1380
FAILURE CODE [CA4156] 1383
FAILURE CODE [CA4157] 1386
FAILURE CODE [CA4159] 1388
FAILURE CODE [CA4164] 1389
FAILURE CODE [CA4165] 1391
FAILURE CODE [CA4166] 1393
FAILURE CODE [CA4168] 1394
FAILURE CODE [CA4169] 1397
FAILURE CODE [CA4171] 1399
FAILURE CODE [CA4249] 1401
FAILURE CODE [CA4251] 1403
FAILURE CODE [CA4261] 1405
FAILURE CODE [CA4277] 1408
FAILURE CODE [CA4459] 1412
FAILURE CODE [CA4461] 1414
FAILURE CODE [CA4533] 1417
FAILURE CODE [CA4534] 1418
FAILURE CODE [CA4731] 1419
FAILURE CODE [CA4732] 1420
FAILURE CODE [CA4739] 1421
FAILURE CODE [CA4768] 1422
FAILURE CODE [CA4769] 1424
FAILURE CODE [CA4842] 1427
FAILURE CODE [CA4952] 1430
FAILURE CODE [CA5115] 1432
FAILURE CODE [CA5179] 1435
FAILURE CODE [CA5181] 1437
FAILURE CODE [CA5387] 1439
FAILURE CODE [CA5388] 1441
FAILURE CODE [CA5389] 1444
FAILURE CODE [CA5391] 1446
FAILURE CODE [CA5392] 1450
FAILURE CODE [CA5393] 1452
FAILURE CODE [CA5394] 1454
FAILURE CODE [CA5395] 1456
FAILURE CODE [CA5396] 1459
FAILURE CODE [CA5631] 1460
FAILURE CODE [CA5938] 1462
FAILURE CODE [D110KB] 1464
FAILURE CODE [D19JKZ] 1466
FAILURE CODE [D811MC] 1469
FAILURE CODE [D862KA] 1470
FAILURE CODE [D8ALKA] 1471
FAILURE CODE [D8ALKB] 1473
FAILURE CODE [D8AQKR] 1475
FAILURE CODE [DA20MC] 1480
FAILURE CODE [DA22KK] 1481
FAILURE CODE [DA25KP] 1484
FAILURE CODE [DA26KP] 1487
FAILURE CODE [DA29KQ] 1490
FAILURE CODE [DA2LKA] 1493
FAILURE CODE [DA2LKB] 1495
FAILURE CODE [DA2QKR] 1497
FAILURE CODE [DA2RKR] 1502
FAILURE CODE [DAF0KM] 1507
FAILURE CODE [DAF0MB] 1508
FAILURE CODE [DAF0MC] 1509
FAILURE CODE [DAF8KB] 1510
FAILURE CODE [DAF9KQ] 1512
FAILURE CODE [DAFGMC] 1513
FAILURE CODE [DAFLKA] 1514
FAILURE CODE [DAFLKB] 1516
FAILURE CODE [DAFQKR] 1518
FAILURE CODE [DAZ9KQ] 1522
FAILURE CODE [DAZQKR] 1523
FAILURE CODE [DB2QKR] 1527
FAILURE CODE [DB2RKR] 1533
FAILURE CODE [DBP0KM] 1539
FAILURE CODE [DBP0KT] 1540
FAILURE CODE [DBP5KB] 1541
FAILURE CODE [DBP5KY] 1544
FAILURE CODE [DBPQKR] 1547
FAILURE CODE [DDNRKA] 1552
FAILURE CODE [DDNRKY] 1555
FAILURE CODE [DDNS00] 1558
FAILURE CODE [DFB1KZ] 1561
FAILURE CODE [DFB2KZ] 1563
FAILURE CODE [DFB3L8] 1565
FAILURE CODE [DFB4L8] 1567
FAILURE CODE [DFB5KZ] 1569
FAILURE CODE [DFB6KZ] 1571
FAILURE CODE [DGH2KA] 1573
FAILURE CODE [DGH2KB] 1575
FAILURE CODE [DHA4KA] 1577
FAILURE CODE [DHAAMA] 1579
FAILURE CODE [DHACMA] 1581
FAILURE CODE [DHPAMA] 1583
FAILURE CODE [DHPBMA] 1585
FAILURE CODE [DHS3MA] 1587
FAILURE CODE [DHS4MA] 1589
FAILURE CODE [DHS8MA] 1591
FAILURE CODE [DHS9MA] 1593
FAILURE CODE [DHSAKZ] 1595
FAILURE CODE [DHSBKZ] 1597
FAILURE CODE [DHSCMA] 1599
FAILURE CODE [DHSDMA] 1601
FAILURE CODE [DHSFMA] 1603
FAILURE CODE [DHSGMA] 1605
FAILURE CODE [DHSHMA] 1607
FAILURE CODE [DHSJMA] 1609
FAILURE CODE [DHVAKZ] 1611
FAILURE CODE [DHVAL8] 1613
FAILURE CODE [DHVAMA] 1615
FAILURE CODE [DHVBKZ] 1616
FAILURE CODE [DHVBL8] 1618
FAILURE CODE [DHVBMA] 1621
FAILURE CODE [DHX1MA] 1622
FAILURE CODE [DKR0MA] 1624
FAILURE CODE [DKR1MA] 1626
FAILURE CODE [DKTKKX] 1628
FAILURE CODE [DKTLKX] 1630
FAILURE CODE [DKTMKX] 1632
FAILURE CODE [DKTNKX] 1634
FAILURE CODE [DKTPKX] 1636
FAILURE CODE [DKTQKX] 1638
FAILURE CODE [DKULKA] 1640
FAILURE CODE [DKULKB] 1643
FAILURE CODE [DKULKY] 1646
FAILURE CODE [DLM5KA] 1649
FAILURE CODE [DLM5MB] 1651
FAILURE CODE [DR10KA] 1653
FAILURE CODE [DR12KA] 1656
FAILURE CODE [DR20KA] 1658
FAILURE CODE [DR21KX] 1660
FAILURE CODE [DR30KA] 1662
FAILURE CODE [DR31KX] 1664
FAILURE CODE [DR40KA] 1666
FAILURE CODE [DUMBKA] 1668
FAILURE CODE [DUMBKB] 1670
FAILURE CODE [DV20KB] 1672
FAILURE CODE [DW43KA] 1674
FAILURE CODE [DW43KB] 1676
FAILURE CODE [DW43KY] 1678
FAILURE CODE [DW45KA] 1680
FAILURE CODE [DW45KB] 1683
FAILURE CODE [DW45KK] 1686
FAILURE CODE [DW45KY] 1688
FAILURE CODE [DW4CKY] 1690
FAILURE CODE [DW91KA] 1693
FAILURE CODE [DW91KB] 1695
FAILURE CODE [DW91KY] 1697
FAILURE CODE [DWA2KA] 1699
FAILURE CODE [DWA2KB] 1701
FAILURE CODE [DWA2KY] 1703
FAILURE CODE [DWK0KA] 1705
FAILURE CODE [DWK0KB] 1707
FAILURE CODE [DWK0KY] 1709
FAILURE CODE [DWK2KA] 1711
FAILURE CODE [DWK2KB] 1713
FAILURE CODE [DWK2KY] 1715
FAILURE CODE [DWN5KA] 1717
FAILURE CODE [DWN5KB] 1719
FAILURE CODE [DWN5KY] 1721
FAILURE CODE [DWPUKA] 1723
FAILURE CODE [DWPUKB] 1725
FAILURE CODE [DWPUKY] 1727
FAILURE CODE [DXA8KA] 1729
FAILURE CODE [DXA8KB] 1732
FAILURE CODE [DXA9KA] 1734
FAILURE CODE [DXA9KB] 1737
FAILURE CODE [DXE0KA] 1739
FAILURE CODE [DXE0KB] 1741
FAILURE CODE [DXE4KA] 1743
FAILURE CODE [DXE4KB] 1745
FAILURE CODE [DXE4KY] 1747
FAILURE CODE [DXE5KA] 1748
FAILURE CODE [DXE5KB] 1750
FAILURE CODE [DXE6KA] 1752
FAILURE CODE [DXE6KB] 1754
FAILURE CODE [DXE7KA] 1756
