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

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Komatsu HB365LC-3,HB365NLC-3 Hydraulic Excavator Shop Manual UENBM00523 – PDF DOWNLOAD

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Komatsu HB365LC-3,HB365NLC-3 Hydraulic Excavator Shop Manual UENBM00523 – PDF DOWNLOAD

Language : English
Pages : 3284
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu HB365LC-3,HB365NLC-3 Hydraulic Excavator Shop Manual UENBM00523 – PDF DOWNLOAD

SERIAL NUMBERS

• 5001 and up
• K70001 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 25
FOREWORD, SAFETY, BASIC INFORMATION . 31
HOW TO READ THE SHOP MANUAL . 31
SAFETY NOTICE FOR OPERATION . 33
PRECAUTIONS PARTICULARLY FOR HYBRID MACHINES 41
PRECAUTIONS TO PREVENT FIRE . 42
ACTIONS IF FIRE OCCURS 44
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 45
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 46
PRECAUTIONS FOR DEF . 47
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 47
PRECAUTIONS FOR ADDING 47
PRECAUTIONS FOR STORING . 47
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 47
THE OTHER PRECAUTIONS . 47
STORE AdBlue/DEF 48
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 49
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 52
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 59
PRECAUTIONS FOR MAINTENANCE OF HYBRID SYSTEM 61
PRECAUTIONS AGAINST HIGH VOLTAGE AND HIGH TEMPERATURE . 62
PRECAUTIONS FOR NORMAL CHECK AND MAINTENANCE 63
PRECAUTIONS FOR THE MACHINE NOT TO BE TIPPED OVER AND FOR HYBRID COMPONENTS NOT TO BE DAMAGED . 64
PRECAUTIONS FOR THE MACHINE NOT TO BE SUBMERGED . 65
PRECAUTIONS FOR THE COLD SEASON . 66
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 67
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 68
PRACTICAL USE OF KOMTRAX 69
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 70
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 70
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 71
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 72
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 74
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 78
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 79
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 81
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 82
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 84
HOW TO READ THE CODES (SYMBOLS) FOR ELECTRIC CABLE 85
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 91
STANDARD TIGHTENING TORQUE TABLE 94
CONVERSION TABLE 101
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 161
AdBlue/DEF MIXING TUBE 161
SCR ASSEMBLY 161
AdBlue/DEF TANK . 164
AdBlue/DEF PUMP . 166
AdBlue/DEF INJECTOR . 167
AdBlue/DEF HOSE . 168
AdBlue/DEF TANK HEATING VALVE . 169
BOOT-UP SYSTEM 170
LAYOUT DRAWING OF BOOT-UP SYSTEM 170
SYSTEM OPERATING LAMP SYSTEM 172
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 172
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 172
BATTERY DISCONNECT SWITCH . 174
FUNCTION OF BATTERY DISCONNECT SWITCH . 174
ENGINE SYSTEM . 175
LAYOUT DRAWING OF ENGINE SYSTEM . 175
FUNCTION OF ENGINE SYSTEM . 176
ENGINE CONTROL SYSTEM . 177
ENGINE CONTROL SYSTEM DIAGRAM . 177
OPERATION OF ENGINE CONTROL SYSTEM 178
AUTO-DECELERATION SYSTEM 180
AUTO-DECELERATION SYSTEM DIAGRAM 180
FUNCTION OF AUTO-DECELERATION SYSTEM 180
OPERATION OF AUTO-DECELERATION SYSTEM . 181
ENGINE AUTOMATIC WARM-UP SYSTEM . 182
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 182
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 183
