Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
KOMATSU HB365LC-3E0 HB365NLC-3E0 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00641 – PDF DOWNLOAD
$43.95
KOMATSU HB365LC-3E0 HB365NLC-3E0 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00641 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU HB365LC-3E0 HB365NLC-3E0 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00641 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU HB365LC-3E0 HB365NLC-3E0 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00641 – PDF DOWNLOAD
Language : English
Pages : 3236
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU HB365LC-3E0 HB365NLC-3E0 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00641 – 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 METHOD FOR CHECKING ENGINE TYPE................................................................................................. 46 PRECAUTIONS FOR DEF............................................................................................................. 48 GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING.............................................................................. 48 PRECAUTIONS FOR ADDING...................................................................................................... 48 PRECAUTIONS FOR STORING..................................................................................................... 48 PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE..................................................................................... 48 THE OTHER PRECAUTIONS....................................................................................................... 48 STORE AdBlue/DEF................................................................................................................ 49 PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT.................................................................................... 50 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS......................................................................... 53 PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT................................................................................... 60 PRECAUTIONS FOR MAINTENANCE OF HYBRID SYSTEM.................................................................................... 62 PRECAUTIONS AGAINST HIGH VOLTAGE AND HIGH TEMPERATURE........................................................................... 63 PRECAUTIONS FOR NORMAL CHECK AND MAINTENANCE.................................................................................... 64 PRECAUTIONS FOR THE MACHINE NOT TO BE TIPPED OVER AND FOR HYBRID COMPONENTS NOT TO BE DAMAGED................................... 65 PRECAUTIONS FOR THE MACHINE NOT TO BE SUBMERGED................................................................................. 66 PRECAUTIONS FOR THE COLD SEASON................................................................................................. 67 PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT.................................................................................. 68 PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT................................................................................ 69 PRACTICAL USE OF KOMTRAX........................................................................................................ 70 DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER................................................................................... 71 METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER....................................................... 71 METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER....................................................... 72 METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER....................................................... 73 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS...................................................................... 75 METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR....................................................................... 79 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR............................................................... 80 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL............................................................. 82 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH............................................................. 83 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE........................................................ 85 HOW TO READ THE CODES (SYMBOLS) FOR ELECTRIC CABLE.............................................................................. 86 EXPLANATION OF TERMS FOR MAINTENANCE STANDARD................................................................................... 92 STANDARD TIGHTENING TORQUE TABLE................................................................................................ 95 CONVERSION TABLE................................................................................................................ 102 01 SPECIFICATIONS....................................................................................................................... 107 CONTENTS............................................................................................................................ 108 ABBREVIATION LIST................................................................................................................... 109 SPECIFICATIONS...................................................................................................................... 115 SPECIFICATION DRAWING........................................................................................................... 115 SPECIFICATION DRAWING: HB365LC-3E0, HB365NLC-3E0............................................................................ 115 WORKING RANGE DRAWINGS.......................................................................................................... 116 WORKING RANGE: HB365LC-3E0, HB365NLC-3E0.................................................................................... 116 SPECIFICATIONS.................................................................................................................. 117 SPECIFICATIONS: HB365LC-3E0, HB365NLC-3E0................................................................................... 117 WEIGHT TABLE.................................................................................................................... 121 WEIGHT TABLE: HB365LC-3E0, HB365NLC-3E0..................................................................................... 121 TABLE OF FUEL, COOLANT, AND LUBRICANTS.......................................................................................... 123 10 STRUCTURE AND FUNCTION............................................................................................................... 125 CONTENTS............................................................................................................................ 126 ABBREVIATION LIST................................................................................................................... 130 UREA SCR SYSTEM..................................................................................................................... 136 LAYOUT DRAWING OF UREA SCR SYSTEM............................................................................................... 136 UREA SCR SYSTEM DIAGRAM......................................................................................................... 140 FUNCTION OF UREA SCR SYSTEM..................................................................................................... 141 FUNCTION OF AdBlue/DEF SYSTEM............................................................................................... 141 INDUCEMENT STRATEGY......................................................................................................... 143 COMPONENT PARTS OF UREA SCR SYSTEM.............................................................................................. 167 AdBlue/DEF MIXING TUBE...................................................................................................... 167 SCR ASSEMBLY................................................................................................................ 167 AdBlue/DEF TANK............................................................................................................. 170 AdBlue/DEF PUMP............................................................................................................. 172 AdBlue/DEF INJECTOR......................................................................................................... 173 AdBlue/DEF HOSE............................................................................................................. 174 AdBlue/DEF TANK HEATING VALVE............................................................................................... 175 BOOT-UP SYSTEM...................................................................................................................... 176 LAYOUT DRAWING OF BOOT-UP SYSTEM................................................................................................ 176 SYSTEM OPERATING LAMP SYSTEM.................................................................................................... 178 SYSTEM OPERATING LAMP SYSTEM DIAGRAM........................................................................................ 178 FUNCTION OF SYSTEM OPERATING LAMP SYSTEM.................................................................................... 178 BATTERY DISCONNECT SWITCH....................................................................................................... 180 FUNCTION OF BATTERY DISCONNECT SWITCH....................................................................................... 180 ENGINE SYSTEM....................................................................................................................... 181 LAYOUT DRAWING OF ENGINE SYSTEM................................................................................................. 181 FUNCTION OF ENGINE SYSTEM................................................................................................... 182 ENGINE CONTROL SYSTEM........................................................................................................... 183 ENGINE CONTROL SYSTEM DIAGRAM............................................................................................... 183 OPERATION OF ENGINE CONTROL SYSTEM.......................................................................................... 184 AUTO-DECELERATION SYSTEM........................................................................................................ 186 AUTO-DECELERATION SYSTEM DIAGRAM............................................................................................ 186 FUNCTION OF AUTO-DECELERATION SYSTEM........................................................................................ 186 OPERATION OF AUTO-DECELERATION SYSTEM....................................................................................... 187 ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................................. 188 ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM..................................................................................... 188 FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM................................................................................. 189 OVERHEAT PREVENTION SYSTEM...................................................................................................... 190 OVERHEAT PREVENTION SYSTEM DIAGRAM.......................................................................................... 190 FUNCTION OF OVERHEAT PREVENTION SYSTEM...................................................................................... 191 TURBOCHARGER PROTECTION SYSTEM.................................................................................................. 193 TURBOCHARGER PROTECTION SYSTEM DIAGRAM...................................................................................... 193 FUNCTION OF TURBOCHARGER PROTECTION SYSTEM.................................................................................. 194 AUTOMATIC IDLE STOP SYSTEM...................................................................................................... 195 AUTOMATIC IDLE STOP SYSTEM DIAGRAM.......................................................................................... 195 FUNCTION OF AUTOMATIC IDLE STOP SYSTEM...................................................................................... 195 COMPONENT PARTS OF ENGINE SYSTEM................................................................................................ 199 VGT......................................................................................................................... 199 EGR SYSTEM.................................................................................................................. 202 EGR VALVE................................................................................................................... 204 EGR COOLER.................................................................................................................. 206 KCCV SYSTEM................................................................................................................. 207 KCCV VENTILATOR............................................................................................................. 209 KDPF........................................................................................................................ 210 COOLING SYSTEM...................................................................................................................... 215 LAYOUT DRAWING OF COOLING SYSTEM................................................................................................ 215 SPECIFICATIONS OF COOLING SYSTEM............................................................................................ 216 HYBRID SYSTEM....................................................................................................................... 217 LAYOUT DRAWING OF HYBRID SYSTEM................................................................................................. 217 SYSTEM DIAGRAM OF HYBRID SYSTEM................................................................................................. 218 STRUCTURE OF HYBRID SYSTEM...................................................................................................... 219 HYBRID PROTECTION SYSTEM........................................................................................................ 220 SYSTEM DIAGRAM OF HYBRID PROTECTION SYSTEM.................................................................................. 220 FUNCTION OF HYBRID PROTECTION SYSTEM........................................................................................ 220 COOLING SYSTEM OF HYBRID COMPONENTS............................................................................................. 222 SYSTEM DIAGRAM OF COOLING SYSTEM OF HYBRID COMPONENTS....................................................................... 222 INTERLOCK SYSTEM OF HYBRID COMPONENTS........................................................................................... 223 SYSTEM DIAGRAM OF INTERLOCK SYSTEM OF HYBRID COMPONENTS..................................................................... 223 FUNCTION OF INTERLOCK SYSTEM OF HYBRID COMPONENTS........................................................................... 223 WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID COMPONENTS........................................................... 224 SYSTEM DIAGRAM OF WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID COMPONENTS..................................... 224 FUNCTION OF WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID COMPONENTS........................................... 225 COMPONENT PARTS OF HYBRID SYSTEM................................................................................................ 226 MOTOR-GENERATOR............................................................................................................. 226 ELECTRIC CONTROL UNIT....................................................................................................... 227 HIGH VOLTAGE WIRING (POWER CABLE)........................................................................................... 228 HYBRID WATER PUMP........................................................................................................... 229 INVERTER (HYBRID CONTROLLER)................................................................................................ 230 CONTROL SYSTEM...................................................................................................................... 233 LAYOUT DRAWING OF CONTROL SYSTEM................................................................................................ 233 MACHINE MONITOR SYSTEM.......................................................................................................... 236 MACHINE MONITOR SYSTEM DIAGRAM.............................................................................................. 236 FUNCTION OF MACHINE MONITOR SYSTEM.......................................................................................... 236 KomVision SYSTEM................................................................................................................ 237 LAYOUT DRAWING OF KOMVISION SYSTEM.......................................................................................... 237 KomVision SYSTEM DIAGRAM.................................................................................................... 239 FUNCTION OF KomVision SYSTEM................................................................................................ 239 KOMTRAX SYSTEM.................................................................................................................. 241 KOMTRAX SYSTEM DIAGRAM...................................................................................................... 241 FUNCTION OF KOMTRAX SYSTEM.................................................................................................. 241 PPC LEVERS...................................................................................................................... 242 LH PPC LEVER................................................................................................................ 242 RH PPC LEVER................................................................................................................ 243 AUTOMATIC GREASE SYSTEM......................................................................................................... 244 OUTLINE OF AUTO GREASE SYSTEM............................................................................................... 244 STRUCTURE OF AUTO GREASE PRESSURE SWITCH.................................................................................... 258 SPECIFICATIONS - AUTO GREASE PRESSURE SWITCH................................................................................ 258 FUNCTION OF AUTO GREASE PRESSURE SWITCH..................................................................................... 258 COMPONENT PARTS OF CONTROL SYSTEM............................................................................................... 259 MACHINE MONITOR............................................................................................................. 259 KomVision CAMERA............................................................................................................ 273 GATEWAY FUNCTION CONTROLLER................................................................................................. 274 COMMUNICATION TERMINAL...................................................................................................... 277 KomVision CONTROLLER........................................................................................................ 278 PUMP CONTROLLER............................................................................................................. 283 RESISTOR FOR PC-EPC VALVE................................................................................................... 287 CAN TERMINATING RESISTOR.................................................................................................... 287 ENGINE CONTROLLER........................................................................................................... 289 FUEL CONTROL DIAL........................................................................................................... 295 HYDRAULIC SYSTEM.................................................................................................................... 297 LAYOUT DRAWING OF HYDRAULIC SYSTEM.............................................................................................. 297 CLSS............................................................................................................................ 300 STRUCTURE OF CLSS........................................................................................................... 300 OPERATION OF UNLOAD VALVE AND LS PRESSURE................................................................................... 302 PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL................................................................................... 303 PRESSURE COMPENSATION CONTROL............................................................................................... 316 ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................................... 320 ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM............................................................................. 320 FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................... 321 PUMP AND VALVE CONTROL SYSTEM................................................................................................... 326 PUMP AND VALVE CONTROL SYSTEM DIAGRAM....................................................................................... 326 FUNCTION OF PUMP AND VALVE CONTROL SYSTEM................................................................................... 327 COMPONENT PARTS OF HYDRAULIC SYSTEM............................................................................................. 329 HYDRAULIC TANK.............................................................................................................. 329 MAIN PUMP................................................................................................................... 331 CONTROL VALVE............................................................................................................... 358 WORK EQUIPMENT SYSTEM............................................................................................................... 412 LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM......................................................................................... 412 STRUCTURE OF VALVE CONTROL...................................................................................................... 418 ONE-TOUCH POWER MAXIMIZING SYSTEM............................................................................................... 419 ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM................................................................................... 419 FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM............................................................................... 420 MACHINE PUSH-UP SYSTEM.......................................................................................................... 421 MACHINE PUSH-UP SYSTEM DIAGRAM.............................................................................................. 421 FUNCTION OF MACHINE PUSH-UP SYSTEM.......................................................................................... 422 PPC LOCK SYSTEM................................................................................................................. 423 PPC LOCK SYSTEM DIAGRAM..................................................................................................... 423 FUNCTION OF PPC LOCK SYSTEM................................................................................................. 423 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................................. 424 WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM..................................................................... 424 FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................. 