Komatsu HB215LC-3 Hydraulic Excavator Shop Manual UENBM00690 PDF

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Komatsu HB215LC-3 Hydraulic Excavator Shop Manual UENBM00690 – PDF DOWNLOAD

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Komatsu HB215LC-3 Hydraulic Excavator Shop Manual UENBM00690 – PDF DOWNLOAD 

Language : English
Pages : 3228
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu HB215LC-3 Hydraulic Excavator Shop Manual UENBM00690 – PDF DOWNLOAD 

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
OPERATION OF SYSTEM OPERATING LAMP SYSTEM 164
BATTERY DISCONNECT SWITCH 165
FUNCTION OF BATTERY DISCONNECT SWITCH 165
ENGINE SYSTEM 166
LAYOUT DRAWING OF ENGINE SYSTEM 166
FUNCTION OF ENGINE SYSTEM 167
ENGINE CONTROL SYSTEM 168
ENGINE CONTROL SYSTEM DIAGRAM 168
OPERATION OF ENGINE CONTROL SYSTEM 169
AUTO-DECELERATION SYSTEM 171
AUTO-DECELERATION SYSTEM DIAGRAM 171
FUNCTION OF AUTO-DECELERATION SYSTEM 171
OPERATION OF AUTO-DECELERATION SYSTEM 172
ENGINE AUTOMATIC WARM-UP SYSTEM 173
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 173
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 174
OVERHEAT PREVENTION SYSTEM 175
OVERHEAT PREVENTION SYSTEM DIAGRAM 175
FUNCTION OF OVERHEAT PREVENTION SYSTEM 176
TURBOCHARGER PROTECTION SYSTEM 179
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 179
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 180
AUTOMATIC IDLE STOP SYSTEM 181
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 181
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 181
COMPONENT PARTS OF ENGINE SYSTEM 185
VGT 185
EGR SYSTEM 187
EGR VALVE 189
EGR COOLER 191
KCCV SYSTEM 192
KCCV VENTILATOR 194
KDOC 196
COOLING SYSTEM 200
LAYOUT DRAWING OF COOLING SYSTEM 200
SPECIFICATIONS OF COOLING SYSTEM 201
FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 202
FAN SPEED CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 202
FUNCTION OF FAN SPEED CONTROL SYSTEM OF FAN CLUTCH 203
ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 204
ENGINE OUTPUT CONTROL SYSTEM DIAGRAM OF FAN CLUTCH 204
FUNCTION OF ENGINE OUTPUT CONTROL SYSTEM OF FAN CLUTCH 205
COMPONENT PARTS OF COOLING SYSTEM 207
FAN CLUTCH 207
HYBRID SYSTEM 208
LAYOUT DRAWING OF HYBRID SYSTEM 208
SYSTEM DIAGRAM OF HYBRID SYSTEM 209
STRUCTURE OF HYBRID SYSTEM 210
HYBRID PROTECTION SYSTEM 211
SYSTEM DIAGRAM OF HYBRID PROTECTION SYSTEM 211
FUNCTION OF HYBRID PROTECTION SYSTEM 211
COOLING SYSTEM OF HYBRID COMPONENTS 213
SYSTEM DIAGRAM OF COOLING SYSTEM OF HYBRID COMPONENTS 213
INTERLOCK SYSTEM OF HYBRID COMPONENTS 214
SYSTEM DIAGRAM OF INTERLOCK SYSTEM OF HYBRID COMPONENTS 214
FUNCTION OF INTERLOCK SYSTEM OF HYBRID COMPONENTS 214
WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID COMPONENTS 215
SYSTEM DIAGRAM OF WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID COMPONENTS 215
FUNCTION OF WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID COMPONENTS 216
COMPONENT PARTS OF HYBRID SYSTEM 217
MOTOR-GENERATOR 217
ELECTRIC CONTROL UNIT 218
HIGH VOLTAGE WIRING (POWER CABLE) 219
HYBRID WATER PUMP 220
INVERTER (HYBRID CONTROLLER) 221
CONTROL SYSTEM 224
LAYOUT DRAWING OF CONTROL SYSTEM 224
MACHINE MONITOR SYSTEM 227
MACHINE MONITOR SYSTEM DIAGRAM 227
FUNCTION OF MACHINE MONITOR SYSTEM 227
KomVision SYSTEM 228
LAYOUT DRAWING OF KOMVISION SYSTEM 228
KomVision SYSTEM DIAGRAM 230
FUNCTION OF KomVision SYSTEM 230
COMPONENT PARTS OF CONTROL SYSTEM 232
MACHINE MONITOR 232
KomVision CONTROLLER 246
KomVision CAMERA 250
KOMTRAX SYSTEM 251
GATEWAY FUNCTION CONTROLLER 252
COMMUNICATION TERMINAL 255
PUMP CONTROLLER 257
RESISTOR FOR PC-EPC VALVE 261
CAN TERMINATING RESISTOR 261
ENGINE CONTROLLER 263
FUEL CONTROL DIAL 269
HYDRAULIC SYSTEM 271
LAYOUT DRAWING OF HYDRAULIC SYSTEM 271
CLSS 276
STRUCTURE OF CLSS 276
OPERATION OF UNLOAD VALVE AND LS PRESSURE 278
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 279
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 300
COMPONENT PARTS OF HYDRAULIC SYSTEM 302
HYDRAULIC TANK 302
MAIN PUMP 304
CONTROL VALVE 329
WORK EQUIPMENT SYSTEM 385
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 385
ONE-TOUCH POWER MAXIMIZING SYSTEM 389
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 389
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 390
PPC LOCK SYSTEM 391
PPC LOCK SYSTEM DIAGRAM 391
FUNCTION OF PPC LOCK SYSTEM 391
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 392
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 392
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 392
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 393
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 394
ATTACHMENT OIL FLOW ADJUSTER SYSTEM DIAGRAM 394
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 395
TOOL CONTROL SYSTEM 396
TOOL CONTROL SYSTEM DIAGRAM 396
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 398
WORK EQUIPMENT AND SWING PPC VALVE 398
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 403
2ND-LINE ATTACHMENT PPC VALVE 409
SOLENOID VALVE 411
ANTI-DROP VALVE FOR BOOM 414
ANTI-DROP VALVE FOR ARM 418
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 422
ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 424
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE 427
2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE 429
ATTACHMENT BYPASS SOLENOID VALVE 432
PILOT CIRCUIT ACCUMULATOR 434
ATTACHMENT CIRCUIT ACCUMULATOR 435
SWING SYSTEM 436
LAYOUT DRAWING OF SWING SYSTEM 436
SWING CONTROL SYSTEM DIAGRAM 439
FUNCTION OF SWING CONTROL SYSTEM 440
COMPONENT PARTS OF SWING SYSTEM 443
ELECTRIC SWING MOTOR 443
SWING MACHINERY WITH SWING PARKING BRAKE 444
SWING CIRCLE 446
TRAVEL SYSTEM 447
LAYOUT DRAWING OF TRAVEL SYSTEM 447
TRAVEL CONTROL SYSTEM DIAGRAM 451
FUNCTION OF TRAVEL CONTROL SYSTEM 451
COMPONENT PARTS OF TRAVEL SYSTEM 453
TRAVEL MOTOR 453
FINAL DRIVE 465
TRAVEL PPC VALVE 467
CENTER SWIVEL JOINT 472
UNDERCARRIAGE AND FRAME 474
LAYOUT DRAWING OF UNDERCARRIAGE 474
SPECIFICATIONS OF UNDERCARRIAGE 475
WORK EQUIPMENT 476
STRUCTURE OF WORK EQUIPMENT 476
FUNCTION OF WORK EQUIPMENT 477
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 478
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 478