OVERHEAT PREVENTION SYSTEM 184
OVERHEAT PREVENTION SYSTEM DIAGRAM 184
FUNCTION OF OVERHEAT PREVENTION SYSTEM 185
TURBOCHARGER PROTECTION SYSTEM 187
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 187
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 188
AUTOMATIC IDLE STOP SYSTEM 189
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 189
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 189
COMPONENT PARTS OF ENGINE SYSTEM 193
VGT . 193
EGR SYSTEM 196
EGR VALVE . 198
EGR COOLER 200
KCCV SYSTEM . 201
KCCV VENTILATOR . 203
KDPF 204
COOLING SYSTEM 209
LAYOUT DRAWING OF COOLING SYSTEM 209
SPECIFICATIONS OF COOLING SYSTEM 210
HYBRID SYSTEM . 211
LAYOUT DRAWING OF HYBRID SYSTEM . 211
SYSTEM DIAGRAM OF HYBRID SYSTEM . 212
STRUCTURE OF HYBRID SYSTEM 213
HYBRID PROTECTION SYSTEM 214
SYSTEM DIAGRAM OF HYBRID PROTECTION SYSTEM 214
FUNCTION OF HYBRID PROTECTION SYSTEM 214
COOLING SYSTEM OF HYBRID COMPONENTS . 216
SYSTEM DIAGRAM OF COOLING SYSTEM OF HYBRID COMPONENTS . 216
INTERLOCK SYSTEM OF HYBRID COMPONENTS . 217
SYSTEM DIAGRAM OF INTERLOCK SYSTEM OF HYBRID COMPONENTS . 217
FUNCTION OF INTERLOCK SYSTEM OF HYBRID COMPONENTS . 217
WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID COMPONENTS . 218
SYSTEM DIAGRAM OF WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID COMPONENTS . 218
FUNCTION OF WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID COMPONENTS . 219
COMPONENT PARTS OF HYBRID SYSTEM 220
MOTOR-GENERATOR . 220
ELECTRIC CONTROL UNIT . 221
HIGH VOLTAGE WIRING (POWER CABLE) . 222
HYBRID WATER PUMP . 223
INVERTER (HYBRID CONTROLLER) 224
CONTROL SYSTEM 227
LAYOUT DRAWING OF CONTROL SYSTEM 227
MACHINE MONITOR SYSTEM 230
MACHINE MONITOR SYSTEM DIAGRAM 230
FUNCTION OF MACHINE MONITOR SYSTEM 230
KomVision SYSTEM 231
LAYOUT DRAWING OF KOMVISION SYSTEM 231
KomVision SYSTEM DIAGRAM 233
FUNCTION OF KomVision SYSTEM 233
KOMTRAX SYSTEM 235
KOMTRAX SYSTEM DIAGRAM 235
FUNCTION OF KOMTRAX SYSTEM 235
PPC LEVERS 236
LH PPC LEVER 236
RH PPC LEVER 237
AUTOMATIC GREASE SYSTEM . 238
OUTLINE OF AUTO GREASE SYSTEM . 238
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 252
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 252
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 252
COMPONENT PARTS OF CONTROL SYSTEM . 253
MACHINE MONITOR . 253
KomVision CAMERA 267
GATEWAY FUNCTION CONTROLLER . 268
COMMUNICATION TERMINAL 271
KomVision CONTROLLER 272
PUMP CONTROLLER . 277
RESISTOR FOR PC-EPC VALVE . 281
CAN TERMINATING RESISTOR 281
ENGINE CONTROLLER . 283
FUEL CONTROL DIAL . 289
HYDRAULIC SYSTEM 291
LAYOUT DRAWING OF HYDRAULIC SYSTEM 291
CLSS 294
STRUCTURE OF CLSS . 294
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 296
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 297
PRESSURE COMPENSATION CONTROL . 310
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 314
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 314
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 315
PUMP AND VALVE CONTROL SYSTEM . 320
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 320
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 321
COMPONENT PARTS OF HYDRAULIC SYSTEM . 323
HYDRAULIC TANK 323
MAIN PUMP . 325
CONTROL VALVE . 352
WORK EQUIPMENT SYSTEM . 406
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 406
STRUCTURE OF VALVE CONTROL 412
ONE-TOUCH POWER MAXIMIZING SYSTEM . 413
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 413
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 414
MACHINE PUSH-UP SYSTEM 415
MACHINE PUSH-UP SYSTEM DIAGRAM 415