424 OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM................................................................ 425 OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT......................................................................................... 426 OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT............................................................................. 426 FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT......................................................................... 427 TOOL CONTROL SYSTEM............................................................................................................. 428 TOOL CONTROL SYSTEM DIAGRAM................................................................................................. 428 FUNCTION OF TOOL CONTROL SYSTEM............................................................................................. 429 COMPONENT PARTS OF WORK EQUIPMENT SYSTEM........................................................................................ 430 WORK EQUIPMENT AND SWING PPC VALVE.......................................................................................... 430 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE).............................................................................. 435 2ND-LINE ATTACHMENT PPC VALVE............................................................................................... 439 SOLENOID VALVE.............................................................................................................. 441 ANTI-DROP VALVE FOR BOOM.................................................................................................... 444 ANTI-DROP VALVE FOR ARM..................................................................................................... 447 ATTACHMENT CIRCUIT SELECTOR VALVE........................................................................................... 451 ATT EPC VALVE ASSEMBLY...................................................................................................... 454 PILOT CIRCUIT ACCUMULATOR................................................................................................... 455 1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE................................................................................... 456 2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE................................................................................... 459 ATTACHMENT BYPASS SOLENOID VALVE............................................................................................ 461 SWING SYSTEM........................................................................................................................ 463 LAYOUT DRAWING OF SWING SYSTEM.................................................................................................. 463 SWING CONTROL SYSTEM DIAGRAM.................................................................................................... 466 FUNCTION OF SWING CONTROL SYSTEM............................................................................................ 467 COMPONENT PARTS OF SWING SYSTEM................................................................................................. 469 ELECTRIC SWING MOTOR........................................................................................................ 469 SWING MACHINERY WITH SWING PARKING BRAKE.................................................................................... 470 SWING CIRCLE................................................................................................................ 472 TRAVEL SYSTEM....................................................................................................................... 473 LAYOUT DRAWING OF TRAVEL SYSTEM................................................................................................. 473 TRAVEL CONTROL SYSTEM DIAGRAM................................................................................................... 477 FUNCTION OF TRAVEL CONTROL SYSTEM........................................................................................... 478 COMPONENT PARTS OF TRAVEL SYSTEM................................................................................................ 479 TRAVEL MOTOR................................................................................................................ 479 FINAL DRIVE................................................................................................................. 492 TRAVEL PPC VALVE............................................................................................................ 493 CENTER SWIVEL JOINT......................................................................................................... 498 UNDERCARRIAGE AND FRAME............................................................................................................. 500 LAYOUT DRAWING OF UNDERCARRIAGE................................................................................................. 500 SPECIFICATIONS OF UNDERCARRIAGE............................................................................................. 500 WORK EQUIPMENT...................................................................................................................... 502 STRUCTURE OF WORK EQUIPMENT..................................................................................................... 502 FUNCTION OF WORK EQUIPMENT...................................................................................................... 503 WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM........................................................................................ 504 FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM........................................................................ 504 BUCKET CLEARANCE ADJUSTMENT SHIM................................................................................................ 505 FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM................................................................................ 505 CAB AND ITS ATTACHMENTS............................................................................................................. 506 ROPS CAB........................................................................................................................ 506 STRUCTURE OF ROPS CAB....................................................................................................... 506 FUNCTION OF ROPS CAB........................................................................................................ 506 CAB MOUNT....................................................................................................................... 507 STRUCTURE OF CAB MOUNT...................................................................................................... 507 FUNCTION OF CAB MOUNT....................................................................................................... 507 CAB TIPPING STOPPER............................................................................................................. 508 STRUCTURE OF CAB TIPPING STOPPER............................................................................................ 508 FUNCTION OF CAB TIPPING STOPPER............................................................................................. 508 20 STANDARD VALUE TABLE................................................................................................................. 509 CONTENTS............................................................................................................................ 510 ABBREVIATION LIST................................................................................................................... 511 STANDARD VALUE TABLE FOR ENGINE..................................................................................................... 517 STANDARD VALUE TABLE FOR ENGINE:HB365LC-3E0, HB365NLC-3E0....................................................................... 517 STANDARD VALUE TABLE FOR MACHINE.................................................................................................... 523 STANDARD VALUE TABLE FOR MACHINE: HB365LC-3E0, HB365NLC-3E0..................................................................... 523 MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE......................................................................... 540 30 TESTING AND ADJUSTING................................................................................................................ 545 CONTENTS............................................................................................................................ 546 ABBREVIATION LIST................................................................................................................... 549 RELATED INFORMATION ON TESTING AND ADJUSTING........................................................................................ 555 TOOLS FOR TESTING AND ADJUSTING................................................................................................. 555 SKETCH OF TOOLS FOR TESTING AND ADJUSTING....................................................................................... 562 ENGINE AND COOLING SYSTEM........................................................................................................... 564 TEST ENGINE SPEED............................................................................................................... 564 METHOD FOR TESTING ENGINE SPEED............................................................................................. 564 TEST BOOST PRESSURE............................................................................................................. 567 METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR........................................................................ 567 METHOD FOR TESTING BOOST PRESSURE........................................................................................... 568 TEST EXHAUST GAS COLOR.......................................................................................................... 569 METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER................................................................. 569 METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER......................................................................... 570 TEST AND ADJUST VALVE CLEARANCE................................................................................................. 572 METHOD FOR TESTING VALVE CLEARANCE.......................................................................................... 572 METHOD FOR ADJUSTING VALVE CLEARANCE........................................................................................ 574 TEST COMPRESSION PRESSURE....................................................................................................... 575 METHOD FOR TESTING COMPRESSION PRESSURE..................................................................................... 575 TEST BLOWBY PRESSURE............................................................................................................ 578 METHOD FOR TESTING BLOWBY PRESSURE.......................................................................................... 578 TEST ENGINE OIL PRESSURE........................................................................................................ 580 METHOD FOR TESTING ENGINE OIL PRESSURE...................................................................................... 580 TEST EGR VALVE AND VGT OIL PRESSURE............................................................................................. 582 METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE........................................................................... 582 TEST FUEL PRESSURE.............................................................................................................. 584 METHOD FOR TESTING FUEL PRESSURE............................................................................................ 585 TEST FUEL DISCHARGE, RETURN AND LEAKAGE......................................................................................... 592 METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE....................................................................... 593 BLEED AIR FROM FUEL SYSTEM...................................................................................................... 600 METHOD FOR BLEEDING AIR FROM FUEL SYSTEM.................................................................................... 600 TEST FUEL CIRCUIT FOR LEAKAGE................................................................................................... 601 METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE................................................................................. 601 HANDLE CYLINDER CUT-OUT MODE OPERATION.......................................................................................... 603 HANDLE NO-INJECTION CRANKING OPERATION.......................................................................................... 604 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION......................................................................... 605 METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT......................................................................... 605 METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT........................................................................ 605 TEST COOLING FAN SPEED.......................................................................................................... 607 METHOD FOR TESTING COOLING FAN SPEED........................................................................................ 607 WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER.................................................................. 608 METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER................................................. 608 TEST SCR RELATED FUNCTIONS...................................................................................................... 609 TEST AdBlue/DEF PUMP RAISED PRESSURE........................................................................................ 612 TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR.............................................................................. 615 TEST AdBlue/DEF LINE HEATER RELAY 1......................................................................................... 619 TEST AdBlue/DEF LINE HEATER RELAY 2......................................................................................... 621 TEST AdBlue/DEF PUMP HEATER RELAY........................................................................................... 624 TEST AdBlue/DEF TANK HEATER VALVE........................................................................................... 627 TEST DENITRATION EFFICIENCY OF SCR.......................................................................................... 630 CLEAN AdBlue/DEF TANK........................................................................................................... 634 METHOD FOR CLEANING AdBlue/DEF TANK......................................................................................... 634 HYBRID SYSTEM....................................................................................................................... 639 PRECAUTIONS FOR USING HYBRID SYSTEMS............................................................................................ 639 DRAIN, REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT......................................................................... 640 METHOD FOR DRAINING THE HYBRID SYSTEM COOLANT............................................................................... 641 REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT............................................................................ 644 WATER PRESSURE TEST OF THE HYBRID SYSTEM COOLANT................................................................................ 646 METHOD FOR TESTING THE WATER PRESSURE OF THE HYBRID SYSTEM COOLANT.......................................................... 646 TEST LUBRICATION CIRCUIT OIL PRESSURE OF HYBRID SYSTEM.......................................................................... 648 TEST LUBRICATION CIRCUIT OIL PRESSURE OF ELECTRIC SWING MOTOR CASE.......................................................... 648 TEST LUBRICATION CIRCUIT OIL PRESSURE OF MOTOR-GENERATOR OIL CASE........................................................... 648 TEST SWING PARKING BRAKE PRESSURE............................................................................................... 650 METHOD FOR TESTING THE SWING PARKING BRAKE PRESSURE......................................................................... 650 TEST AND CLEAN DELIVERY FILTER OF SWING MOTOR................................................................................... 652 METHOD FOR CHECKING AND CLEANING ELECTRIC SWING MOTOR COOLING OIL DELIVERY FILTER........................................... 652 POWER TRAIN......................................................................................................................... 653 TEST SWING CIRCLE BEARING CLEARANCE............................................................................................. 653 METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE........................................................................... 653 UNDERCARRIAGE AND FRAME............................................................................................................. 654 TEST AND ADJUST TRACK TENSION................................................................................................... 654 METHOD FOR TESTING TRACK TENSION............................................................................................ 654 METHOD FOR ADJUSTING TRACK TENSION.......................................................................................... 654 HYDRAULIC SYSTEM.................................................................................................................... 656 RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM................................................................................ 656 METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK................................................................. 656 METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT....................................................... 656 METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT........................................................... 661 TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUITS.............................................................. 662 METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, AND TRAVEL CIRCUITS...................................................... 663 METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,AND TRAVEL CIRCUITS..................................................... 668 TEST OIL PRESSURE OF CONTROL CIRCUIT............................................................................................ 671 METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT.......................................................................... 671 TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT......................................................................... 673 METHOD FOR TESTING PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)................................................... 673 METHOD FOR TESTING PC-EPC VALVE OUTLET PRESSURE............................................................................. 674 METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT................................................................ 675 TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT......................................................................... 677 METHOD FOR TESTING LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR............................................................ 677 METHOD FOR TESTING LS DIFFERENTIAL PRESSURE................................................................................. 678 METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE)................................................... 680 METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE............................................................................. 682 METHOD FOR ADJUSTING LS VALVE............................................................................................... 682 TEST OUTLET PRESSURE OF SOLENOID VALVE.......................................................................................... 684 METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE........................................................................ 684 OPERATING CONDITION OF SOLENOID VALVE....................................................................................... 685 TEST PPC VALVE OUTPUT PRESSURE.................................................................................................. 688 METHOD FOR TESTING PPC VALVE OUTLET PRESSURE................................................................................ 688 ADJUST WORK EQUIPMENT AND SWING PPC VALVES...................................................................................... 690 METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES............................................................ 690 MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE............................................................. 691 TEST PUMP SWASH PLATE SENSOR.................................................................................................... 693 METHOD FOR TESTING PUMP SWASH PLATE SENSOR.................................................................................. 693 TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT........................................................................ 694 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER................................... 694 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER........................................................ 694 METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE........................................................... 695 TEST OIL LEAKAGE................................................................................................................ 696 METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER........................................................................... 696 METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER............................................................................ 697 METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER......................................................................... 697 METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR............................................................................ 698 BLEED AIR FROM HYDRAULIC CIRCUIT................................................................................................ 699 METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT.............................................................................. 699 CAB AND ITS ATTACHMENTS............................................................................................................. 702 TEST CAB TIPPING STOPPER........................................................................................................ 702 METHOD FOR TESTING CAB TIPPING STOPPER...................................................................................... 702 METHOD FOR ADJUSTING MIRRORS.................................................................................................... 703 PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A)....................................................................... 703 PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A)................................................... 704 PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B)...................................................................... 705 PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B).................................................. 706 PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C)....................................................................... 707 ELECTRICAL SYSTEM................................................................................................................... 