BUCKET CLEARANCE ADJUSTMENT SHIM 479
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 479
CAB AND ITS ATTACHMENTS 480
ROPS CAB 480
STRUCTURE OF ROPS CAB 480
FUNCTION OF ROPS CAB 480
CAB MOUNT 481
STRUCTURE OF CAB MOUNT 481
FUNCTION OF CAB MOUNT 481
CAB TIPPING STOPPER 482
STRUCTURE OF CAB TIPPING STOPPER 482
FUNCTION OF CAB TIPPING STOPPER 482
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 SYSTEM 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 GATEWAY FUNCTION CONTROLLER 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) 1001
FAILURE CODE [879AKA] 1001
FAILURE CODE [879AKB] 1002
FAILURE CODE [879BKA] 1003
FAILURE CODE [879BKB] 1005
FAILURE CODE [879CKA] 1007
FAILURE CODE [879CKB] 1008
FAILURE CODE [879DKZ] 1009
FAILURE CODE [879EMC] 1011
FAILURE CODE [879FMC] 1012
FAILURE CODE [879GKX] 1013
FAILURE CODE [989L00] 1015
FAILURE CODE [989M00] 1016
FAILURE CODE [989N00] 1017
FAILURE CODE [A1U0N3] 1018
FAILURE CODE [A1U0N4] 1020
FAILURE CODE [A900FR] 1022
FAILURE CODE [A900N6] 1023
FAILURE CODE [A900NY] 1024
FAILURE CODE [AA10NX] 1025
FAILURE CODE [AB00KE] 1027
FAILURE CODE [AQ10MB] 1029
FAILURE CODE [AQ10N3] 1031
FAILURE CODE [AS00R2] 1033
FAILURE CODE [AS00R3] 1034
FAILURE CODE [AS00R4] 1035
FAILURE CODE [AS00R5] 1036
FAILURE CODE [AS00R6] 1037
FAILURE CODE [AS00ZK] 1038
FAILURE CODE [AS10KM] 1039
FAILURE CODE [AS10NR] 1040
FAILURE CODE [AS10NT] 1041
FAILURE CODE [B@BAZG] 1042
FAILURE CODE [B@BAZK] 1043
FAILURE CODE [B@BCNS] 1045
FAILURE CODE [B@BCQA] 1046
FAILURE CODE [B@BCZK] 1048
FAILURE CODE [B@HANS] 1049
FAILURE CODE [CA115] 1050
FAILURE CODE [CA122] 1051
FAILURE CODE [CA123] 1053
FAILURE CODE [CA131] 1055
FAILURE CODE [CA132] 1057
FAILURE CODE [CA144] 1059
FAILURE CODE [CA145] 1061
FAILURE CODE [CA153] 1063
FAILURE CODE [CA154] 1065
FAILURE CODE [CA187] 1067
FAILURE CODE [CA221] 1069
FAILURE CODE [CA222] 1071
FAILURE CODE [CA227] 1073
FAILURE CODE [CA234] 1075
FAILURE CODE [CA238] 1076
FAILURE CODE [CA239] 1077
FAILURE CODE [CA249] 1078
FAILURE CODE [CA256] 1080
FAILURE CODE [CA271] 1083
FAILURE CODE [CA272] 1085
FAILURE CODE [CA295] 1087
FAILURE CODE [CA322] 1088
FAILURE CODE [CA324] 1090
FAILURE CODE [CA331] 1092
FAILURE CODE [CA332] 1094
FAILURE CODE [CA343] 1096
FAILURE CODE [CA351] 1097
FAILURE CODE [CA352] 1098
FAILURE CODE [CA356] 1100
FAILURE CODE [CA357] 1102
FAILURE CODE [CA386] 1104
FAILURE CODE [CA428] 1105
FAILURE CODE [CA429] 1107
FAILURE CODE [CA435] 1109
FAILURE CODE [CA441] 1111
FAILURE CODE [CA442] 1113
FAILURE CODE [CA451] 1114
FAILURE CODE [CA452] 1116
FAILURE CODE [CA488] 1118
FAILURE CODE [CA515] 1119
FAILURE CODE [CA516] 1121
FAILURE CODE [CA553] 1123
FAILURE CODE [CA555] 1124
FAILURE CODE [CA556] 1125
FAILURE CODE [CA559] 1126
FAILURE CODE [CA595] 1129
FAILURE CODE [CA687] 1131
FAILURE CODE [CA689] 1133
FAILURE CODE [CA691] 1136
FAILURE CODE [CA692] 1138
FAILURE CODE [CA697] 1140
FAILURE CODE [CA698] 1141
FAILURE CODE [CA731] 1142
FAILURE CODE [CA778] 1144
FAILURE CODE [CA1117] 1148
FAILURE CODE [CA1664] 1150
FAILURE CODE [CA1669] 1152
FAILURE CODE [CA1673] 1153
FAILURE CODE [CA1677] 1154
FAILURE CODE [CA1678] 1155
FAILURE CODE [CA1682] 1156
FAILURE CODE [CA1683] 1160
FAILURE CODE [CA1684] 1162
FAILURE CODE [CA1686] 1164
FAILURE CODE [CA1691] 1165
FAILURE CODE [CA1694] 1167
FAILURE CODE [CA1695] 1169
FAILURE CODE [CA1696] 1170
FAILURE CODE [CA1712] 1172
FAILURE CODE [CA1713] 1175
FAILURE CODE [CA1714] 1178
FAILURE CODE [CA1715] 1179
FAILURE CODE [CA1776] 1180
FAILURE CODE [CA1777] 1183
FAILURE CODE [CA1843] 1186
FAILURE CODE [CA1844] 1188
FAILURE CODE [CA1885] 1191
FAILURE CODE [CA1887] 1193
FAILURE CODE [CA1896] 1195
FAILURE CODE [CA1898] 1196
FAILURE CODE [CA1938] 1198
FAILURE CODE [CA1942] 1200
FAILURE CODE [CA1961] 1201
FAILURE CODE [CA1962] 1202
FAILURE CODE [CA2185] 1203
FAILURE CODE [CA2186] 1205
FAILURE CODE [CA2198] 1207
FAILURE CODE [CA2272] 1209
FAILURE CODE [CA2288] 1211
FAILURE CODE [CA2311] 1212
FAILURE CODE [CA2349] 1213
FAILURE CODE [CA2353] 1215
FAILURE CODE [CA2357] 1217
FAILURE CODE [CA2373] 1218
FAILURE CODE [CA2374] 1220
FAILURE CODE [CA2375] 1222
FAILURE CODE [CA2376] 1224
FAILURE CODE [CA2387] 1227
FAILURE CODE [CA2554] 1228
FAILURE CODE [CA2555] 1230
FAILURE CODE [CA2556] 1233
FAILURE CODE [CA2634] 1235
FAILURE CODE [CA2635] 1237
FAILURE CODE [CA2636] 1238
FAILURE CODE [CA2637] 1240
FAILURE CODE [CA2771] 1242
FAILURE CODE [CA2961] 1246
FAILURE CODE [CA2973] 1247
FAILURE CODE [CA2976] 1248
FAILURE CODE [CA3142] 1250
FAILURE CODE [CA3143] 1251
FAILURE CODE [CA3144] 1252
FAILURE CODE [CA3146] 1254
FAILURE CODE [CA3147] 1255
FAILURE CODE [CA3148] 1256
FAILURE CODE [CA3151] 1258
FAILURE CODE [CA3165] 1265
FAILURE CODE [CA3228] 1267
FAILURE CODE [CA3229] 1270
FAILURE CODE [CA3231] 1272
FAILURE CODE [CA3232] 1274
FAILURE CODE [CA3235] 1278
FAILURE CODE [CA3239] 1280
FAILURE CODE [CA3241] 1283
FAILURE CODE [CA3242] 1286
FAILURE CODE [CA3251] 1289
FAILURE CODE [CA3313] 1291
FAILURE CODE [CA3314] 1292
FAILURE CODE [CA3315] 1293
FAILURE CODE [CA3419] 1295
FAILURE CODE [CA3421] 1297
FAILURE CODE [CA3497] 1299
FAILURE CODE [CA3498] 1300
FAILURE CODE [CA3545] 1301
FAILURE CODE [CA3547] 1303
FAILURE CODE [CA3558] 1304
FAILURE CODE [CA3559] 1306
FAILURE CODE [CA3562] 1308
FAILURE CODE [CA3563] 1310
FAILURE CODE [CA3567] 1313
FAILURE CODE [CA3568] 1317
FAILURE CODE [CA3571] 1322
FAILURE CODE [CA3572] 1324
FAILURE CODE [CA3574] 1326
FAILURE CODE [CA3575] 1329
FAILURE CODE [CA3577] 1331
FAILURE CODE [CA3578] 1333
FAILURE CODE [CA3582] 1335
FAILURE CODE [CA3583] 1342
FAILURE CODE [CA3596] 1344
FAILURE CODE [CA3649] 1347
FAILURE CODE [CA3681] 1349
FAILURE CODE [CA3682] 1353
FAILURE CODE [CA3713] 1357
FAILURE CODE [CA3717] 1360
FAILURE CODE [CA3718] 1361
FAILURE CODE [CA3724] 1362
FAILURE CODE [CA3725] 1363
FAILURE CODE [CA3741] 1366
FAILURE CODE [CA3748] 1367
FAILURE CODE [CA3755] 1370
FAILURE CODE [CA3866] 1372
FAILURE CODE [CA3868] 1375
FAILURE CODE [CA4152] 1378
FAILURE CODE [CA4155] 1382
FAILURE CODE [CA4156] 1385
FAILURE CODE [CA4157] 1388
FAILURE CODE [CA4159] 1390
FAILURE CODE [CA4164] 1391
FAILURE CODE [CA4165] 1393
FAILURE CODE [CA4166] 1395
FAILURE CODE [CA4168] 1396
FAILURE CODE [CA4169] 1399
FAILURE CODE [CA4171] 1401
FAILURE CODE [CA4249] 1403