FAILURE CODE [DXE7KB] 1758
FAILURE CODE [DXE7KY] 1760
FAILURE CODE [DXE8KA] 1762
FAILURE CODE [DXE8KB] 1764
FAILURE CODE [DXE8KY] 1766
FAILURE CODE [DXE9KA] 1768
FAILURE CODE [DXE9KB] 1770
FAILURE CODE [DXE9KY] 1772
FAILURE CODE [DXEAKA] 1774
FAILURE CODE [DXEAKB] 1776
FAILURE CODE [DXEAKY] 1778
FAILURE CODE [DXEKKA] 1780
FAILURE CODE [DXEKKB] 1782
FAILURE CODE [DXEKKY] 1784
FAILURE CODE [DXELKA] 1786
FAILURE CODE [DXELKB] 1788
FAILURE CODE [DXELKY] 1790
FAILURE CODE [DY20KA] 1792
FAILURE CODE [DY20MA] 1794
FAILURE CODE [DY2CKB] 1796
FAILURE CODE [DY2DKB] 1798
FAILURE CODE [DY2EKB] 1800
FAILURE CODE [GA00NS] 1802
FAILURE CODE [GA01KA] 1803
FAILURE CODE [GA01KB] 1805
FAILURE CODE [GA02KZ] 1807
FAILURE CODE [GA04KG] 1810
FAILURE CODE [GA05KG] 1813
FAILURE CODE [GA05KP] 1816
FAILURE CODE [GA06KZ] 1820
FAILURE CODE [GA08KG] 1821
FAILURE CODE [GA09KG] 1829
FAILURE CODE [GA09KP] 1837
FAILURE CODE [GA0AKZ] 1838
FAILURE CODE [GA0BKZ] 1839
FAILURE CODE [GA10MA] 1846
FAILURE CODE [GA10MC] 1853
FAILURE CODE [GA12NK] 1854
FAILURE CODE [GA13KP] 1860
FAILURE CODE [GA13KY] 1862
FAILURE CODE [GA15KZ] 1864
FAILURE CODE [GA17KR] 1872
FAILURE CODE [GA17MB] 1873
FAILURE CODE [GA18MC] 1874
FAILURE CODE [GA19KR] 1879
FAILURE CODE [GA19KT] 1880
FAILURE CODE [GA1BMA] 1881
FAILURE CODE [GA1FKR] 1883
FAILURE CODE [GA1FMA] 1884
FAILURE CODE [GA1GKR] 1887
FAILURE CODE [GA1GKT] 1888
FAILURE CODE [GA1GMB] 1889
FAILURE CODE [GA1HKZ] 1890
FAILURE CODE [GA1JKZ] 1891
FAILURE CODE [GA1KKZ] 1892
FAILURE CODE [GA1LKZ] 1893
FAILURE CODE [GA1MKZ] 1894
FAILURE CODE [GA1NNS] 1895
FAILURE CODE [GA1SFS] 1896
FAILURE CODE [GA1SMC] 1897
FAILURE CODE [GA1TKP] 1898
FAILURE CODE [GA1TNS] 1902
FAILURE CODE [GA1UKZ] 1905
FAILURE CODE [GA1VFS] 1908
FAILURE CODE [GA1VMC] 1909
FAILURE CODE [GA1XKZ] 1910
FAILURE CODE [GA1YNS] 1911
FAILURE CODE [GA1ZKZ] 1912
FAILURE CODE [GA1ZNS] 1913
FAILURE CODE [GA22NS] 1914
FAILURE CODE [GA23KZ] 1915
FAILURE CODE [GA24KZ] 1916
FAILURE CODE [GA25MA] 1917
FAILURE CODE [GA25NS] 1921
FAILURE CODE [GA26MA] 1922
FAILURE CODE [GA26NS] 1926
FAILURE CODE [GA27KZ] 1927
FAILURE CODE [GA2QKR] 1928
FAILURE CODE [GA2RKR] 1933
FAILURE CODE [GA60KZ] 1938
FAILURE CODE [GA60MC] 1943
FAILURE CODE [GA60N1] 1945
FAILURE CODE [GA61KZ] 1947
FAILURE CODE [GA61NS] 1949
FAILURE CODE [GA62KY] 1950
FAILURE CODE [GA62KZ] 1955
FAILURE CODE [GA62MA] 1959
FAILURE CODE [GA62MC] 1960
FAILURE CODE [GA63KY] 1961
FAILURE CODE [GA63KZ] 1966
FAILURE CODE [GA63MA] 1970
FAILURE CODE [GA63MC] 1971
FAILURE CODE [GA64KY] 1972
FAILURE CODE [GA64KZ] 1977
FAILURE CODE [GA64MA] 1981
FAILURE CODE [GA64MC] 1982
FAILURE CODE [GA70KB] 1983
FAILURE CODE [GA70MD] 1986
FAILURE CODE [GA70NS] 1988
FAILURE CODE [GA71KZ] 1989
FAILURE CODE [GA72MA] 1991
FAILURE CODE [GA72MC] 1993
FAILURE CODE [GA81KZ] 1995
FAILURE CODE [GAA0KB] 1998
FAILURE CODE [GAA2KB] 2000
FAILURE CODE [GAA6KP] 2002
FAILURE CODE [GAA6KY] 2004
FAILURE CODE [GACLKA] 2006
FAILURE CODE [GACLKB] 2008
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2010
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2010
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 2016
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2019
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2021
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 2023
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 2026
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 2027
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 2028
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 2029
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 2030
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2031
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2032
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2033
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2034
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2035
E-16 HYBRID TEMPERATURE MONITOR LIGHTS UP IN RED RED ENGINE IS RUNNING 2036
E-17 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2038
E-18 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2039
E-19 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 2041
E-20 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2042
E-21 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 2043
E-22 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2044
E-23 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE 2046
E-24 HYBRID TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2047
E-25 HYBRID TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE (INDICATES NEITHER MINIMUM NOR MAXIMUM) 2049