709 SET AND OPERATE MACHINE MONITOR................................................................................................. 709 OPERATOR MODE............................................................................................................... 712 DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN................................................................. 713 DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN.................................................................... 713 CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)........................................................................... 714 CHECKING FUNCTION OF SERVICE METER.......................................................................................... 714 METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD................................................................... 714 SERVICE MODE................................................................................................................ 717 METHOD FOR OPERATING SERVICE MODE........................................................................................... 717 METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION...................................................................... 719 METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION...................................................................... 728 ABNORMALITY RECORD MENU..................................................................................................... 741 METHOD FOR CONFIRMING MAINTENANCE RECORD.................................................................................... 746 METHOD FOR OPERATING MAINTENANCE MODE SETTING............................................................................... 747 METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING............................................................................. 750 DEFAULT MENU................................................................................................................ 751 DIAGNOSTIC TESTS MENU....................................................................................................... 763 ADJUSTMENT MENU............................................................................................................. 777 METHOD FOR PERFORMING NO-INJECTION CRANKING................................................................................. 797 KOMTRAX SETTINGS MENU....................................................................................................... 798 METHOD FOR DISPLAYING SERVICE MESSAGE....................................................................................... 800 METHOD FOR STARTING UP KOMTRAX TERMINAL......................................................................................... 802 ADJUST REARVIEW CAMERA ANGLE.................................................................................................... 807 METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE................................................................................. 807 ADJUST KomVision CAMERA ANGLE................................................................................................... 810 METHOD FOR ADJUSTING KomVision CAMERA ANGLE................................................................................. 811 ADJUST KomVision RELATED ITEMS.................................................................................................. 815 SETTING OF KomVision (MAIN SETTING)......................................................................................... 815 SETTING OF KomVision (CAMERA SETTING)....................................................................................... 817 SETTING OF KomVision (CAMERA CALIBRATION)................................................................................... 819 KomVision screen - Check 12 m visibility.................................................................................... 832 HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER..................................................................................... 835 HANDLE BATTERY DISCONNECT SWITCH................................................................................................ 836 TEST DIODES..................................................................................................................... 837 METHOD FOR TESTING DIODE USING DIGITAL TESTER............................................................................... 837 METHOD FOR TESTING DIODE USING ANALOG TESTER................................................................................ 837 Pm CLINIC........................................................................................................................... 838 Pm CLINIC SERVICE............................................................................................................... 838 Pm CLINIC CHECK SHEET:HB365LC-3E0, HB365NLC-3E0............................................................................. 839 40 TROUBLESHOOTING...................................................................................................................... 851 CONTENTS............................................................................................................................ 852 ABBREVIATION LIST................................................................................................................... 865 RELATED INFORMATION ON TROUBLESHOOTING.............................................................................................. 871 GENERAL TROUBLESHOOTING POINTS.................................................................................................. 871 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM...................................................................................... 872 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................... 884 PRECAUTIONS FOR USING HYBRID SYSTEMS, TROUBLESHOOTING FOR HIGH-VOLTAGE EQUIPMENT................................................ 886 TABLE OF SELF-DEFINE MONITORING ITEMS AND CHECK SHEET FOR HYBRID COMPONENTS..................................................... 893 CHECKS BEFORE TROUBLESHOOTING................................................................................................... 899 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING..................................................................................... 901 WALK-AROUND CHECK........................................................................................................... 901 TESTING IN ACCORDANCE WITH TESTING PROCEDURE.................................................................................... 903 CHECK FUEL LEVEL AND TYPE................................................................................................... 903 CHECK IMPURE INGREDIENT IN FUEL............................................................................................. 904 CHECK FUEL PREFILTER........................................................................................................ 904 WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT.......................................................................... 904 METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE............................................................................... 905 CHECK MAIN FILTER........................................................................................................... 908 CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN).............................................................................. 910 CHECK OIL LEVEL IN MOTOR-GENERATOR CASE..................................................................................... 911 CHECK COOLANT LEVEL (RESERVOIR TANK)........................................................................................ 912 CHECK CLOGGING OF AIR CLEANER............................................................................................... 913 OUTER ELEMENT - CLEAN....................................................................................................... 914 ELEMENTS - REPLACE.......................................................................................................... 916 CHECK HYDRAULIC OIL LEVEL................................................................................................... 918 CHECK HYDRAULIC OIL STRAINER................................................................................................ 919 CHECK HYDRAULIC FILTER...................................................................................................... 920 CHECK CAPACITOR............................................................................................................. 921 CHECK OIL LEVEL IN ELECTRIC SWING MOTOR CASE................................................................................ 921 CHECK OIL LEVEL IN SWING MACHINERY CASE..................................................................................... 922 CHECK OIL LEVEL IN FINAL DRIVE CASE......................................................................................... 923 BLEED AIR FROM FUEL SYSTEM.................................................................................................. 924 BLEED AIR FROM HYDRAULIC SYSTEM............................................................................................. 924 METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod................................................................................ 924 AUTOMATIC GREASE SYSTEM......................................................................................................... 929 FINDING MALFUNCTIONS........................................................................................................ 929 MALFUNCTION FINDING PROCEDURES.............................................................................................. 933 PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM............................................................................ 935 PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR.......................................................................... 935 PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER........................................................................ 935 PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER.......................................................................... 936 PREPARATION FOR TROUBLESHOOTING OF GATEWAY TERMINAL......................................................................... 936 PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER..................................................................... 936 PREPARATION FOR TROUBLESHOOTING OF INVERTER (HYBRID CONTROLLER)............................................................. 937 DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK........................................................................ 937 PROCEDURE FOR TESTING AND TROUBLESHOOTING....................................................................................... 941 SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS................................................................................. 944 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.................................................................................. 948 TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM............................................. 950 CONNECTOR LIST AND LAYOUT....................................................................................................... 953 CONNECTOR CONTACT IDENTIFICATION................................................................................................ 967 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE.........................................................................................1007 FUSE LOCATION TABLE (MACHINE WITH KOMTRAX TERMINAL).............................................................................1013 PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC).....................................................................1016 PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]).....................................1020 FAILURE CODES TABLE.............................................................................................................1022 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)...................................................................................1044 FAILURE CODE [879AKA]...........................................................................................................1044 FAILURE CODE [879AKB]...........................................................................................................1045 FAILURE CODE [879BKA]...........................................................................................................1046 FAILURE CODE [879BKB]...........................................................................................................1048 FAILURE CODE [879CKA]...........................................................................................................1050 FAILURE CODE [879CKB]...........................................................................................................1051 FAILURE CODE [879DKZ]...........................................................................................................1052 FAILURE CODE [879EMC]...........................................................................................................1054 FAILURE CODE [879FMC]...........................................................................................................1055 FAILURE CODE [879GKX]...........................................................................................................1056 FAILURE CODE [989L00]...........................................................................................................1058 FAILURE CODE [989M00]...........................................................................................................1059 FAILURE CODE [989N00]...........................................................................................................1060 FAILURE CODE [A1U0N3]...........................................................................................................1061 FAILURE CODE [A1U0N4]...........................................................................................................1063 FAILURE CODE [A900FR]...........................................................................................................1065 FAILURE CODE [A900N6]...........................................................................................................1066 FAILURE CODE [A900NY]...........................................................................................................1067 FAILURE CODE [AA10NX]...........................................................................................................1068 FAILURE CODE [AB00KE]...........................................................................................................1070 FAILURE CODE [AQ10N3]...........................................................................................................1072 FAILURE CODE [AS00N3]...........................................................................................................1074 FAILURE CODE [AS00R2]...........................................................................................................1076 FAILURE CODE [AS00R3]...........................................................................................................1077 FAILURE CODE [AS00R4]...........................................................................................................1078 FAILURE CODE [AS00R5]...........................................................................................................1079 FAILURE CODE [AS00R6]...........................................................................................................1080 FAILURE CODE [AS00ZK]...........................................................................................................1081 FAILURE CODE [AS10KM]...........................................................................................................1082 FAILURE CODE [AS10NR]...........................................................................................................1083 FAILURE CODE [AS10NT]...........................................................................................................1084 FAILURE CODE [B@BAZG]...........................................................................................................1085 FAILURE CODE [B@BAZK]...........................................................................................................1086 FAILURE CODE [B@BCNS]...........................................................................................................1088 FAILURE CODE [B@BCZK]...........................................................................................................1089 FAILURE CODE [B@HANS]...........................................................................................................1090 FAILURE CODE [CA115]............................................................................................................1091 FAILURE CODE [CA122]............................................................................................................1092 FAILURE CODE [CA123]............................................................................................................1094 FAILURE CODE [CA131]............................................................................................................1096 FAILURE CODE [CA132]............................................................................................................1098 FAILURE CODE [CA144]............................................................................................................1100 FAILURE CODE [CA145]............................................................................................................1102 FAILURE CODE [CA153]............................................................................................................1104 FAILURE CODE [CA154]............................................................................................................1107 FAILURE CODE [CA187]............................................................................................................1110 FAILURE CODE [CA221]............................................................................................................1112 FAILURE CODE [CA222]............................................................................................................1114 FAILURE CODE [CA227]............................................................................................................1116 FAILURE CODE [CA234]............................................................................................................1117 FAILURE CODE [CA238]............................................................................................................1118 FAILURE CODE [CA239]............................................................................................................1120 FAILURE CODE [CA249]............................................................................................................1122 FAILURE CODE [CA256]............................................................................................................1124 FAILURE CODE [CA271]............................................................................................................1126 FAILURE CODE [CA272]............................................................................................................1128 FAILURE CODE [CA281]............................................................................................................1130 FAILURE CODE [CA322]............................................................................................................1131 FAILURE CODE [CA323]............................................................................................................1133 FAILURE CODE [CA324]............................................................................................................1135 FAILURE CODE [CA325]............................................................................................................1137 FAILURE CODE [CA331]............................................................................................................1139 FAILURE CODE [CA332]............................................................................................................1141 FAILURE CODE [CA343]............................................................................................................1143 FAILURE CODE [CA351]............................................................................................................1144 FAILURE CODE [CA352]............................................................................................................1145 FAILURE CODE [CA356]............................................................................................................1148 FAILURE CODE [CA357]............................................................................................................1150 FAILURE CODE [CA386]............................................................................................................1152 FAILURE CODE [CA428]............................................................................................................1153 FAILURE CODE [CA429]............................................................................................................1155 FAILURE CODE [CA435]............................................................................................................1157 FAILURE CODE [CA441]............................................................................................................1159 FAILURE CODE [CA442]............................................................................................................1161 FAILURE CODE [CA449]............................................................................................................1162 FAILURE CODE [CA451]............................................................................................................1165 FAILURE CODE [CA452]............................................................................................................1168 FAILURE CODE [CA488]............................................................................................................1170 FAILURE CODE [CA515]............................................................................................................1171 FAILURE CODE [CA516]............................................................................................................1173 FAILURE CODE [CA553]............................................................................................................1175 FAILURE CODE [CA555]............................................................................................................1176 FAILURE CODE [CA556]............................................................................................................1177 FAILURE CODE [CA559]............................................................................................................1178 FAILURE CODE [CA595]............................................................................................................1182 FAILURE CODE [CA687]............................................................................................................1183 FAILURE CODE [CA689]............................................................................................................1185 FAILURE CODE [CA691]............................................................................................................1190 FAILURE CODE [CA692]............................................................................................................1192 FAILURE CODE [CA697]............................................................................................................1194 FAILURE CODE [CA698]............................................................................................................1195 FAILURE CODE [CA731]............................................................................................................1196 FAILURE CODE [CA778]............................................................................................................1198 FAILURE CODE [CA1117]...........................................................................................................1203 