FAILURE CODE [CA4251] 1405
FAILURE CODE [CA4261] 1407
FAILURE CODE [CA4277] 1410
FAILURE CODE [CA4459] 1414
FAILURE CODE [CA4461] 1416
FAILURE CODE [CA4533] 1419
FAILURE CODE [CA4534] 1420
FAILURE CODE [CA4731] 1421
FAILURE CODE [CA4732] 1422
FAILURE CODE [CA4739] 1423
FAILURE CODE [CA4768] 1424
FAILURE CODE [CA4769] 1426
FAILURE CODE [CA4842] 1429
FAILURE CODE [CA4952] 1432
FAILURE CODE [CA5115] 1434
FAILURE CODE [CA5179] 1437
FAILURE CODE [CA5181] 1439
FAILURE CODE [CA5387] 1441
FAILURE CODE [CA5388] 1443
FAILURE CODE [CA5389] 1446
FAILURE CODE [CA5391] 1448
FAILURE CODE [CA5392] 1452
FAILURE CODE [CA5393] 1454
FAILURE CODE [CA5394] 1456
FAILURE CODE [CA5395] 1458
FAILURE CODE [CA5396] 1461
FAILURE CODE [CA5631] 1462
FAILURE CODE [CA5938] 1464
FAILURE CODE [D110KB] 1466
FAILURE CODE [D19JKZ] 1468
FAILURE CODE [D811MC] 1471
FAILURE CODE [D862KA] 1472
FAILURE CODE [D8ALKA] 1474
FAILURE CODE [D8ALKB] 1477
FAILURE CODE [D8AQKR] 1479
FAILURE CODE [D8ARKR] 1486
FAILURE CODE [D8G1KT] 1491
FAILURE CODE [D8G6KT] 1492
FAILURE CODE [DA20MC] 1493
FAILURE CODE [DA22KK] 1494
FAILURE CODE [DA25KP] 1497
FAILURE CODE [DA26KP] 1500
FAILURE CODE [DA29KQ] 1503
FAILURE CODE [DA2LKA] 1506
FAILURE CODE [DA2LKB] 1509
FAILURE CODE [DA2QKR] 1511
FAILURE CODE [DA2RKR] 1520
FAILURE CODE [DAF0KM] 1525
FAILURE CODE [DAF0MB] 1526
FAILURE CODE [DAF0MC] 1527
FAILURE CODE [DAF8KB] 1528
FAILURE CODE [DAF9KQ] 1530
FAILURE CODE [DAFGMC] 1531
FAILURE CODE [DAFLKA] 1532
FAILURE CODE [DAFLKB] 1535
FAILURE CODE [DAFQKR] 1537
FAILURE CODE [DAZ9KQ] 1545
FAILURE CODE [DAZQKR] 1546
FAILURE CODE [DB2QKR] 1553
FAILURE CODE [DB2RKR] 1561
FAILURE CODE [DBP0KM] 1567
FAILURE CODE [DBP0KT] 1568
FAILURE CODE [DBP5KB] 1569
FAILURE CODE [DBP5KY] 1572
FAILURE CODE [DBPQKR] 1575
FAILURE CODE [DDNRKA] 1583
FAILURE CODE [DDNRKY] 1586
FAILURE CODE [DDNS00] 1589
FAILURE CODE [DFB1KZ] 1592
FAILURE CODE [DFB2KZ] 1594
FAILURE CODE [DFB3L8] 1596
FAILURE CODE [DFB4L8] 1598
FAILURE CODE [DFB5KZ] 1600
FAILURE CODE [DFB6KZ] 1602
FAILURE CODE [DGH2KA] 1604
FAILURE CODE [DGH2KB] 1606
FAILURE CODE [DHA4KA] 1608
FAILURE CODE [DHAAMA] 1610
FAILURE CODE [DHACMA] 1612
FAILURE CODE [DHPAMA] 1614
FAILURE CODE [DHPBMA] 1616
FAILURE CODE [DHS3MA] 1618
FAILURE CODE [DHS4MA] 1620
FAILURE CODE [DHS8MA] 1622
FAILURE CODE [DHS9MA] 1624
FAILURE CODE [DHSAKZ] 1626
FAILURE CODE [DHSBKZ] 1628
FAILURE CODE [DHSCMA] 1630
FAILURE CODE [DHSDMA] 1632
FAILURE CODE [DHSFMA] 1634
FAILURE CODE [DHSGMA] 1636
FAILURE CODE [DHSHMA] 1638
FAILURE CODE [DHSJMA] 1640
FAILURE CODE [DHVAKZ] 1642
FAILURE CODE [DHVAL8] 1644
FAILURE CODE [DHVAMA] 1646
FAILURE CODE [DHVBKZ] 1647
FAILURE CODE [DHVBL8] 1649
FAILURE CODE [DHVBMA] 1652
FAILURE CODE [DHX1MA] 1653
FAILURE CODE [DHZAMA] 1655
FAILURE CODE [DHZCL8] 1659
FAILURE CODE [DKR0MA] 1660
FAILURE CODE [DKR1MA] 1662
FAILURE CODE [DKTKKX] 1664
FAILURE CODE [DKTLKX] 1666
FAILURE CODE [DKTMKX] 1668
FAILURE CODE [DKTNKX] 1670
FAILURE CODE [DKTPKX] 1672
FAILURE CODE [DKTQKX] 1674
FAILURE CODE [DKULKA] 1676
FAILURE CODE [DKULKB] 1679
FAILURE CODE [DKULKY] 1682
FAILURE CODE [DLM5KA] 1685
FAILURE CODE [DLM5MB] 1687
FAILURE CODE [DR10KA] 1689
FAILURE CODE [DR12KA] 1692
FAILURE CODE [DR20KA] 1694
FAILURE CODE [DR21KX] 1696
FAILURE CODE [DR30KA] 1698
FAILURE CODE [DR31KX] 1700
FAILURE CODE [DR40KA] 1702
FAILURE CODE [DUMBKA] 1704
FAILURE CODE [DUMBKB] 1707
FAILURE CODE [DV00KA] 1709
FAILURE CODE [DV20KB] 1710
FAILURE CODE [DW43KA] 1712
FAILURE CODE [DW43KB] 1714
FAILURE CODE [DW43KY] 1716
FAILURE CODE [DW45KA] 1718
FAILURE CODE [DW45KB] 1721
FAILURE CODE [DW45KK] 1724
FAILURE CODE [DW45KY] 1726
FAILURE CODE [DW4CKY] 1728
FAILURE CODE [DW91KA] 1731
FAILURE CODE [DW91KB] 1733
FAILURE CODE [DW91KY] 1735
FAILURE CODE [DWA2KA] 1737
FAILURE CODE [DWA2KB] 1739
FAILURE CODE [DWA2KY] 1741
FAILURE CODE [DWK0KA] 1743
FAILURE CODE [DWK0KB] 1745
FAILURE CODE [DWK0KY] 1747
FAILURE CODE [DWK2KA] 1749
FAILURE CODE [DWK2KB] 1751
FAILURE CODE [DWK2KY] 1753
FAILURE CODE [DWN5KA] 1755
FAILURE CODE [DWN5KB] 1758
FAILURE CODE [DWN5KY] 1760
FAILURE CODE [DWPUKA] 1762
FAILURE CODE [DWPUKB] 1764
FAILURE CODE [DWPUKY] 1766
FAILURE CODE [DXA8KA] 1767
FAILURE CODE [DXA8KB] 1770
FAILURE CODE [DXA9KA] 1772
FAILURE CODE [DXA9KB] 1775
FAILURE CODE [DXE0KA] 1777
FAILURE CODE [DXE0KB] 1779
FAILURE CODE [DXE4KA] 1781
FAILURE CODE [DXE4KB] 1783
FAILURE CODE [DXE4KY] 1785
FAILURE CODE [DXE5KA] 1786
FAILURE CODE [DXE5KB] 1788
FAILURE CODE [DXE6KA] 1790
FAILURE CODE [DXE6KB] 1792
FAILURE CODE [DXE7KA] 1794
FAILURE CODE [DXE7KB] 1796
FAILURE CODE [DXE7KY] 1798
FAILURE CODE [DXE8KA] 1800
FAILURE CODE [DXE8KB] 1802
FAILURE CODE [DXE8KY] 1804
FAILURE CODE [DXE9KA] 1806
FAILURE CODE [DXE9KB] 1808
FAILURE CODE [DXE9KY] 1810
FAILURE CODE [DXEAKA] 1812
FAILURE CODE [DXEAKB] 1814
FAILURE CODE [DXEAKY] 1816
FAILURE CODE [DXEKKA] 1818
FAILURE CODE [DXEKKB] 1820
FAILURE CODE [DXEKKY] 1822
FAILURE CODE [DXELKA] 1823
FAILURE CODE [DXELKB] 1825
FAILURE CODE [DXELKY] 1827
FAILURE CODE [DY20KA] 1828
FAILURE CODE [DY20MA] 1830
FAILURE CODE [DY2CKB] 1832
FAILURE CODE [DY2DKB] 1834
FAILURE CODE [DY2EKB] 1836
FAILURE CODE [F313KA] 1838
FAILURE CODE [F313KB] 1840
FAILURE CODE [F318KB] 1843
FAILURE CODE [F318KY] 1846
FAILURE CODE [GA00NS] 1848
FAILURE CODE [GA01KA] 1849
FAILURE CODE [GA01KB] 1851
FAILURE CODE [GA02KZ] 1853
FAILURE CODE [GA04KG] 1856
FAILURE CODE [GA05KG] 1859
FAILURE CODE [GA05KP] 1862
FAILURE CODE [GA06KZ] 1866
FAILURE CODE [GA08KG] 1867
FAILURE CODE [GA09KG] 1875
FAILURE CODE [GA09KP] 1883
FAILURE CODE [GA0AKZ] 1884
FAILURE CODE [GA0BKZ] 1885
FAILURE CODE [GA10MA] 1892
FAILURE CODE [GA10MC] 1898
FAILURE CODE [GA12NK] 1899
FAILURE CODE [GA13KP] 1905
FAILURE CODE [GA13KY] 1907
FAILURE CODE [GA15KZ] 1909
FAILURE CODE [GA17KR] 1917
FAILURE CODE [GA17MB] 1918
FAILURE CODE [GA18MC] 1919
FAILURE CODE [GA19KR] 1924
FAILURE CODE [GA19KT] 1925
FAILURE CODE [GA1BMA] 1926
FAILURE CODE [GA1FKR] 1928
FAILURE CODE [GA1FMA] 1929
FAILURE CODE [GA1GKR] 1932
FAILURE CODE [GA1GKT] 1933
FAILURE CODE [GA1GMB] 1934
FAILURE CODE [GA1HKZ] 1935
FAILURE CODE [GA1JKZ] 1936
FAILURE CODE [GA1KKZ] 1937
FAILURE CODE [GA1LKZ] 1938
FAILURE CODE [GA1MKZ] 1939
FAILURE CODE [GA1NNS] 1940
FAILURE CODE [GA1SFS] 1941