E-26 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 2051
E-27 FUNCTION SWITCH DOES NOT OPERATE 2052
E-28 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) 2053
E-29 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 2054
E-30 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 2055
E-31 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED 2056
E-32 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 2057
E-33 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE 2058
E-34 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 2059
E-35 ALARM BUZZER CANNOT BE CANCELED 2061
E-36 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 2062
E-37 SERVICE MODE CANNOT BE SELECTED 2063
E-38 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 2064
E-39 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 2068
E-40 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING 2071
E-41 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE 2074
E-42 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR 2076
E-43 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED 2078
E-44 ALARM DOES NOT SOUND DURING TRAVEL 2079
E-45 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 2081
E-46 HORN DOES NOT SOUND 2082
E-47 HORN DOES NOT STOP SOUNDING 2085
E-48 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF 2087
E-49 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 2088
E-50 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 2090
E-51 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2091
E-52 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2092
E-53 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2093
E-54 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2094
E-55 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2095
E-56 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2096
E-57 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2097
E-58 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2098
E-59 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2099
E-60 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED 2101
E-61 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2102
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2103
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2103
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 2104
FAILURE MODE AND CAUSE TABLE 2106
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 2118
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER 2119
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 2121
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 2123
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2124
H-6 SPEED OR POWER OF BOOM IS LOW 2126
H-7 ARM SPEED OR POWER IS LOW 2130
H-8 BUCKET SPEED OR POWER IS LOW 2135
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 2138
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE 2139
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 2141
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE 2143
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 2144
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 2145
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE 2147
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED 2148
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 2149
H-18 THE SET PRESSURE OF ATTACHMENT IS NOT OUTPUT 2150
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 2151
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 2152
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 2153
H-22 MACHINE DOES NOT TRAVEL STRAIGHT 2154
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 2157
H-24 TRAVEL SPEED IS LOW 2160
H-25 ONE OF TRACKS DOES NOT RUN 2162
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2163
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 2164
H-28 SWINGS ONLY IN ONE DIRECTION 2165
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 2166
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 2167
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 2168
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 2169
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 2170
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 2171
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 2172
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2173
H-1 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2174
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN 2175
TROUBLESHOOTING OF ENGINE (S-MODE) 2176
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2176
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2177