FAILURE CODE [CA1664]...........................................................................................................1204 FAILURE CODE [CA1669]...........................................................................................................1206 FAILURE CODE [CA1673]...........................................................................................................1207 FAILURE CODE [CA1677]...........................................................................................................1208 FAILURE CODE [CA1678]...........................................................................................................1209 FAILURE CODE [CA1682]...........................................................................................................1210 FAILURE CODE [CA1683]...........................................................................................................1212 FAILURE CODE [CA1684]...........................................................................................................1214 FAILURE CODE [CA1686]...........................................................................................................1216 FAILURE CODE [CA1691]...........................................................................................................1217 FAILURE CODE [CA1694]...........................................................................................................1220 FAILURE CODE [CA1695]...........................................................................................................1223 FAILURE CODE [CA1696]...........................................................................................................1224 FAILURE CODE [CA1712]...........................................................................................................1226 FAILURE CODE [CA1713]...........................................................................................................1229 FAILURE CODE [CA1714]...........................................................................................................1231 FAILURE CODE [CA1715]...........................................................................................................1232 FAILURE CODE [CA1776]...........................................................................................................1233 FAILURE CODE [CA1777]...........................................................................................................1236 FAILURE CODE [CA1843]...........................................................................................................1239 FAILURE CODE [CA1844]...........................................................................................................1241 FAILURE CODE [CA1879]...........................................................................................................1243 FAILURE CODE [CA1881]...........................................................................................................1246 FAILURE CODE [CA1883]...........................................................................................................1248 FAILURE CODE [CA1885]...........................................................................................................1251 FAILURE CODE [CA1887]...........................................................................................................1253 FAILURE CODE [CA1921]...........................................................................................................1255 FAILURE CODE [CA1922]...........................................................................................................1258 FAILURE CODE [CA1942]...........................................................................................................1263 FAILURE CODE [CA1993]...........................................................................................................1264 FAILURE CODE [CA2185]...........................................................................................................1267 FAILURE CODE [CA2186]...........................................................................................................1268 FAILURE CODE [CA2249]...........................................................................................................1270 FAILURE CODE [CA2265]...........................................................................................................1271 FAILURE CODE [CA2266]...........................................................................................................1273 FAILURE CODE [CA2271]...........................................................................................................1275 FAILURE CODE [CA2272]...........................................................................................................1277 FAILURE CODE [CA2288]...........................................................................................................1280 FAILURE CODE [CA2311]...........................................................................................................1281 FAILURE CODE [CA2349]...........................................................................................................1282 FAILURE CODE [CA2353]...........................................................................................................1285 FAILURE CODE [CA2357]...........................................................................................................1287 FAILURE CODE [CA2381]...........................................................................................................1288 FAILURE CODE [CA2382]...........................................................................................................1290 FAILURE CODE [CA2383]...........................................................................................................1293 FAILURE CODE [CA2386]...........................................................................................................1296 FAILURE CODE [CA2387]...........................................................................................................1298 FAILURE CODE [CA2555]...........................................................................................................1299 FAILURE CODE [CA2556]...........................................................................................................1302 FAILURE CODE [CA2637]...........................................................................................................1305 FAILURE CODE [CA2639]...........................................................................................................1307 FAILURE CODE [CA2771]...........................................................................................................1310 FAILURE CODE [CA2777]...........................................................................................................1316 FAILURE CODE [CA2976]...........................................................................................................1319 FAILURE CODE [CA3133]...........................................................................................................1321 FAILURE CODE [CA3134]...........................................................................................................1323 FAILURE CODE [CA3135]...........................................................................................................1325 FAILURE CODE [CA3142]...........................................................................................................1328 FAILURE CODE [CA3143]...........................................................................................................1329 FAILURE CODE [CA3144]...........................................................................................................1330 FAILURE CODE [CA3146]...........................................................................................................1332 FAILURE CODE [CA3147]...........................................................................................................1333 FAILURE CODE [CA3148]...........................................................................................................1334 FAILURE CODE [CA3151]...........................................................................................................1336 FAILURE CODE [CA3165]...........................................................................................................1343 FAILURE CODE [CA3229]...........................................................................................................1345 FAILURE CODE [CA3231]...........................................................................................................1347 FAILURE CODE [CA3232]...........................................................................................................1349 FAILURE CODE [CA3235]...........................................................................................................1353 FAILURE CODE [CA3239]...........................................................................................................1355 FAILURE CODE [CA3241]...........................................................................................................1358 FAILURE CODE [CA3242]...........................................................................................................1361 FAILURE CODE [CA3251]...........................................................................................................1364 FAILURE CODE [CA3253]...........................................................................................................1366 FAILURE CODE [CA3254]...........................................................................................................1369 FAILURE CODE [CA3255]...........................................................................................................1372 FAILURE CODE [CA3256]...........................................................................................................1376 FAILURE CODE [CA3311]...........................................................................................................1378 FAILURE CODE [CA3312]...........................................................................................................1380 FAILURE CODE [CA3313]...........................................................................................................1383 FAILURE CODE [CA3314]...........................................................................................................1384 FAILURE CODE [CA3315]...........................................................................................................1385 FAILURE CODE [CA3316]...........................................................................................................1387 FAILURE CODE [CA3317]...........................................................................................................1388 FAILURE CODE [CA3318]...........................................................................................................1389 FAILURE CODE [CA3319]...........................................................................................................1391 FAILURE CODE [CA3321]...........................................................................................................1392 FAILURE CODE [CA3322]...........................................................................................................1394 FAILURE CODE [CA3419]...........................................................................................................1396 FAILURE CODE [CA3421]...........................................................................................................1398 FAILURE CODE [CA3497]...........................................................................................................1400 FAILURE CODE [CA3498]...........................................................................................................1401 FAILURE CODE [CA3543]...........................................................................................................1402 FAILURE CODE [CA3545]...........................................................................................................1408 FAILURE CODE [CA3547]...........................................................................................................1410 FAILURE CODE [CA3558]...........................................................................................................1411 FAILURE CODE [CA3559]...........................................................................................................1413 FAILURE CODE [CA3562]...........................................................................................................1415 FAILURE CODE [CA3563]...........................................................................................................1417 FAILURE CODE [CA3567]...........................................................................................................1420 FAILURE CODE [CA3568]...........................................................................................................1423 FAILURE CODE [CA3571]...........................................................................................................1427 FAILURE CODE [CA3572]...........................................................................................................1429 FAILURE CODE [CA3574]...........................................................................................................1431 FAILURE CODE [CA3575]...........................................................................................................1433 FAILURE CODE [CA3577]...........................................................................................................1435 FAILURE CODE [CA3578]...........................................................................................................1437 FAILURE CODE [CA3582]...........................................................................................................1439 FAILURE CODE [CA3583]...........................................................................................................1445 FAILURE CODE [CA3596]...........................................................................................................1447 FAILURE CODE [CA3649]...........................................................................................................1450 FAILURE CODE [CA3681]...........................................................................................................1452 FAILURE CODE [CA3682]...........................................................................................................1457 FAILURE CODE [CA3713]...........................................................................................................1462 FAILURE CODE [CA3717]...........................................................................................................1465 FAILURE CODE [CA3718]...........................................................................................................1466 FAILURE CODE [CA3725]...........................................................................................................1467 FAILURE CODE [CA3741]...........................................................................................................1470 FAILURE CODE [CA3748]...........................................................................................................1471 FAILURE CODE [CA3751]...........................................................................................................1474 FAILURE CODE [CA3755]...........................................................................................................1476 FAILURE CODE [CA3866]...........................................................................................................1478 FAILURE CODE [CA3867]...........................................................................................................1482 FAILURE CODE [CA3868]...........................................................................................................1485 FAILURE CODE [CA3899]...........................................................................................................1489 FAILURE CODE [CA3911]...........................................................................................................1491 FAILURE CODE [CA3912]...........................................................................................................1495 FAILURE CODE [CA3932]...........................................................................................................1497 FAILURE CODE [CA3933]...........................................................................................................1499 FAILURE CODE [CA3934]...........................................................................................................1501 FAILURE CODE [CA3935]...........................................................................................................1504 FAILURE CODE [CA3936]...........................................................................................................1506 FAILURE CODE [CA4151]...........................................................................................................1508 FAILURE CODE [CA4152]...........................................................................................................1512 FAILURE CODE [CA4155]...........................................................................................................1516 FAILURE CODE [CA4156]...........................................................................................................1518 FAILURE CODE [CA4157]...........................................................................................................1521 FAILURE CODE [CA4158]...........................................................................................................1523 FAILURE CODE [CA4159]...........................................................................................................1524 FAILURE CODE [CA4161]...........................................................................................................1525 FAILURE CODE [CA4162]...........................................................................................................1528 FAILURE CODE [CA4163]...........................................................................................................1531 FAILURE CODE [CA4164]...........................................................................................................1533 FAILURE CODE [CA4165]...........................................................................................................1535 FAILURE CODE [CA4166]...........................................................................................................1537 FAILURE CODE [CA4168]...........................................................................................................1539 FAILURE CODE [CA4169]...........................................................................................................1542 FAILURE CODE [CA4171]...........................................................................................................1544 FAILURE CODE [CA4249]...........................................................................................................1547 FAILURE CODE [CA4251]...........................................................................................................1549 FAILURE CODE [CA4259]...........................................................................................................1551 FAILURE CODE [CA4261]...........................................................................................................1554 FAILURE CODE [CA4277]...........................................................................................................1557 FAILURE CODE [CA4281]...........................................................................................................1561 FAILURE CODE [CA4459]...........................................................................................................1565 FAILURE CODE [CA4461]...........................................................................................................1568 FAILURE CODE [CA4658]...........................................................................................................1571 FAILURE CODE [CA4731]...........................................................................................................1575 FAILURE CODE [CA4732]...........................................................................................................1576 FAILURE CODE [CA4739]...........................................................................................................1577 FAILURE CODE [CA4768]...........................................................................................................1578 FAILURE CODE [CA4769]...........................................................................................................1580 FAILURE CODE [CA4842]...........................................................................................................1582 FAILURE CODE [CA4952]...........................................................................................................1586 FAILURE CODE [CA5115]...........................................................................................................1588 FAILURE CODE [CA5179]...........................................................................................................1591 FAILURE CODE [CA5181]...........................................................................................................1593 FAILURE CODE [CA5383]...........................................................................................................1595 FAILURE CODE [D110KB]...........................................................................................................1597 FAILURE CODE [D19JKZ]...........................................................................................................1599 FAILURE CODE [D811MC]...........................................................................................................1602 FAILURE CODE [D862KA]...........................................................................................................1603 FAILURE CODE [D8ALKA]...........................................................................................................1605 FAILURE CODE [D8ALKB]...........................................................................................................1608 FAILURE CODE [D8AQKR]...........................................................................................................1610 FAILURE CODE [D8G1KT]...........................................................................................................1617 FAILURE CODE [DA20MC]...........................................................................................................1618 FAILURE CODE [DA22KK]...........................................................................................................1619 FAILURE CODE [DA25KP]...........................................................................................................1622 FAILURE CODE [DA26KP]...........................................................................................................1624 FAILURE CODE [DA29KQ]...........................................................................................................1627 FAILURE CODE [DA2LKA]...........................................................................................................1629 FAILURE CODE [DA2LKB]...........................................................................................................1632 FAILURE CODE [DA2QKR]...........................................................................................................1634 FAILURE CODE [DA2RKR]...........................................................................................................1643 FAILURE CODE [DAF0KM]...........................................................................................................1648 FAILURE CODE [DAF0MB]...........................................................................................................1649 FAILURE CODE [DAF0MC]...........................................................................................................1650 FAILURE CODE [DAF8KB]...........................................................................................................1651 FAILURE CODE [DAF9KQ]...........................................................................................................1653 FAILURE CODE [DAFGMC]...........................................................................................................1654 FAILURE CODE [DAFLKA]...........................................................................................................1655 FAILURE CODE [DAFLKB]...........................................................................................................1658 FAILURE CODE [DAFQKR]...........................................................................................................1660 FAILURE CODE [DAZ9KQ]...........................................................................................................1668 FAILURE CODE [DAZQKR]...........................................................................................................1669 FAILURE CODE [DB2QKR]...........................................................................................................1676 FAILURE CODE [DB2RKR]...........................................................................................................1684 FAILURE CODE [DBP0KM]...........................................................................................................1689 FAILURE CODE [DBP0KT]...........................................................................................................1690 FAILURE CODE [DBPQKR]...........................................................................................................1691 FAILURE CODE [DDNRKA]...........................................................................................................1699 FAILURE CODE [DDNRKY]...........................................................................................................1701 FAILURE CODE [DDNS00]...........................................................................................................1703 FAILURE CODE [DFB1KZ]...........................................................................................................1705 FAILURE CODE [DFB2KZ]...........................................................................................................1707 FAILURE CODE [DFB3L8]...........................................................................................................1709 FAILURE CODE [DFB4L8]...........................................................................................................1711 FAILURE CODE [DFB5KZ]...........................................................................................................1713 FAILURE CODE [DFB6KZ]...........................................................................................................1715 FAILURE CODE [DGH2KA]...........................................................................................................1717 FAILURE CODE [DGH2KB]...........................................................................................................1719 FAILURE CODE [DHA4KA]...........................................................................................................1721 FAILURE CODE [DHAAMA]...........................................................................................................1723 FAILURE CODE [DHACMA]...........................................................................................................1725 FAILURE CODE [DHPAMA]...........................................................................................................1727 FAILURE CODE [DHPBMA]...........................................................................................................1729 FAILURE CODE [DHS3MA]...........................................................................................................1731 FAILURE CODE [DHS4MA]...........................................................................................................1733 FAILURE CODE [DHS8MA]...........................................................................................................1735 FAILURE CODE [DHS9MA]...........................................................................................................1737 FAILURE CODE [DHSAKZ]...........................................................................................................1739 FAILURE CODE [DHSBKZ]...........................................................................................................1741 FAILURE CODE [DHSCMA]...........................................................................................................1743 FAILURE CODE [DHSDMA]...........................................................................................................1745 FAILURE CODE [DHSFMA]...........................................................................................................1747 FAILURE CODE [DHSGMA]...........................................................................................................1749 FAILURE CODE [DHSHMA]...........................................................................................................1751 FAILURE CODE [DHSJMA]...........................................................................................................1753 FAILURE CODE [DHVAKZ]...........................................................................................................1755 FAILURE CODE [DHVAL8]...........................................................................................................1757 FAILURE CODE [DHVAMA]...........................................................................................................1759 FAILURE CODE [DHVBKZ]...........................................................................................................1760 FAILURE CODE [DHVBL8]...........................................................................................................1762 FAILURE CODE [DHVBMA]...........................................................................................................1764 FAILURE CODE [DHZAMA]...........................................................................................................1765 FAILURE CODE [DHZCL8]...........................................................................................................1769 FAILURE CODE [DKR0MA]...........................................................................................................1770 FAILURE CODE [DKR1MA]...........................................................................................................1772 FAILURE CODE [DKULKA]...........................................................................................................1774 FAILURE CODE [DKULKB]...........................................................................................................1776 FAILURE CODE [DKULKY]...........................................................................................................1778 FAILURE CODE [DLM5KA]...........................................................................................................1779 FAILURE CODE [DLM5MB]...........................................................................................................1781 FAILURE CODE [DR10KA]...........................................................................................................1783 FAILURE CODE [DR21KX]...........................................................................................................1786 FAILURE CODE [DUMBKA]...........................................................................................................1788 FAILURE CODE [DUMBKB]...........................................................................................................1791 FAILURE CODE [DV00KA]...........................................................................................................1793 FAILURE CODE [DV00KB]...........................................................................................................1794 FAILURE CODE [DV20KB]...........................................................................................................1795 FAILURE CODE [DW43KA]...........................................................................................................1797 FAILURE CODE [DW43KB]...........................................................................................................1799 FAILURE CODE [DW43KY]...........................................................................................................1800 FAILURE CODE [DW45KA]...........................................................................................................1801 FAILURE CODE [DW45KB]...........................................................................................................1804 FAILURE CODE [DW45KK]...........................................................................................................1807 FAILURE CODE [DW45KY]...........................................................................................................1809 FAILURE CODE [DW4CKY]...........................................................................................................1811 FAILURE CODE [DW91KA]...........................................................................................................1812 FAILURE CODE [DW91KB]...........................................................................................................1814 FAILURE CODE [DW91KY]...........................................................................................................1815 FAILURE CODE [DWA2KA]...........................................................................................................1816 FAILURE CODE [DWA2KB]...........................................................................................................1818 FAILURE CODE [DWA2KY]...........................................................................................................1819 FAILURE CODE [DWK0KA]...........................................................................................................1820 FAILURE CODE [DWK0KB]...........................................................................................................1822 FAILURE CODE [DWK0KY]...........................................................................................................1824 FAILURE CODE [DWK2KA]...........................................................................................................1825 FAILURE CODE [DWK2KB]...........................................................................................................1827 FAILURE CODE [DWK2KY]...........................................................................................................1829 FAILURE CODE [DWN5KA]...........................................................................................................1830 FAILURE CODE [DWN5KB]...........................................................................................................1833 FAILURE CODE [DWN5KY]...........................................................................................................1835 FAILURE CODE [DWPUKA]...........................................................................................................1836 FAILURE CODE [DWPUKB]...........................................................................................................1838 FAILURE CODE [DWPUKY]...........................................................................................................1840 FAILURE CODE [DXA8KA]...........................................................................................................1842 FAILURE CODE [DXA8KB]...........................................................................................................1845 FAILURE CODE [DXA9KA]...........................................................................................................1847 FAILURE CODE [DXA9KB]...........................................................................................................1850 FAILURE CODE [DXE0KA]...........................................................................................................1852 FAILURE CODE [DXE0KB]...........................................................................................................1854 FAILURE CODE [DXE4KA]...........................................................................................................1855 FAILURE CODE [DXE4KB]...........................................................................................................1857 FAILURE CODE [DXE4KY]...........................................................................................................1858 FAILURE CODE [DXE5KA]...........................................................................................................1859 FAILURE CODE [DXE5KB]...........................................................................................................1861 FAILURE CODE [DXE6KA]...........................................................................................................1863 FAILURE CODE [DXE6KB]...........................................................................................................1865 FAILURE CODE [DXE7KA]...........................................................................................................1867 FAILURE CODE [DXE7KB]...........................................................................................................1869 FAILURE CODE [DXE7KY]...........................................................................................................1871 FAILURE CODE [DXE8KA]...........................................................................................................1873 FAILURE CODE [DXE8KB]...........................................................................................................1875 FAILURE CODE [DXE8KY]...........................................................................................................1877 FAILURE CODE [DXE9KA]...........................................................................................................1879 FAILURE CODE [DXE9KB]...........................................................................................................1881 FAILURE CODE [DXE9KY]...........................................................................................................1883 FAILURE CODE [DXEAKA]...........................................................................................................1885 FAILURE CODE [DXEAKB]...........................................................................................................1887 FAILURE CODE [DXEAKY]...........................................................................................................1889 FAILURE CODE [DXEKKA]...........................................................................................................1891 FAILURE CODE [DXEKKB]...........................................................................................................1893 FAILURE CODE [DXEKKY]...........................................................................................................1895 FAILURE CODE [DXELKA]...........................................................................................................1897 FAILURE CODE [DXELKB]...........................................................................................................1899 FAILURE CODE [DXELKY]...........................................................................................................1901 FAILURE CODE [DY20KA]...........................................................................................................1903 FAILURE CODE [DY20MA]...........................................................................................................1905 FAILURE CODE [DY2CKB]...........................................................................................................1907 FAILURE CODE [DY2DKB]...........................................................................................................1909 FAILURE CODE [DY2EKB]...........................................................................................................1911 FAILURE CODE [F313KA]...........................................................................................................1913 FAILURE CODE [F313KB]...........................................................................................................1915 FAILURE CODE [F318KB]...........................................................................................................1918 FAILURE CODE [F318KY]...........................................................................................................1921 FAILURE CODE [GA00NS]...........................................................................................................1923 FAILURE CODE [GA01KA]...........................................................................................................1924 FAILURE CODE [GA02KZ]...........................................................................................................1926 FAILURE CODE [GA04KG]...........................................................................................................1929 FAILURE CODE [GA05KG]...........................................................................................................1932 FAILURE CODE [GA05KP]...........................................................................................................1935 FAILURE CODE [GA06KZ]...........................................................................................................1938 FAILURE CODE [GA08KG]...........................................................................................................1939 FAILURE CODE [GA09KG]...........................................................................................................1947 FAILURE CODE [GA09KP]...........................................................................................................1955 FAILURE CODE [GA0AKZ]...........................................................................................................1956 FAILURE CODE [GA0BKZ]...........................................................................................................1957 FAILURE CODE [GA10MA]...........................................................................................................1964 FAILURE CODE [GA10MC]...........................................................................................................1971 FAILURE CODE [GA12NK]...........................................................................................................1972 FAILURE CODE [GA13KP]...........................................................................................................1978 FAILURE CODE [GA13KY]...........................................................................................................1980 FAILURE CODE [GA15KZ]...........................................................................................................1982 FAILURE CODE [GA17KR]...........................................................................................................1990 FAILURE CODE [GA17MB]...........................................................................................................1991 FAILURE CODE [GA18MC]...........................................................................................................1992 FAILURE CODE [GA19KR]...........................................................................................................1997 FAILURE CODE [GA19KT]...........................................................................................................1998 FAILURE CODE [GA1BMA]...........................................................................................................1999 FAILURE CODE [GA1FKR]...........................................................................................................2001 FAILURE CODE [GA1FMA]...........................................................................................................2002 FAILURE CODE [GA1GKR]...........................................................................................................2005 FAILURE CODE [GA1GKT]...........................................................................................................2006 FAILURE CODE [GA1GMB]...........................................................................................................2007 FAILURE CODE [GA1HKZ]...........................................................................................................2008 FAILURE CODE [GA1JKZ]...........................................................................................................2009 FAILURE CODE [GA1KKZ]...........................................................................................................2010 FAILURE CODE [GA1LKZ]...........................................................................................................2011 FAILURE CODE [GA1MKZ]...........................................................................................................2012 FAILURE CODE [GA1NNS]...........................................................................................................2013 FAILURE CODE [GA1SFS]...........................................................................................................2014 FAILURE CODE [GA1SMC]...........................................................................................................2015 FAILURE CODE [GA1TKP]...........................................................................................................2016 FAILURE CODE [GA1TNS]...........................................................................................................2019 FAILURE CODE [GA1UKZ]...........................................................................................................2022 FAILURE CODE [GA1VFS]...........................................................................................................2025 FAILURE CODE [GA1VMC]...........................................................................................................2026 FAILURE CODE [GA1XKZ]...........................................................................................................2027 FAILURE CODE [GA1YNS]...........................................................................................................2028 FAILURE CODE [GA1ZKZ]...........................................................................................................2029 FAILURE CODE [GA1ZNS]...........................................................................................................2030 FAILURE CODE [GA22NS]...........................................................................................................2031 FAILURE CODE [GA23KZ]...........................................................................................................2032 FAILURE CODE [GA24KZ]...........................................................................................................2033 FAILURE CODE [GA25MA]...........................................................................................................2034 FAILURE CODE [GA25NS]...........................................................................................................2039 FAILURE CODE [GA26MA]...........................................................................................................2040 FAILURE CODE [GA26NS]...........................................................................................................2045 FAILURE CODE [GA27KZ]...........................................................................................................2046 FAILURE CODE [GA2QKR]...........................................................................................................2047 FAILURE CODE [GA2RKR]...........................................................................................................2052 FAILURE CODE [GA60MC]...........................................................................................................2057 FAILURE CODE [GA60N1]...........................................................................................................2059 FAILURE CODE [GA61KZ]...........................................................................................................2061 FAILURE CODE [GA61NS]...........................................................................................................2063 FAILURE CODE [GA62KY]...........................................................................................................2064 FAILURE CODE [GA62KZ]...........................................................................................................2069 FAILURE CODE [GA62MA]...........................................................................................................2073 FAILURE CODE [GA63KY]...........................................................................................................2074 FAILURE CODE [GA63KZ]...........................................................................................................2079 FAILURE CODE [GA63MA]...........................................................................................................2083 FAILURE CODE [GA64KY]...........................................................................................................2084 FAILURE CODE [GA64KZ]...........................................................................................................2089 FAILURE CODE [GA64MA]...........................................................................................................2093 FAILURE CODE [GA70KB]...........................................................................................................2094 FAILURE CODE [GA70MD]...........................................................................................................2097 FAILURE CODE [GA70NS]...........................................................................................................2099 FAILURE CODE [GA71KZ]...........................................................................................................2100 FAILURE CODE [GA72MA]...........................................................................................................2102 FAILURE CODE [GA72MC]...........................................................................................................2104 FAILURE CODE [GA81KZ]...........................................................................................................2106 FAILURE CODE [GAA0KB]...........................................................................................................2109 FAILURE CODE [GAA2KB]...........................................................................................................2111 FAILURE CODE [GAA6KP]...........................................................................................................2113 FAILURE CODE [GAA6KY]...........................................................................................................2115 FAILURE CODE [GACA00]...........................................................................................................2117 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).......................................................................................2118 E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)...............................................................................2118 E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK......................................................................................2124 E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK...................................................................................2127 E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP...........................................................2129 E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING.............................................2131 E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW..........2134 E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW....2135 E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING...............................................2136 E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING................................................2137 E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING...................................................2138 E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..............................................................2139 E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING................................................................2140 E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...........................................................2141 E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING................................................2142 E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.......................................................2143 E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.................................................2144 E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM...................................................................2145 E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL.......................................................................2147 E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM.............................................2148 E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE........................................2149 E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM..............................................2150 E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE.............................................2152 E-23 MONITOR TEMPERATURE GAUGE OF HYBRID SYSTEMS DOES NOT INDICATE CORRECT TEMPERATURE..........................................2153 E-24 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED.....................................................................2154 E-25 FUNCTION SWITCH DOES NOT OPERATE...........................................................................................2155 E-26 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)...................................................................2156 E-27 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF....................2157 E-28 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER....................................................................2158 E-29 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED.......................................2159 E-30 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED..........................................2160 E-31 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE.................................................2161 E-32 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE................................................2162 E-33 ALARM BUZZER CANNOT BE CANCELED............................................................................................2163 E-34 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION...................................................2164 E-35 SERVICE MODE CANNOT BE SELECTED............................................................................................2165 E-36 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE............................................................2166 E-37 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK.............................................................2168 E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING.............................................2169 E-39 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE.............................2172 E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR.......................2174 E-41 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED.......................................................................2176 E-42 ALARM DOES NOT SOUND DURING TRAVEL.........................................................................................2177 E-43 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED......................................................................2179 E-44 HORN DOES NOT SOUND........................................................................................................2180 E-45 HORN DOES NOT STOP SOUNDING................................................................................................2183 E-46 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF...................................................2185 E-47 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE...........................................................2186 E-48 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE......................................................2188 E-49 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION....................................................2189 E-50 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION....................................................2190 E-51 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.......................................................2191 E-52 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................................2192 E-53 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...................................................2193 E-54 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...................................................2194 E-55 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.........................................................2195 E-56 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................................2196 E-57 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.......................................................2197 E-58 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED.............................................................................2199 E-59 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY...................................................................................2200 E-60 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED................................................................................2201 E-61 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE..................................................................................2203 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE).......................................................................2204 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE).........................................................................2204 FAILURE MODE AND CAUSE TABLE....................................................................................................2205 H-1 ALL WORK EQUIPMENTS OR TRAVEL DOES NOT OPERATE..............................................................................2216 H-2 ALL WORK EQUIPMENT AND TRAVEL SPEED OR POWER IS LOW.........................................................................2217 H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR................................................................................2219 H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP...........................................................................2220 H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS..................................................................................2221 H-6 SPEED OR POWER OF BOOM IS LOW...............................................................................................2223 H-7 ARM SPEED OR POWER IS LOW...................................................................................................2229 H-8 BUCKET SPEED OR POWER IS LOW................................................................................................2234 H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION............................................................................2238 H-10 HYDRAULIC DRIFT OF BOOM IS LARGE...........................................................................................2239 H-11 HYDRAULIC DRIFT OF ARM IS LARGE............................................................................................2241 H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE.........................................................................................2243 H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES...........................................2244 H-14 TIME LAG OF WORK EQUIPMENT IS LARGE........................................................................................2245 H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE.......................................................................2246 H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE..................................................................................2247 H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED.......................................................................................2248 H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED...........................................................................2249 H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER........................................2250 H-20 MACHINE DOES NOT TRAVEL STRAIGHT...........................................................................................2251 H-21 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW.......................................................................2253 H-22 TRAVEL SPEED IS LOW........................................................................................................2256 H-23 ONE OF TRACKS DOES NOT RUN.................................................................................................2258 H-24 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST..........................................................2260 H-25 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY).....................................................................2261 H-26 UNUSUAL NOISE IS HEARD FROM AROUND FAN.....................................................................................2262 H-27 Quick coupler cylinder will not extend.....................................................................................2263 H-28 Quick coupler cylinder will not retract (but buzzer doesnot sound).........................................................2265 H-29 Buzzer does not sound (but quick coupler cylinder doesretract).............................................................2267 H-30 Quick coupler cylinder extends and retracts slowly.........................................................................2269 H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED).....................................................2270 H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)....................................................2271 TROUBLESHOOTING OF ENGINE (S-MODE)..................................................................................................2272 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE).........................................................................2272 S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION......................................................2273 S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT..................................................................................2274 S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)..............................2275 S-4 ENGINE STARTABILITY IS POOR.................................................................................................2277 S-5 ENGINE DOES NOT PICK UP SMOOTHLY............................................................................................2279 S-6 ENGINE STOPS DURING OPERATION...............................................................................................2281 S-7 ENGINE RUNS ROUGH OR IS UNSTABLE............................................................................................2283 S-8 ENGINE LACKS POWER..........................................................................................................2284 S-9 KDPF GETS CLOGGED IN A SHORT TIME...........................................................................................2286 S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE........................................................................................2288 S-11 OIL BECOMES CONTAMINATED QUICKLY...........................................................................................2289 S-12 FUEL CONSUMPTION IS EXCESSIVE..............................................................................................2290 S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)......................................................2291 S-14 OIL PRESSURE DROPS.........................................................................................................2292 S-15 FUEL MIXES INTO ENGINE OIL.................................................................................................2294 S-16 WATER MIXES INTO ENGINE OIL (MILKY)........................................................................................2295 S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)...........................................................................2296 S-18 UNUSUAL NOISE IS HEARD.....................................................................................................2297 S-19 VIBRATION IS EXCESSIVE.....................................................................................................2298 S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT.......................................................................................2299 S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY.................................................................................2300 S-22 ACTIVE REGENERATION TAKES TIME.............................................................................................2302 S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION........................................................................2303 S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE........................................................................................2304 S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)...................................................................................2306 S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)..................................................................2307 TROUBLESHOOTING FOR HYBRID SYSTEMS (Y MODE).........................................................................................2308 PRECAUTIONS FOR USING HYBRID SYSTEMS............................................................................................2308 Y-1 HYBRID MONITOR DOES NOT GO OUT..............................................................................................2309 Y-2 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT...................................................................2311 Y-3 UPPER STRUCTURE SWINGS ONLY TO THE RIGHT OR LEFT............................................................................2312 Y-4 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)............................2313 Y-5 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS LOW IN ONLY ONE DIRECTION..........................................2314 Y-6 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)...........................................2315 Y-7 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (EITHER RIGHT OR LEFT)..........................................2316 Y-8 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING..........................................................................2317 Y-9 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING............................................................2318 Y-10 SWING DRIFT ON A SLOPE IS LARGE (WHILE PARKING BRAKE IS APPLIED)...........................................................2319 Y-11 SWING DRIFT ON A SLOPE IS LARGE (WHILE PARKING BRAKE IS RELEASED)..........................................................2320 Y-12 ELECTRIC SWING MOTOR TEMPERATURE INCREASES ABNORMALLY......................................................................2321 Y-13 MOTOR-GENERATOR TEMPERATURE INCREASES ABNORMALLY...........................................................................2324 Y-14 INVERTER TEMPERATURE INCREASES ABNORMALLY..................................................................................2326 Y-15 CAPACITOR TEMPERATURE INCREASES ABNORMALLY.................................................................................2328 50 DISASSEMBLY AND ASSEMBLY.............................................................................................................2331 CONTENTS............................................................................................................................2332 ABBREVIATION LIST...................................................................................................................2337 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY.....................................................................................2343 HOW TO READ THIS MANUAL.........................................................................................................2343 COATING MATERIALS LIST..........................................................................................................2345 SPECIAL TOOLS LIST..............................................................................................................2350 SKETCHES OF SPECIAL TOOLS.......................................................................................................2369 ENGINE AND COOLING SYSTEM...........................................................................................................2377 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY.........................................................................................2377 METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY....................................................................................2377 METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY..................................................................................2381 REMOVE AND INSTALL INJECTOR ASSEMBLY............................................................................................2389 METHOD FOR REMOVING INJECTOR ASSEMBLY.......................................................................................2389 METHOD FOR INSTALLING INJECTOR ASSEMBLY.....................................................................................2395 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY.......................................................................................2407 METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY..................................................................................2407 METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY................................................................................2416 REMOVE AND INSTALL EGR VALVE ASSEMBLY...........................................................................................2433 METHOD FOR REMOVING EGR VALVE ASSEMBLY......................................................................................2433 METHOD FOR INSTALLING EGR VALVE ASSEMBLY....................................................................................2434 REMOVE AND INSTALL EGR COOLER ASSEMBLY..........................................................................................2436 METHOD FOR REMOVING EGR COOLER ASSEMBLY.....................................................................................2436 METHOD FOR INSTALLING EGR COOLER ASSEMBLY...................................................................................2437 REMOVE AND INSTALL STARTER ASSEMBLY.............................................................................................2439 METHOD FOR REMOVING STARTER ASSEMBLY........................................................................................2439 METHOD FOR INSTALLING STARTER ASSEMBLY......................................................................................2440 REMOVE AND INSTALL ALTERNATOR BELT..............................................................................................2441 METHOD FOR REMOVING ALTERNATOR BELT.........................................................................................2441 METHOD FOR INSTALLING ALTERNATOR BELT.......................................................................................2444 REMOVE AND INSTALL RADIATOR ASSEMBLY............................................................................................2447 METHOD FOR REMOVING RADIATOR ASSEMBLY.......................................................................................2447 METHOD FOR INSTALLING RADIATOR ASSEMBLY.....................................................................................2450 REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY................................................................................2453 METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY...........................................................................2453 METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY.........................................................................2457 REMOVE AND INSTALL AFTERCOOLER ASSEMBLY.........................................................................................2460 METHOD FOR REMOVING AFTERCOOLER ASSEMBLY....................................................................................2460 METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY..................................................................................2462 REMOVE AND INSTALL FAN CLUTCH ASSEMBLY..........................................................................................2464 METHOD FOR REMOVING FAN CLUTCH ASSEMBLY.....................................................................................2464 METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY...................................................................................2468 REMOVE AND INSTALL FAN..........................................................................................................2471 METHOD FOR INSTALLING FAN...................................................................................................2471 METHOD FOR REMOVING FAN.....................................................................................................2471 REMOVE AND INSTALL ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY..............................................................2472 METHOD FOR REMOVING ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY.........................................................2473 METHOD FOR INSTALLING ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY.......................................................2482 REMOVE AND INSTALL ENGINE FRONT OIL SEAL........................................................................................2494 METHOD FOR REMOVING ENGINE FRONT OIL SEAL...................................................................................2494 METHOD FOR INSTALLING ENGINE FRONT OIL SEAL.................................................................................2496 REMOVE AND INSTALL ENGINE REAR OIL SEAL.........................................................................................2498 METHOD FOR REMOVING ENGINE REAR OIL SEAL....................................................................................2498 METHOD FOR INSTALLING ENGINE REAR OIL SEAL..................................................................................2499 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY.........................................................................................2507 METHOD FOR REMOVING ENGINE HOOD ASSEMBLY....................................................................................2507 METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY..................................................................................2509 REMOVE AND INSTALL FUEL TANK ASSEMBLY...........................................................................................2512 METHOD FOR REMOVING FUEL TANK ASSEMBLY......................................................................................2512 METHOD FOR INSTALLING FUEL TANK ASSEMBLY....................................................................................2515 REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY.....................................................................................2518 METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY................................................................................2518 METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY..............................................................................2524 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY.......................................................................2529 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY..................................................................2529 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY................................................................2536 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR.......................................................................................2540 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR..................................................................................2540 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR................................................................................2540 REMOVE AND INSTALL AdBlue/DEF TANK STRAINER.....................................................................................2547 METHOD FOR REMOVING AdBlue/DEF TANK STRAINER................................................................................2547 METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER..............................................................................2547 REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER...........................................................................2548 METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER......................................................................2548 METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER....................................................................2550 REMOVE AND INSTALL KDPF ASSEMBLY................................................................................................2553 METHOD FOR REMOVING KDPF ASSEMBLY...........................................................................................2553 METHOD FOR INSTALLING KDPF ASSEMBLY.........................................................................................2556 DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY.......................................................................................2559 METHOD FOR DISASSEMBLING KDPF ASSEMBLY......................................................................................2560 METHOD FOR ASSEMBLING KDPF ASSEMBLY.........................................................................................2563 REMOVE AND INSTALL SCR ASSEMBLY.................................................................................................2568 METHOD FOR REMOVING SCR ASSEMBLY............................................................................................2568 METHOD FOR INSTALLING SCR ASSEMBLY..........................................................................................2571 REMOVE AND INSTALL KDPF, SCR ASSEMBLY...........................................................................................2574 METHOD FOR REMOVING KDPF, SCR ASSEMBLY......................................................................................2575 METHOD FOR INSTALLING KDPF, SCR ASSEMBLY....................................................................................2581 REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET...................................................................................2586 METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET..............................................................................2586 METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET............................................................................2589 REMOVE AND INSTALL KCCV ASSEMBLY................................................................................................2593 METHOD FOR REMOVING KCCV ASSEMBLY...........................................................................................2593 METHOD FOR INSTALLING KCCV ASSEMBLY.........................................................................................2594 REMOVE AND INSTALL AdBlue/DEF MIXING TUBE.......................................................................................2596 METHOD FOR REMOVING AdBlue/DEF MIXING TUBE..................................................................................2597 METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE................................................................................2600 REMOVE AND INSTALL AdBlue/DEF INJECTOR..........................................................................................2604 METHOD FOR REMOVING AdBlue/DEF INJECTOR.....................................................................................2604 METHOD FOR INSTALLING AdBlue/DEF INJECTOR...................................................................................2607 REMOVE AND INSTALL AdBlue/DEF PUMP..............................................................................................2611 METHOD FOR REMOVING AdBlue/DEF PUMP.........................................................................................2611 METHOD FOR INSTALLING AdBlue/DEF PUMP.......................................................................................2614 REMOVE AND INSTALL AdBlue/DEF HOSE..............................................................................................2617 METHOD FOR REMOVING AdBlue/DEF HOSE.........................................................................................2618 METHOD FOR INSTALLING AdBlue/DEF HOSE.......................................................................................2624 REMOVE AND INSTALL AIR CLEANER ASSEMBLY.........................................................................................2632 METHOD FOR REMOVING AIR CLEANER ASSEMBLY....................................................................................2632 METHOD FOR INSTALLING AIR CLEANER ASSEMBLY..................................................................................2634 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY..........................................................................2637 METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY.....................................................................2637 METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY...................................................................2638 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...........................................................................2640 METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY......................................................................2640 METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY....................................................................2641 HYBRID SYSTEM.......................................................................................................................2644 REMOVE AND INSTALL HYBRID RADIATOR ASSEMBLY.....................................................................................2644 METHOD FOR REMOVING HYBRID RADIATOR ASSEMBLY................................................................................2644 METHOD FOR INSTALLING HYBRID RADIATOR ASSEMBLY..............................................................................2646 REMOVE AND INSTALL HYBRID WATER PUMP ASSEMBLY...................................................................................2648 METHOD FOR REMOVING HYBRID WATER PUMP ASSEMBLY..............................................................................2648 METHOD FOR INSTALLING HYBRID WATER PUMP ASSEMBLY............................................................................2650 REMOVE AND INSTALL INVERTER ASSEMBLY............................................................................................2653 METHOD FOR REMOVING INVERTER ASSEMBLY.......................................................................................2653 METHOD FOR INSTALLING INVERTER ASSEMBLY.....................................................................................2657 REMOVE AND INSTALL INVERTER AND CAPACITOR ASSEMBLY..............................................................................2662 METHOD FOR REMOVING INVERTER AND CAPACITOR ASSEMBLY.........................................................................2662 METHOD FOR INSTALLING INVERTER AND CAPACITOR ASSEMBLY.......................................................................2667 REMOVE AND INSTALL MOTOR-GENERATOR AND HOUSING ASSEMBLY.........................................................................2672 METHOD FOR REMOVING MOTOR-GENERATOR AND HOUSING ASSEMBLY....................................................................2672 METHOD FOR INSTALLING MOTOR-GENERATOR AND HOUSING ASSEMBLY..................................................................2676 REMOVE AND INSTALL ELECTRIC SWING MOTOR.........................................................................................2682 METHOD FOR REMOVING ELECTRIC SWING MOTOR....................................................................................2682 METHOD FOR INSTALLING ELECTRIC SWING MOTOR..................................................................................2686 POWER TRAIN.........................................................................................................................2692 REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY........................................................................2692 METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...................................................................2692 METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY.................................................................2693 DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY...................................................................................2695 METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY...............................................................................2696 METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY..................................................................................2700 REMOVE AND INSTALL ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY............................................................2708 METHOD FOR REMOVING ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY.......................................................2708 METHOD FOR INSTALLING ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY.....................................................2712 DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY...............................................................................2717 METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY...........................................................................2717 METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY..............................................................................2724 REMOVE AND INSTALL SWING CIRCLE ASSEMBLY........................................................................................2737 METHOD FOR REMOVING SWING CIRCLE ASSEMBLY...................................................................................2737 METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY.................................................................................2737 UNDERCARRIAGE AND FRAME.............................................................................................................2739 SEPARATION AND CONNECTION OF TRACK ASSEMBLY.....................................................................................2739 METHOD FOR SEPARATING TRACK ASSEMBLY........................................................................................2739 METHOD FOR INSTALLING TRACK ASSEMBLY........................................................................................2741 REMOVE AND INSTALL SPROCKET.....................................................................................................2744 METHOD FOR REMOVING SPROCKET................................................................................................2744 METHOD FOR INSTALLING SPROCKET..............................................................................................2745 REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY.............................................................................2746 METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY........................................................................2746 METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY......................................................................2747 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY.........................................................................................2748 METHOD FOR DISASSEMBLING IDLER ASSEMBLY.....................................................................................2748 METHOD FOR ASSEMBLING IDLER ASSEMBLY........................................................................................2749 DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY..............................................................................2753 METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY.............................................................................2754 METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY................................................................................2754 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY..................................................................................2756 METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY..............................................................................2757 METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY.................................................................................2758 DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY.................................................................................2760 METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY............................................................................2760 METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY...............................................................................2762 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY.....................................................................................2765 METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY................................................................................2765 METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY..............................................................................2767 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY.......................................................................................2770 METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY..................................................................................2770 METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY................................................................................2771 HYDRAULIC SYSTEM....................................................................................................................2774 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY.................................................................................2774 METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY............................................................................2774 METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY..........................................................................2776 DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY...........................................................................2779 METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY.......................................................................2780 METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY..........................................................................2781 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY......................................................................................2782 METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY.................................................................................2782 METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY...............................................................................2785 REMOVE AND INSTALL MAIN PUMP ASSEMBLY...........................................................................................2789 METHOD FOR REMOVING MAIN PUMP ASSEMBLY......................................................................................2789 METHOD FOR INSTALLING MAIN PUMP ASSEMBLY....................................................................................2792 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY.......................................................................................2795 METHOD FOR REMOVING CONTROL VALVE ASSEMBLY..................................................................................2795 METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY................................................................................2802 DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY.................................................................................2809 METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING..................................................................2809 METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY................................................................................2811 REMOVE AND INSTALL ATT BYPASS SOLENOID..........................................................................................2816 REMOVE ATT BYPASS SOLENOID..................................................................................................2816 INSTALL ATT BYPASS SOLENOID.................................................................................................2819 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY......................................................................2821 METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY..................................................................2821 METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY.....................................................................2822 DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY..............................................................................2824 METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY..........................................................................2824 METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY.............................................................................2825 REMOVE AND INSTALL QUICK COUPLER VALVE..........................................................................................2827 WORK EQUIPMENT......................................................................................................................2829 REMOVE AND INSTALL BUCKET ASSEMBLY..............................................................................................2829 METHOD FOR REMOVING BUCKET ASSEMBLY.........................................................................................2829 METHOD FOR INSTALLING BUCKET ASSEMBLY.......................................................................................2829 REMOVE AND INSTALL ARM ASSEMBLY.................................................................................................2831 METHOD FOR REMOVING ARM ASSEMBLY............................................................................................2831 METHOD FOR INSTALLING ARM ASSEMBLY..........................................................................................2832 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY......................................................................................2834 METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY.................................................................................2834 METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY...............................................................................2836 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY.......................................................................2839 METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY...................................................................2839 METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY......................................................................2842 CAB AND ITS ATTACHMENTS.............................................................................................................2849 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY......................................................................................2849 METHOD FOR REMOVING OPERATOR CAB ASSEMBLY...................................................................................2849 METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY.................................................................................2856 REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)...........................................................................2864 METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)......................................................................2866 METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)....................................................................2866 REMOVE AND INSTALL FRONT WINDOW ASSEMBLY........................................................................................2876 METHOD FOR REMOVING FRONT WINDOW ASSEMBLY...................................................................................2876 METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY.................................................................................2879 REMOVE AND INSTALL FLOOR FRAME ASSEMBLY.........................................................................................2885 METHOD FOR REMOVING FLOOR FRAME ASSEMBLY....................................................................................2885 METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY..................................................................................2890 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY................................................................................2895 METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY...........................................................................2895 METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY.........................................................................2900 REMOVE AND INSTALL OPERATOR'S SEAT..............................................................................................2906 METHOD FOR REMOVING OPERATOR'S SEAT.........................................................................................2906 METHOD FOR INSTALLING OPERATOR'S SEAT.......................................................................................2908 REMOVE AND INSTALL SEAT BELT....................................................................................................2911 METHOD FOR REMOVING SEAT BELT...............................................................................................2911 METHOD FOR INSTALLING SEAT BELT.............................................................................................2911 REMOVE AND INSTALL FRONT WIPER ASSEMBLY.........................................................................................2913 METHOD FOR REMOVING FRONT WIPER ASSEMBLY....................................................................................2913 METHOD FOR INSTALLING FRONT WIPER ASSEMBLY..................................................................................2918 ELECTRICAL SYSTEM...................................................................................................................2927 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...................................................................................2927 METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY..............................................................................2927 METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY............................................................................2929 REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY.....................................................................................2933 METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY................................................................................2933 METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY..............................................................................2936 REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY................................................................................2939 METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY...........................................................................2939 METHOD FOR INSTALLING KomVision CONTROLLER..................................................................................2940 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY.....................................................................................2941 METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY................................................................................2941 METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY..............................................................................2943 REMOVE AND INSTALL PUMP SWASH PLATE SENSOR......................................................................................2947 METHOD FOR REMOVING PUMP SWASH PLATE SENSOR.................................................................................2947 METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR...............................................................................2947 REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR.........................................................................2949 METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR....................................................................2949 METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR..................................................................2950 REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR...............................................................................2952 METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR..........................................................................2952 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..........................................................................................3003 POWER TRAIN.........................................................................................................................3005 MAINTENANCE STANDARD OF SWING CIRCLE............................................................................................3005 MAINTENANCE STANDARD OF SWING MACHINERY WITH SWING PARKING BRAKE................................................................3006 MAINTENANCE STANDARD OF FINAL DRIVE.............................................................................................3008 MAINTENANCE STANDARD OF SPROCKET................................................................................................3010 MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING...............................................................3011 UNDERCARRIAGE AND FRAME.............................................................................................................3013 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION...........................................................................3013 MAINTENANCE STANDARD OF IDLER...................................................................................................3015 MAINTENANCE STANDARD OF TRACK ROLLER............................................................................................3017 MAINTENANCE STANDARD OF CARRIER ROLLER..........................................................................................3019 MAINTENANCE STANDARD OF TRACK SHOE..............................................................................................3020 MAINTENANCE STANDARD OF TRIPLE SHOE.............................................................................................3023 HYDRAULIC SYSTEM....................................................................................................................3024 MAINTENANCE STANDARD OF HYDRAULIC TANK..........................................................................................3024 MAINTENANCE STANDARD OF MAIN PUMP...............................................................................................3025 MAINTENANCE STANDARD OF MAIN PUMP LS-EPC VALVE..............................................................................3027 MAINTENANCE STANDARD OF MAIN PUMP PC-EPC VALVE..............................................................................3028 MAINTENANCE STANDARD OF TRAVEL MOTOR............................................................................................3029 MAINTENANCE STANDARD OF CONTROL VALVE...........................................................................................3032 MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM................................................................................3044 MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM.................................................................................3046 MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE......................................................................3048 MAINTENANCE STANDARD OF TRAVEL PPC VALVE........................................................................................3051 MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)..........................................................3054 MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE..........................................................3056 MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE...........................................................................3057 MAINTENANCE STANDARD OF SOLENOID VALVE..........................................................................................3059 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE.......................................................................3060 MAINTENANCE STANDARD OF CENTER SWIVEL JOINT.....................................................................................3061 WORK EQUIPMENT......................................................................................................................3062 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE..................................................................................3062 DIMENSION OF ARM............................................................................................................3067 DIMENSIONS OF BUCKET........................................................................................................3069 MAINTENANCE STANDARD OF BOOM CYLINDER...........................................................................................3071 MAINTENANCE STANDARD OF ARM CYLINDER............................................................................................3072 MAINTENANCE STANDARD OF BUCKET CYLINDER.........................................................................................3073 80 APPENDIX.............................................................................................................................3075 CONTENTS............................................................................................................................3076 ABBREVIATION LIST...................................................................................................................3078 AIR CONDITIONER SYSTEM..............................................................................................................3084 PRECAUTIONS FOR REFRIGERANT.....................................................................................................3084 AIR CONDITIONER COMPONENT.......................................................................................................3085 SPECIFICATIONS OF AIR CONDITIONER...............................................................................................3087 CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE...............................................................................3088 OUTLINE OF REFRIGERATION CYCLE..................................................................................................3089 COMPONENT PARTS OF AIR CONDITIONER SYSTEM...........................................................................................3091 AIR CONDITIONER UNIT............................................................................................................3091 CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT...............................................................................3091 FUNCTION OF AIR CONDITIONER UNIT............................................................................................3093 COMPONENT PARTS OF AIR CONDITIONER UNIT.........................................................................................3095 FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT....................................................................3096 FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT...................................................................3096 FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT.................................................3096 FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT...................................................................3096 STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT..............................................................3097 FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...............................................................3097 OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...................................................................3097 FUNCTION OF DUAL PRESSURE SWITCH............................................................................................3098 AIR CONDITIONER CONTROLLER......................................................................................................3099 STRUCTURE OF AIR CONDITIONER CONTROLLER.....................................................................................3099 COMPRESSOR......................................................................................................................3100 STRUCTURE OF COMPRESSOR.....................................................................................................3100 SPECIFICATIONS OF COMPRESSOR................................................................................................3100 FUNCTION OF COMPRESSOR......................................................................................................3100 CONDENSER.......................................................................................................................3101 STRUCTURE OF CONDENSER......................................................................................................3101 SPECIFICATIONS OF CONDENSER.................................................................................................3101 FUNCTION OF CONDENSER.......................................................................................................3101 RECEIVER DRIER..................................................................................................................3102 STRUCTURE OF RECEIVER DRIER.................................................................................................3102 SPECIFICATIONS OF RECEIVER DRIER............................................................................................3102 FUNCTION OF RECEIVER DRIER..................................................................................................3102 SENSORS FOR AIR CONDITIONER SYSTEM..............................................................................................3103 STRUCTURE OF SUNLIGHT SENSOR................................................................................................3103 FUNCTION OF SUNLIGHT SENSOR.................................................................................................3103 STRUCTURE OF AMBIENT TEMPERATURE SENSOR.....................................................................................3103 FUNCTION OF AMBIENT TEMPERATURE SENSOR......................................................................................3103 EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER.........................................................3105 CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER...............................................................3107 AIR CONDITIONER SYSTEM DIAGRAM......................................................................................................3109 INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER..........................................................................3110 FUNCTION OF AIR CONDITIONER CONTROLLER......................................................................................3111 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS.......................................................3112 TESTING AIR LEAKAGE (DUCT)..........................................................................................................3116 METHOD FOR TESTING AIR LEAKAGE (DUCT)...........................................................................................3116 TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION...............................................................................3118 HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR..................................3119 TEST VENT (MODE) CHANGEOVER.........................................................................................................3120 METHOD FOR TESTING VENT (MODE) CHANGEOVER.......................................................................................3120 TESTING FRESH/RECIRC AIR CHANGEOVER.................................................................................................3122 METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER..................................................................................3122 TEST SUNLIGHT SENSOR................................................................................................................3123 METHOD FOR TESTING SUNLIGHT SENSOR..............................................................................................3123 TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT.........................................................................................3124 METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT.......................................................................3124 TEST RELAYS.........................................................................................................................3125 METHOD FOR TESTING RELAYS.......................................................................................................3125 AIR CONDITIONER TROUBLESHOOTING CHART 1.............................................................................................3126 AIR CONDITIONER TROUBLESHOOTING CHART 2.............................................................................................3127 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE......................................................................................3130 FAILURE CODE [879AKA]...............................................................................................................3132 FAILURE CODE [879AKB]...............................................................................................................3133 FAILURE CODE [879BKA]...............................................................................................................3134 FAILURE CODE [879BKB]...............................................................................................................3136 FAILURE CODE [879CKA]...............................................................................................................3138 FAILURE CODE [879CKB]...............................................................................................................3139 FAILURE CODE [879DKZ]...............................................................................................................3140 FAILURE CODE [879EMC]...............................................................................................................3142 FAILURE CODE [879FMC]...............................................................................................................3143 FAILURE CODE [879GKX]...............................................................................................................3144 A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)......................................................3146 A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED).......................................................3148 A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)..............................................3151 A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER.................................................................................3153 TROUBLESHOOTING USING GAUGE PRESSURE................................................................................................3155 CONNECTION OF SERVICE TOOL..........................................................................................................3158 METHOD FOR CONNECTING SERVICE TOOL..............................................................................................3158 PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS.............................................3160 HANDLE COMPRESSOR OIL...............................................................................................................3162 90 CIRCUIT DIAGRAMS.....................................................................................................................3165 CONTENTS............................................................................................................................3166 ABBREVIATION LIST...................................................................................................................3167 HYDRAULIC CIRCUIT DIAGRAM...........................................................................................................3173 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM.......................................................................................3173 HYDRAULIC CIRCUIT DIAGRAM (1/3).................................................................................................3177 HYDRAULIC CIRCUIT DIAGRAM (2/3).................................................................................................3179 HYDRAULIC CIRCUIT DIAGRAM (3/3).................................................................................................3181 ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................3183 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM......................................................................................3183 ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................3187 ELECTRICAL CIRCUIT DIAGRAM (1/13)...............................................................................................3189 ELECTRICAL CIRCUIT DIAGRAM (2/13)...............................................................................................3191 ELECTRICAL CIRCUIT DIAGRAM (3/13)...............................................................................................3193 ELECTRICAL CIRCUIT DIAGRAM (4/13)...............................................................................................3195 ELECTRICAL CIRCUIT DIAGRAM (5/13)...............................................................................................3197 ELECTRICAL CIRCUIT DIAGRAM (6/13)...............................................................................................3199 ELECTRICAL CIRCUIT DIAGRAM (7/13)...............................................................................................3201 ELECTRICAL CIRCUIT DIAGRAM (8/13)...............................................................................................3203 ELECTRICAL CIRCUIT DIAGRAM (9/13)...............................................................................................3205 ELECTRICAL CIRCUIT DIAGRAM (10/13)..............................................................................................3207 ELECTRICAL CIRCUIT DIAGRAM (11/13)..............................................................................................3209 ELECTRICAL CIRCUIT DIAGRAM (12/13)..............................................................................................3211 ELECTRICAL CIRCUIT DIAGRAM (13/13)..............................................................................................3213 INDEX....................................................................................................................................3215
DESCRIPTION:
KOMATSU HB365LC-3E0 HB365NLC-3E0 HYDRAULIC EXCAVATOR SHOP MANUAL UENBM00641 – 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.S 31/12/24