FAILURE CODE [GA1SMC] 1942
FAILURE CODE [GA1TKP] 1943
FAILURE CODE [GA1TNS] 1947
FAILURE CODE [GA1UKZ] 1950
FAILURE CODE [GA1VFS] 1953
FAILURE CODE [GA1VMC] 1954
FAILURE CODE [GA1XKZ] 1955
FAILURE CODE [GA1YNS] 1956
FAILURE CODE [GA1ZKZ] 1957
FAILURE CODE [GA1ZNS] 1958
FAILURE CODE [GA22NS] 1959
FAILURE CODE [GA23KZ] 1960
FAILURE CODE [GA24KZ] 1961
FAILURE CODE [GA25MA] 1962
FAILURE CODE [GA25NS] 1966
FAILURE CODE [GA26MA] 1967
FAILURE CODE [GA26NS] 1971
FAILURE CODE [GA27KZ] 1972
FAILURE CODE [GA2QKR] 1973
FAILURE CODE [GA2RKR] 1980
FAILURE CODE [GA60KZ] 1985
FAILURE CODE [GA60MC] 1990
FAILURE CODE [GA60N1] 1992
FAILURE CODE [GA61KZ] 1994
FAILURE CODE [GA61NS] 1996
FAILURE CODE [GA62KY] 1997
FAILURE CODE [GA62KZ] 2002
FAILURE CODE [GA62MA] 2006
FAILURE CODE [GA62MC] 2007
FAILURE CODE [GA63KY] 2008
FAILURE CODE [GA63KZ] 2013
FAILURE CODE [GA63MA] 2017
FAILURE CODE [GA63MC] 2018
FAILURE CODE [GA64KY] 2019
FAILURE CODE [GA64KZ] 2024
FAILURE CODE [GA64MA] 2028
FAILURE CODE [GA64MC] 2029
FAILURE CODE [GA70KB] 2030
FAILURE CODE [GA70MD] 2033
FAILURE CODE [GA70N1] 2035
FAILURE CODE [GA70NS] 2036
FAILURE CODE [GA71KZ] 2037
FAILURE CODE [GA72MA] 2039
FAILURE CODE [GA72MC] 2041
FAILURE CODE [GA81KZ] 2043
FAILURE CODE [GAA0KB] 2046
FAILURE CODE [GAA2KB] 2048
FAILURE CODE [GAA6KP] 2050
FAILURE CODE [GAA6KY] 2052
FAILURE CODE [GACLKA] 2054
FAILURE CODE [GACLKB] 2056
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2058
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2058
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 2064
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2067
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2069
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 2071
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 2074
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 2075
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 2076
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 2077
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 2078
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2079
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2080
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2081
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2082
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2083
E-16 HYBRID TEMPERATURE MONITOR LIGHTS UP IN RED RED ENGINE IS RUNNING 2084
E-17 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2086
E-18 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2087
E-19 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 2089
E-20 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2090
E-21 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 2091
E-22 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2092
E-23 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE 2094
E-24 HYBRID TEMPERATURE GAUGE DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2095
E-25 HYBRID TEMPERATURE GAUGE INDICATES INCORRECT TEMPERATURE (INDICATES NEITHER MINIMUM NOR MAXIMUM) 2097
E-26 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 2099
E-27 FUNCTION SWITCH DOES NOT OPERATE 2100
E-28 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) 2101
E-29 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 2102
E-30 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 2103
E-31 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED 2104
E-32 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 2105
E-33 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE 2106
E-34 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 2107
E-35 ALARM BUZZER CANNOT BE CANCELED 2109
E-36 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 2110
E-37 SERVICE MODE CANNOT BE SELECTED 2111
E-38 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 2112
E-39 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 2116
E-40 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING 2119
E-41 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE 2122
E-42 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR 2124
E-43 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED 2126
E-44 ALARM DOES NOT SOUND DURING TRAVEL 2127
E-45 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 2129
E-46 HORN DOES NOT SOUND 2130
E-47 HORN DOES NOT STOP SOUNDING 2133
E-48 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF 2135
E-49 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 2136
E-50 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 2138
E-51 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2139
E-52 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2140
E-53 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2141
E-54 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2142
E-55 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2143
E-56 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2144
E-57 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2145
E-58 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2146
E-59 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2147
E-60 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED 2149
E-61 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2150
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2151
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2151
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 2152
FAILURE MODE AND CAUSE TABLE 2154
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 2163
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER 2164
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 2166
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 2168
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2169
H-6 SPEED OR POWER OF BOOM IS LOW 2171
H-7 ARM SPEED OR POWER IS LOW 2175
H-8 BUCKET SPEED OR POWER IS LOW 2180
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 2183
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE 2184
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 2186
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE 2188
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 2189
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 2190
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE 2192