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2178
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2179
S-4 ENGINE STARTABILITY IS POOR 2181
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2183
S-6 ENGINE STOPS DURING OPERATION 2185
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2187
S-8 ENGINE LACKS POWER 2188
S-9 EXHAUST SMOKE IS BLACK 2190
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2192
S-11 OIL BECOMES CONTAMINATED QUICKLY 2193
S-12 FUEL CONSUMPTION IS EXCESSIVE 2194
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2195
S-14 OIL PRESSURE DROPS 2196
S-15 FUEL MIXES INTO ENGINE OIL 2198
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2199
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2200
S-18 UNUSUAL NOISE IS HEARD 2201
S-19 VIBRATION IS EXCESSIVE 2202
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2203
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2204
S-22 ACTIVE REGENERATION TAKES TIME 2205
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2206
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2207
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 2209
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2210
TROUBLESHOOTING FOR HYBRID SYSTEMS (Y MODE) 2211
PRECAUTIONS FOR USING HYBRID SYSTEMS 2211
Y-1 HYBRID MONITOR DOES NOT GO OUT 2212
Y-2 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 2214
Y-3 UPPER STRUCTURE SWINGS ONLY TO THE RIGHT OR LEFT 2215
Y-4 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 2216
Y-5 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS LOW IN ONLY ONE DIRECTION 2217
Y-6 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 2218
Y-7 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (EITHER RIGHT OR LEFT) 2219
Y-8 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 2220
Y-9 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 2221
Y-10 SWING DRIFT ON A SLOPE IS LARGE (WHILE PARKING BRAKE IS APPLIED) 2222
Y-11 SWING DRIFT ON A SLOPE IS LARGE (WHILE PARKING BRAKE IS RELEASED) 2223
Y-12 ELECTRIC SWING MOTOR TEMPERATURE INCREASES ABNORMALLY 2224
Y-13 MOTOR-GENERATOR TEMPERATURE INCREASES ABNORMALLY 2227
Y-14 INVERTER TEMPERATURE INCREASES ABNORMALLY 2229
Y-15 CAPACITOR TEMPERATURE INCREASES ABNORMALLY 2231
50 DISASSEMBLY AND ASSEMBLY 2235
CONTENTS 2236
ABBREVIATION LIST 2241
HOW TO READ THIS MANUAL 2247
HOW TO READ THIS MANUAL 2249
COATING MATERIALS LIST 2251
SPECIAL TOOLS LIST 2255
ENGINE AND COOLING SYSTEM 2270
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2270
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2270
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2274
REMOVE AND INSTALL INJECTOR ASSEMBLY 2278
METHOD FOR REMOVING INJECTOR ASSEMBLY 2278
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2281
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2287
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2287
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2297
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2314
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2314
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2315
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2317
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2317
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2320
REMOVE AND INSTALL STARTER ASSEMBLY 2323
METHOD FOR REMOVING STARTER ASSEMBLY 2323
METHOD FOR INSTALLING STARTER ASSEMBLY 2326
REMOVE AND INSTALL ALTERNATOR BELT 2329
METHOD FOR REMOVING ALTERNATOR BELT 2329
METHOD FOR INSTALLING ALTERNATOR BELT 2331
REMOVE AND INSTALL RADIATOR ASSEMBLY 2333
METHOD FOR REMOVING RADIATOR ASSEMBLY 2333
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2337
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2341
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2341
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2344
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2347
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2347
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2350
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 2354
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY 2354
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY 2355
REMOVE AND INSTALL FAN 2358
METHOD FOR INSTALLING FAN 2358
METHOD FOR REMOVING FAN 2358
REMOVE AND INSTALL ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY 2359
METHOD FOR REMOVING ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY 2359
METHOD FOR INSTALLING ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY 2380