H-16 ATTACHMENT CIRCUIT CANNOT BE CHANGED 2193
H-17 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 2194
H-18 THE SET PRESSURE OF ATTACHMENT IS NOT OUTPUT 2195
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 2196
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 2197
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 2198
H-22 MACHINE DOES NOT TRAVEL STRAIGHT 2199
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 2202
H-24 TRAVEL SPEED IS LOW 2205
H-25 ONE OF TRACKS DOES NOT RUN 2207
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2208
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 2209
H-28 SWINGS ONLY IN ONE DIRECTION 2210
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 2211
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 2212
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 2213
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 2214
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 2215
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 2216
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 2217
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2218
H-37 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) 2219
H-38 UNUSUAL NOISE IS HEARD FROM AROUND FAN 2220
TROUBLESHOOTING OF ENGINE (S-MODE) 2221
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2221
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2222
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2223
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2224
S-4 ENGINE STARTABILITY IS POOR 2226
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2228
S-6 ENGINE STOPS DURING OPERATION 2230
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2232
S-8 ENGINE LACKS POWER 2233
S-9 EXHAUST SMOKE IS BLACK 2235
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2237
S-11 OIL BECOMES CONTAMINATED QUICKLY 2238
S-12 FUEL CONSUMPTION IS EXCESSIVE 2239
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2240
S-14 OIL PRESSURE DROPS 2241
S-15 FUEL MIXES INTO ENGINE OIL 2243
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2244
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2245
S-18 UNUSUAL NOISE IS HEARD 2246
S-19 VIBRATION IS EXCESSIVE 2247
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2248
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2249
S-22 ACTIVE REGENERATION TAKES TIME 2250
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2251
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2252
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 2254
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2255
TROUBLESHOOTING FOR HYBRID SYSTEMS (Y MODE) 2256
PRECAUTIONS FOR USING HYBRID SYSTEMS 2256
Y-1 HYBRID MONITOR DOES NOT GO OUT 2257
Y-2 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 2259
Y-3 UPPER STRUCTURE SWINGS ONLY TO THE RIGHT OR LEFT 2260
Y-4 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 2261
Y-5 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS LOW IN ONLY ONE DIRECTION 2262
Y-6 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 2263
Y-7 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (EITHER RIGHT OR LEFT) 2264
Y-8 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 2265
Y-9 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 2266
Y-10 SWING DRIFT ON A SLOPE IS LARGE (WHILE PARKING BRAKE IS APPLIED) 2267
Y-11 SWING DRIFT ON A SLOPE IS LARGE (WHILE PARKING BRAKE IS RELEASED) 2268
Y-12 ELECTRIC SWING MOTOR TEMPERATURE INCREASES ABNORMALLY 2269
Y-13 MOTOR-GENERATOR TEMPERATURE INCREASES ABNORMALLY 2272
Y-14 INVERTER TEMPERATURE INCREASES ABNORMALLY 2274
Y-15 CAPACITOR TEMPERATURE INCREASES ABNORMALLY 2276
50 DISASSEMBLY AND ASSEMBLY 2279
CONTENTS 2280
ABBREVIATION LIST 2285
HOW TO READ THIS MANUAL 2291
HOW TO READ THIS MANUAL 2293
COATING MATERIALS LIST 2295
SPECIAL TOOLS LIST 2299
ENGINE AND COOLING SYSTEM 2314
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2314
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2314
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2318
REMOVE AND INSTALL INJECTOR ASSEMBLY 2322
METHOD FOR REMOVING INJECTOR ASSEMBLY 2322
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2325
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2331
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2331
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2341
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2358
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2358
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2359
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2361
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2361
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2364
REMOVE AND INSTALL STARTER ASSEMBLY 2367
METHOD FOR REMOVING STARTER ASSEMBLY 2367
METHOD FOR INSTALLING STARTER ASSEMBLY 2370
REMOVE AND INSTALL ALTERNATOR BELT 2373
METHOD FOR REMOVING ALTERNATOR BELT 2373
METHOD FOR INSTALLING ALTERNATOR BELT 2375
REMOVE AND INSTALL RADIATOR ASSEMBLY 2377
METHOD FOR REMOVING RADIATOR ASSEMBLY 2377
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2381
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2385
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2385
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2388
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2391
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2391
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2394
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 2398
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY 2398
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY 2399
REMOVE AND INSTALL FAN 2402
METHOD FOR INSTALLING FAN 2402
METHOD FOR REMOVING FAN 2402
REMOVE AND INSTALL ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY 2403
METHOD FOR REMOVING ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY 2403
METHOD FOR INSTALLING ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY 2424
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2447
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2447
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2450
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2454
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2454
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2455
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2459
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2459
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2461
REMOVE AND INSTALL KDOC ASSEMBLY 2464
METHOD FOR REMOVING KDOC ASSEMBLY 2464
METHOD FOR INSTALLING KDOC ASSEMBLY 2466
REMOVE AND INSTALL KDOC AND SCR ASSEMBLY 2469
METHOD FOR REMOVING KDOC AND SCR ASSEMBLY 2470
METHOD FOR INSTALLING KDOC AND SCR ASSEMBLY 2475
REMOVE AND INSTALL BELLOWS PIPE ASSEMBLY 2480
METHOD FOR REMOVING BELLOWS PIPE ASSEMBLY 2480
METHOD FOR INSTALLING BELLOWS PIPE ASSEMBLY 2483
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2488
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2488
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2492
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2496
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2497
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2503
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2508
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2508
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2509
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2511
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2511
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2512
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2515
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2515
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2515
REMOVE AND INSTALL SCR ASSEMBLY 2516
METHOD FOR REMOVING SCR ASSEMBLY 2516
METHOD FOR INSTALLING SCR ASSEMBLY 2518
REMOVE AND INSTALL KCCV ASSEMBLY 2522
METHOD FOR REMOVING KCCV ASSEMBLY 2522
METHOD FOR INSTALLING KCCV ASSEMBLY 2523
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2526
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2526
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2532
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2539
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2539
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2543
REMOVE AND INSTALL AdBlue/DEF PUMP 2547
METHOD FOR REMOVING AdBlue/DEF PUMP 2547
METHOD FOR INSTALLING AdBlue/DEF PUMP 2551
REMOVE AND INSTALL AdBlue/DEF HOSE 2554
METHOD FOR REMOVING AdBlue/DEF HOSE 2555
METHOD FOR INSTALLING AdBlue/DEF HOSE 2569
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2581
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2581
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2584
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2588
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2588
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2590
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2593
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2593
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2594
HYBRID SYSTEM 2597
REMOVE AND INSTALL HYBRID RADIATOR ASSEMBLY 2597
METHOD FOR REMOVING HYBRID RADIATOR ASSEMBLY 2597
METHOD FOR INSTALLING HYBRID RADIATOR ASSEMBLY 2600
REMOVE AND INSTALL HYBRID WATER PUMP ASSEMBLY 2605
METHOD FOR REMOVING HYBRID WATER PUMP ASSEMBLY 2605
METHOD FOR INSTALLING HYBRID WATER PUMP ASSEMBLY 2609
REMOVE AND INSTALL INVERTER ASSEMBLY 2613
METHOD FOR REMOVING INVERTER ASSEMBLY 2613
METHOD FOR INSTALLING INVERTER ASSEMBLY 2617
REMOVE AND INSTALL INVERTER AND CAPACITOR ASSEMBLY 2624
METHOD FOR REMOVING INVERTER AND CAPACITOR ASSEMBLY 2624
METHOD FOR INSTALLING INVERTER AND CAPACITOR ASSEMBLY 2633
REMOVE AND INSTALL MOTOR-GENERATOR AND HOUSING ASSEMBLY 2644
METHOD FOR REMOVING MOTOR-GENERATOR AND HOUSING ASSEMBLY 2644
METHOD FOR INSTALLING MOTOR-GENERATOR AND HOUSING ASSEMBLY 2652
REMOVE AND INSTALL TANDEM PUNP ASSEMBLY 2663
METHOD FOR REMOVING TANDEM PUNP ASSEMBLY 2663
METHOD FOR REMOVING TANDEM PUNP ASSEMBLY 2664
REMOVE AND INSTALL ELECTRIC SWING MOTOR 2666
METHOD FOR REMOVING ELECTRIC SWING MOTOR 2666
METHOD FOR INSTALLING ELECTRIC SWING MOTOR 2670
POWER TRAIN 2676
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2676
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2676
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2677
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2679
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2679
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2683
REMOVE AND INSTALL ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY 2692
METHOD FOR REMOVING ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY 2692
METHOD FOR INSTALLING ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY 2698
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 2704
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 2705
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2713
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2724
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 2724
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 2724
UNDERCARRIAGE AND FRAME 2726
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 2726
METHOD FOR SEPARATING TRACK ASSEMBLY 2726
METHOD FOR INSTALLING TRACK ASSEMBLY 2728
REMOVE AND INSTALL SPROCKET 2731
METHOD FOR REMOVING SPROCKET 2731
METHOD FOR INSTALLING SPROCKET 2731
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 2733
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2733
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2734
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2735
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2735
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2736
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2740
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY 2741
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2741
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2743
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2743
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2744
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 2746
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2746
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2748
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 2750