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2403
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2403
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2406
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2410
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2410
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2411
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2415
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2415
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2417
REMOVE AND INSTALL KDOC ASSEMBLY 2420
METHOD FOR REMOVING KDOC ASSEMBLY 2420
METHOD FOR INSTALLING KDOC ASSEMBLY 2422
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY 2425
METHOD FOR REMOVING KDOC AND SCR ASSEMBLY 2426
METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY 2431
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 2436
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY 2436
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY 2439
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2444
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2444
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2448
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2452
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2453
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2459
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2464
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2464
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2465
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2467
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2467
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2468
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2471
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2471
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2471
REMOVE AND INSTALL SCR ASSEMBLY 2472
METHOD FOR REMOVING SCR ASSEMBLY 2472
METHOD FOR INSTALLING SCR ASSEMBLY 2474
REMOVE AND INSTALL KCCV ASSEMBLY 2478
METHOD FOR REMOVING KCCV ASSEMBLY 2478
METHOD FOR INSTALLING KCCV ASSEMBLY 2479
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2482
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2482
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2488
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2495
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2495
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2499
REMOVE AND INSTALL AdBlue/DEF PUMP 2503
METHOD FOR REMOVING AdBlue/DEF PUMP 2503
METHOD FOR INSTALLING AdBlue/DEF PUMP 2507
REMOVE AND INSTALL AdBlue/DEF HOSE 2510
METHOD FOR REMOVING AdBlue/DEF HOSE 2511
METHOD FOR INSTALLING AdBlue/DEF HOSE 2525
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2537
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2537
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2540
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2544
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2544
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2546
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2549
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2549
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2550
HYBRID SYSTEM 2553
REMOVE AND INSTALL HYBRID RADIATOR ASSEMBLY 2553
METHOD FOR REMOVING HYBRID RADIATOR ASSEMBLY 2553
METHOD FOR INSTALLING HYBRID RADIATOR ASSEMBLY 2556
REMOVE AND INSTALL HYBRID WATER PUMP ASSEMBLY 2561
METHOD FOR REMOVING HYBRID WATER PUMP ASSEMBLY 2561
METHOD FOR INSTALLING HYBRID WATER PUMP ASSEMBLY 2565
REMOVE AND INSTALL INVERTER ASSEMBLY 2569
METHOD FOR REMOVING INVERTER ASSEMBLY 2569
METHOD FOR INSTALLING INVERTER ASSEMBLY 2573
REMOVE AND INSTALL INVERTER AND CAPACITOR ASSEMBLY 2580
METHOD FOR REMOVING INVERTER AND CAPACITOR ASSEMBLY 2580
METHOD FOR INSTALLING INVERTER AND CAPACITOR ASSEMBLY 2589
REMOVE AND INSTALL MOTOR-GENERATOR AND HOUSING ASSEMBLY 2600
METHOD FOR REMOVING MOTOR-GENERATOR AND HOUSING ASSEMBLY 2600
METHOD FOR INSTALLING MOTOR-GENERATOR AND HOUSING ASSEMBLY 2608
REMOVE AND INSTALL TANDEM PUNP ASSEMBLY 2619
METHOD FOR REMOVING TANDEM PUNP ASSEMBLY 2619
METHOD FOR REMOVING TANDEM PUNP ASSEMBLY 2620
REMOVE AND INSTALL ELECTRIC SWING MOTOR 2622
METHOD FOR REMOVING ELECTRIC SWING MOTOR 2622
METHOD FOR INSTALLING ELECTRIC SWING MOTOR 2626
POWER TRAIN 2632
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2632
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2632
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2633
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2635
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2635