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2750
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2752
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 2754
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2754
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2755
HYDRAULIC SYSTEM 2758
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 2758
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2758
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2760
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 2763
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2763
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2764
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2766
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2766
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2768
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 2772
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2772
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2778
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2786
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2786
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2797
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 2809
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2809
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2810
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2815
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2815
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2815
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2817
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2817
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2818
WORK EQUIPMENT 2820
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2820
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 2820
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 2824
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM 2829
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR BOOM 2829
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR BOOM 2831
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM 2832
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR ARM 2832
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR ARM 2834
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY 2835
METHOD FOR DISASSEMBLING ANTI-DROP VALVE ASSEMBLY 2835
METHOD FOR ASSEMBLING ANTI-DROP VALVE ASSEMBLY 2835
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 2836
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2836
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2839
CAB AND ITS ATTACHMENTS 2845
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2845
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY 2845
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY 2853
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 2861
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2863
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2863
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2873
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 2873
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 2876
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 2882
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2882
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2886
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2891
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2891
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2896
REMOVE AND INSTALL OPERATOR’S SEAT 2902
METHOD FOR REMOVING OPERATOR’S SEAT 2902
METHOD FOR INSTALLING OPERATOR’S SEAT 2904
REMOVE AND INSTALL SEAT BELT 2907
METHOD FOR REMOVING SEAT BELT 2907
METHOD FOR INSTALLING SEAT BELT 2907
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 2909
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2909
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2914
ELECTRICAL SYSTEM 2923
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2923
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2923
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2925
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 2928
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2928
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2931
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2934
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY 2934
METHOD FOR INSTALLING KomVision CONTROLLER 2935
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2936
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2936
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2938
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2942
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR 2942
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR 2943
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2946
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2946
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2948
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2951
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2951
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2952
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2954
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2954
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2955
REMOVE AND INSTALL KomVision CAMERA 2957
METHOD FOR REMOVING KomVision CAMERA 2957
METHOD FOR INSTALLING KomVision CAMERA 2958
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2960
METHOD FOR REMOVING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2960
METHOD FOR INSTALLING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2965
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 2970
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS 2970
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS 2978
REMOVE AND INSTALL COMMUNICATION TERMINAL 2987
METHOD FOR REMOVING COMMUNICATION TERMINAL 2987
METHOD FOR INSTALLING COMMUNICATION TERMINAL 2989
60 MAINTENANCE STANDARD 2993
CONTENTS 2994
ABBREVIATION LIST 2995
ENGINE AND COOLING SYSTEM 3001
MAINTENANCE STANDARD OF ENGINE MOUNT 3001
MAINTENANCE STANDARD OF COOLING SYSTEM 3002
POWER TRAIN 3004
MAINTENANCE STANDARD OF SWING CIRCLE 3004
MAINTENANCE STANDARD OF SWING MACHINERY WITH SWING PARKING BRAKE 3005
MAINTENANCE STANDARD OF FINAL DRIVE 3007
MAINTENANCE STANDARD OF SPROCKET 3009
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING 3010
UNDERCARRIAGE AND FRAME 3012
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 3012
MAINTENANCE STANDARD OF IDLER 3013
MAINTENANCE STANDARD OF TRACK ROLLER 3015
MAINTENANCE STANDARD OF CARRIER ROLLER 3016
MAINTENANCE STANDARD OF TRACK SHOE 3017
MAINTENANCE STANDARD OF TRIPLE SHOE 3020
MAINTENANCE STANDARD OF SWAMP SHOE 3021
MAINTENANCE STANDARD OF ROAD LINER 3022
HYDRAULIC SYSTEM 3023
MAINTENANCE STANDARD OF HYDRAULIC TANK 3023
MAINTENANCE STANDARD OF MAIN PUMP 3024
MAINTENANCE STANDARD OF LS-EPC VALVE 3025
MAINTENANCE STANDARD OF PC-EPC VALVE 3026
MAINTENANCE STANDARD OF TRAVEL MOTOR 3027
MAINTENANCE STANDARD OF CONTROL VALVE 3030
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 3040
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM 3042
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 3044
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 3047
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 3049
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 3051
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE 3052
MAINTENANCE STANDARD OF SOLENOID VALVE 3054
MAINTENANCE STANDARD OF BUCKET DUMP OPARATION LOCK SOLENOID VALVE 3055
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR HIGH PRESSURE) 3056
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE (FOR LOW PRESSURE) 3057
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 3058
WORK EQUIPMENT 3059
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 3059
DIMENSION OF ARM 3064
DIMENSIONS OF BUCKET 3066
MAINTENANCE STANDARD OF BOOM CYLINDER (LARGE DIAMETER PISTON) 3068
MAINTENANCE STANDARD OF ARM CYLINDER 3069
MAINTENANCE STANDARD OF BUCKET CYLINDER 3070
80 APPENDIX 3071
CONTENTS 3072
ABBREVIATION LIST 3074
AIR CONDITIONER SYSTEM 3080
PRECAUTIONS FOR REFRIGERANT 3080
AIR CONDITIONER COMPONENT 3081
SPECIFICATIONS OF AIR CONDITIONER 3083
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 3084
OUTLINE OF REFRIGERATION CYCLE 3085
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 3087
AIR CONDITIONER UNIT 3087
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 3087
FUNCTION OF AIR CONDITIONER UNIT 3089
COMPONENT PARTS OF AIR CONDITIONER UNIT 3091
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3092
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 3092
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 3092
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 3092
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3093
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3093
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3093
FUNCTION OF DUAL PRESSURE SWITCH 3094
AIR CONDITIONER CONTROLLER 3095
STRUCTURE OF AIR CONDITIONER CONTROLLER 3095
COMPRESSOR 3096
STRUCTURE OF COMPRESSOR 3096
SPECIFICATIONS OF COMPRESSOR 3096
FUNCTION OF COMPRESSOR 3096
CONDENSER 3097
STRUCTURE OF CONDENSER 3097
SPECIFICATIONS OF CONDENSER 3097
FUNCTION OF CONDENSER 3097
SENSORS FOR AIR CONDITIONER SYSTEM 3099
STRUCTURE OF SUNLIGHT SENSOR 3099
FUNCTION OF SUNLIGHT SENSOR 3099
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 3099
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3099
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 3101
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 3103
AIR CONDITIONER SYSTEM DIAGRAM 3105
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3106
FUNCTION OF AIR CONDITIONER CONTROLLER 3107
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 3108
TESTING AIR LEAKAGE (DUCT) 3112
METHOD FOR TESTING AIR LEAKAGE (DUCT) 3112
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 3114
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3115
TEST VENT (MODE) CHANGEOVER 3116
METHOD FOR TESTING VENT (MODE) CHANGEOVER 3116
TESTING FRESH/RECIRC AIR CHANGEOVER 3118
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3118
TEST SUNLIGHT SENSOR 3119
METHOD FOR TESTING SUNLIGHT SENSOR 3119
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3120
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 3120
TEST RELAYS 3121
METHOD FOR TESTING RELAYS 3121
AIR CONDITIONER TROUBLESHOOTING CHART 1 3122
AIR CONDITIONER TROUBLESHOOTING CHART 2 3123
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3126
FAILURE CODE [879AKA] 3128
FAILURE CODE [879AKB] 3129
FAILURE CODE [879BKA] 3130
FAILURE CODE [879BKB] 3132
FAILURE CODE [879CKA] 3134
FAILURE CODE [879CKB] 3135
FAILURE CODE [879DKZ] 3136
FAILURE CODE [879EMC] 3138
FAILURE CODE [879FMC] 3139
FAILURE CODE [879GKX] 3140
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3142
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3144
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3147
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3149
TROUBLESHOOTING USING GAUGE PRESSURE 3151
CONNECTION OF SERVICE TOOL 3154
METHOD FOR CONNECTING SERVICE TOOL 3154
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3156
HANDLE COMPRESSOR OIL 3158
METHOD FOR REPLACING DESICCANT 3160
90 CIRCUIT DIAGRAMS 3163
CONTENTS 3164
ABBREVIATION LIST 3165
HYDRAULIC CIRCUIT DIAGRAM 3171
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3171
HYDRAULIC CIRCUIT DIAGRAM (1/2) 3175
HYDRAULIC CIRCUIT DIAGRAM (2/2) 3177
ELECTRICAL CIRCUIT DIAGRAM 3179
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3179
ELECTRICAL CIRCUIT DIAGRAM (1/12) 3183
ELECTRICAL CIRCUIT DIAGRAM (2/12) 3185
ELECTRICAL CIRCUIT DIAGRAM (3/12) 3187
ELECTRICAL CIRCUIT DIAGRAM (4/12) 3189
ELECTRICAL CIRCUIT DIAGRAM (5/12) 3191
ELECTRICAL CIRCUIT DIAGRAM (6/12) 3193
ELECTRICAL CIRCUIT DIAGRAM (7/12) 3195
ELECTRICAL CIRCUIT DIAGRAM (8/12) 3197
ELECTRICAL CIRCUIT DIAGRAM (9/12) 3199
ELECTRICAL CIRCUIT DIAGRAM (10/12) 3201
ELECTRICAL CIRCUIT DIAGRAM (11/12) 3203
ELECTRICAL CIRCUIT DIAGRAM (12/12) 3205
INDEX 3207

DESCRIPTION:

Komatsu HB215LC-3 Hydraulic Excavator Shop Manual UENBM00690 – 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 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 31/12/24