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2639
REMOVE AND INSTALL ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY 2648
METHOD FOR REMOVING ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY 2648
METHOD FOR INSTALLING ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY 2654
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 2660
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 2661
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2669
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2680
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 2680
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 2680
UNDERCARRIAGE AND FRAME 2682
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 2682
METHOD FOR SEPARATING TRACK ASSEMBLY 2682
METHOD FOR INSTALLING TRACK ASSEMBLY 2684
REMOVE AND INSTALL SPROCKET 2687
METHOD FOR REMOVING SPROCKET 2687
METHOD FOR INSTALLING SPROCKET 2687
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 2689
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2689
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2690
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2691
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2691
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2692
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2696
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY 2697
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2697
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2699
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2699
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2700
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 2702
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2702
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2704
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 2706
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2706
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2708
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 2710
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2710
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2711
HYDRAULIC SYSTEM 2714
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 2714
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2714
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2716
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 2719
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2719
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2720
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2722
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2722
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2724
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 2727
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2727
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2734
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2740
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2740
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2751
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 2763
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2763
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2764
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2769
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2769
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2769
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2771
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2771
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2772
WORK EQUIPMENT 2774
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2774
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 2774
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 2778
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM 2783
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR BOOM 2783
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR BOOM 2785
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM 2786
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR ARM 2786
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR ARM 2788
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY 2789
METHOD FOR DISASSEMBLING ANTI-DROP VALVE ASSEMBLY 2789
METHOD FOR ASSEMBLING ANTI-DROP VALVE ASSEMBLY 2789
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 2790
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2790
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2793
CAB AND ITS ATTACHMENTS 2799
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2799
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY 2799
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY 2807
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 2815
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2817
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2817
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2827
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 2827
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 2830
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 2836
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2836
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2840
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2845
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2845
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2850
REMOVE AND INSTALL OPERATOR’S SEAT 2856
METHOD FOR REMOVING OPERATOR’S SEAT 2856
METHOD FOR INSTALLING OPERATOR’S SEAT 2858
REMOVE AND INSTALL SEAT BELT 2861
METHOD FOR REMOVING SEAT BELT 2861
METHOD FOR INSTALLING SEAT BELT 2861
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 2863
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2863
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2868
ELECTRICAL SYSTEM 2877
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2877
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2877
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2879
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 2882
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2882
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2885
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2888
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY 2888
METHOD FOR INSTALLING KomVision CONTROLLER 2889
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2890
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2890
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2892
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2896
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR 2896
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR 2897
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2900
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2900
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2902
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2905
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2905
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2906
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2908
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2908
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2909
REMOVE AND INSTALL KomVision CAMERA 2911
METHOD FOR REMOVING KomVision CAMERA 2911
METHOD FOR INSTALLING KomVision CAMERA 2912
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2914
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 2914
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 2915
60 MAINTENANCE STANDARD 2917
CONTENTS 2918
ABBREVIATION LIST 2919
ENGINE AND COOLING SYSTEM 2925
MAINTENANCE STANDARD OF ENGINE MOUNT 2925
MAINTENANCE STANDARD OF COOLING SYSTEM 2926
POWER TRAIN 2928
MAINTENANCE STANDARD OF SWING CIRCLE 2928
MAINTENANCE STANDARD OF SWING MACHINERY WITH SWING PARKING BRAKE 2929
MAINTENANCE STANDARD OF FINAL DRIVE 2931
MAINTENANCE STANDARD OF SPROCKET 2933
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING 2934
UNDERCARRIAGE AND FRAME 2936
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2936
MAINTENANCE STANDARD OF IDLER 2937
MAINTENANCE STANDARD OF TRACK ROLLER 2939
MAINTENANCE STANDARD OF CARRIER ROLLER 2940
MAINTENANCE STANDARD OF TRACK SHOE 2941
MAINTENANCE STANDARD OF TRIPLE SHOE 2944
MAINTENANCE STANDARD OF SWAMP SHOE 2945
MAINTENANCE STANDARD OF ROAD LINER 2946
HYDRAULIC SYSTEM 2947
MAINTENANCE STANDARD OF HYDRAULIC TANK 2947
MAINTENANCE STANDARD OF MAIN PUMP 2948
MAINTENANCE STANDARD OF LS-EPC VALVE 2949
MAINTENANCE STANDARD OF PC-EPC VALVE 2950
MAINTENANCE STANDARD OF TRAVEL MOTOR 2951
MAINTENANCE STANDARD OF CONTROL VALVE 2954
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 2964
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM 2966
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2968
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2971
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2973
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2975
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE 2976
MAINTENANCE STANDARD OF SOLENOID VALVE 2978
MAINTENANCE STANDARD OF BUCKET DUMP OPARATION LOCK SOLENOID VALVE 2979
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 2980
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 2981
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 2982
WORK EQUIPMENT 2983
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2983
DIMENSION OF ARM 2988
DIMENSIONS OF BUCKET 2990
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) 2992
MAINTENANCE STANDARD OF ARM CYLINDER 2993
MAINTENANCE STANDARD OF BUCKET CYLINDER 2994
80 APPENDIX 2995
CONTENTS 2996
ABBREVIATION LIST 2998
AIR CONDITIONER SYSTEM 3004
PRECAUTIONS FOR REFRIGERANT 3004
AIR CONDITIONER COMPONENT 3005
SPECIFICATIONS OF AIR CONDITIONER 3007
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3008
OUTLINE OF REFRIGERATION CYCLE 3009
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3011
AIR CONDITIONER UNIT 3011
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3011
FUNCTION OF AIR CONDITIONER UNIT 3013
COMPONENT PARTS OF AIR CONDITIONER UNIT 3015
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3016
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3016
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3016
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3016
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3017
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3017
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3017
FUNCTION OF DUAL PRESSURE SWITCH 3018
AIR CONDITIONER CONTROLLER 3019
STRUCTURE OF AIR CONDITIONER CONTROLLER 3019
COMPRESSOR 3020
STRUCTURE OF COMPRESSOR 3020
SPECIFICATIONS OF COMPRESSOR 3020
FUNCTION OF COMPRESSOR 3020
CONDENSER 3021
STRUCTURE OF CONDENSER 3021
SPECIFICATIONS OF CONDENSER 3021
FUNCTION OF CONDENSER 3021
SENSORS FOR AIR CONDITIONER SYSTEM 3023
STRUCTURE OF SUNLIGHT SENSOR 3023
FUNCTION OF SUNLIGHT SENSOR 3023
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 3023
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3023
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3025
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3027
AIR CONDITIONER SYSTEM DIAGRAM 3029
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3030
FUNCTION OF AIR CONDITIONER CONTROLLER 3031
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3032
TESTING AIR LEAKAGE (DUCT) 3036
METHOD FOR TESTING AIR LEAKAGE (DUCT) 3036
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3038
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3039
TEST VENT (MODE) CHANGEOVER 3040
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3040
TESTING FRESH/RECIRC AIR CHANGEOVER 3042
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3042
TEST SUNLIGHT SENSOR 3043
METHOD FOR TESTING SUNLIGHT SENSOR 3043
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3044
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3044
TEST RELAYS 3045
METHOD FOR TESTING RELAYS 3045
AIR CONDITIONER TROUBLESHOOTING CHART 1 3046
AIR CONDITIONER TROUBLESHOOTING CHART 2 3047
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3050
FAILURE CODE [879AKA] 3052
FAILURE CODE [879AKB] 3053
FAILURE CODE [879BKA] 3054
FAILURE CODE [879BKB] 3056
FAILURE CODE [879CKA] 3058
FAILURE CODE [879CKB] 3059
FAILURE CODE [879DKZ] 3060
FAILURE CODE [879EMC] 3062
FAILURE CODE [879FMC] 3063
FAILURE CODE [879GKX] 3064
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3066
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3068
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3071
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3073
TROUBLESHOOTING USING GAUGE PRESSURE 3075
CONNECTION OF SERVICE TOOL 3078
METHOD FOR CONNECTING SERVICE TOOL 3078
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3080
HANDLE COMPRESSOR OIL 3082
METHOD FOR REPLACING DESICCANT 3084
90 CIRCUIT DIAGRAMS 3087
CONTENTS 3088
ABBREVIATION LIST 3089
HYDRAULIC CIRCUIT DIAGRAM 3095
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3095
HYDRAULIC CIRCUIT DIAGRAM (1/2) 3099
HYDRAULIC CIRCUIT DIAGRAM (2/2) 3101
ELECTRICAL CIRCUIT DIAGRAM 3103
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3103
ELECTRICAL CIRCUIT DIAGRAM (1/11) 3107
ELECTRICAL CIRCUIT DIAGRAM (2/11) 3109
ELECTRICAL CIRCUIT DIAGRAM (3/11) 3111
ELECTRICAL CIRCUIT DIAGRAM (4/11) 3113
ELECTRICAL CIRCUIT DIAGRAM (5/11) 3115
ELECTRICAL CIRCUIT DIAGRAM (6/11) 3117
ELECTRICAL CIRCUIT DIAGRAM (7/11) 3119
ELECTRICAL CIRCUIT DIAGRAM (8/11) 3121
ELECTRICAL CIRCUIT DIAGRAM (9/11) 3123
ELECTRICAL CIRCUIT DIAGRAM (10/11) 3125
ELECTRICAL CIRCUIT DIAGRAM (11/11) 3127
INDEX 3129

DESCRIPTION:

Komatsu HB215LC-3 Hydraulic Excavator Shop Manual UENBM00463 – PDF DOWNLOAD 

SERIAL NUMBERS

70009 and up
K70001 and up

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

S.V 30/12/24