FUNCTION OF MACHINE PUSH-UP SYSTEM 416
PPC LOCK SYSTEM . 417
PPC LOCK SYSTEM DIAGRAM . 417
FUNCTION OF PPC LOCK SYSTEM . 417
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 418
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 418
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 418
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 419
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 420
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT . 420
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 421
TOOL CONTROL SYSTEM . 422
TOOL CONTROL SYSTEM DIAGRAM . 422
FUNCTION OF TOOL CONTROL SYSTEM . 423
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 424
WORK EQUIPMENT AND SWING PPC VALVE 424
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 429
2ND-LINE ATTACHMENT PPC VALVE . 433
SOLENOID VALVE 435
ANTI-DROP VALVE FOR BOOM 438
ANTI-DROP VALVE FOR ARM . 441
ATTACHMENT CIRCUIT SELECTOR VALVE . 445
ATT EPC VALVE ASSEMBLY 448
PILOT CIRCUIT ACCUMULATOR . 449
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE . 450
2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE . 453
ATTACHMENT BYPASS SOLENOID VALVE 455
SWING SYSTEM 457
LAYOUT DRAWING OF SWING SYSTEM 457
SWING CONTROL SYSTEM DIAGRAM 460
FUNCTION OF SWING CONTROL SYSTEM 461
COMPONENT PARTS OF SWING SYSTEM . 463
ELECTRIC SWING MOTOR 463
SWING MACHINERY WITH SWING PARKING BRAKE 464
SWING CIRCLE 466
TRAVEL SYSTEM . 467
LAYOUT DRAWING OF TRAVEL SYSTEM . 467
TRAVEL CONTROL SYSTEM DIAGRAM . 471
FUNCTION OF TRAVEL CONTROL SYSTEM . 472
COMPONENT PARTS OF TRAVEL SYSTEM 473
TRAVEL MOTOR 473
FINAL DRIVE . 486
TRAVEL PPC VALVE 487
CENTER SWIVEL JOINT . 492
UNDERCARRIAGE AND FRAME . 494
LAYOUT DRAWING OF UNDERCARRIAGE . 494
SPECIFICATIONS OF UNDERCARRIAGE . 494
WORK EQUIPMENT 496
STRUCTURE OF WORK EQUIPMENT . 496
FUNCTION OF WORK EQUIPMENT 497
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 498
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 498
BUCKET CLEARANCE ADJUSTMENT SHIM 499
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 499
CAB AND ITS ATTACHMENTS . 500
ROPS CAB 500
STRUCTURE OF ROPS CAB . 500
FUNCTION OF ROPS CAB 500
CAB MOUNT . 501
STRUCTURE OF CAB MOUNT 501
FUNCTION OF CAB MOUNT . 501
CAB TIPPING STOPPER . 502
STRUCTURE OF CAB TIPPING STOPPER 502
FUNCTION OF CAB TIPPING STOPPER . 502
20 STANDARD VALUE TABLE . 503
CONTENTS 504
ABBREVIATION LIST . 505
STANDARD VALUE TABLE FOR ENGINE . 511
STANDARD VALUE TABLE FOR ENGINE:HB365LC-3E0, HB365NLC-3E0 . 511
STANDARD VALUE TABLE FOR MACHINE 517
STANDARD VALUE TABLE FOR MACHINE: HB365LC-3E0, HB365NLC-3E0 . 517
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 534
30 TESTING AND ADJUSTING 539
CONTENTS 540
ABBREVIATION LIST . 543
RELATED INFORMATION ON TESTING AND ADJUSTING 549
TOOLS FOR TESTING AND ADJUSTING . 549
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 556
ENGINE AND COOLING SYSTEM . 558
TEST ENGINE SPEED . 558
METHOD FOR TESTING ENGINE SPEED . 558
TEST BOOST PRESSURE . 561
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 561
METHOD FOR TESTING BOOST PRESSURE . 562
TEST EXHAUST GAS COLOR 563
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 563
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 564
TEST AND ADJUST VALVE CLEARANCE . 566
METHOD FOR TESTING VALVE CLEARANCE 566
METHOD FOR ADJUSTING VALVE CLEARANCE 568
TEST COMPRESSION PRESSURE . 569
METHOD FOR TESTING COMPRESSION PRESSURE . 569
TEST BLOWBY PRESSURE 572
METHOD FOR TESTING BLOWBY PRESSURE 572
TEST ENGINE OIL PRESSURE 574
METHOD FOR TESTING ENGINE OIL PRESSURE 574
TEST EGR VALVE AND VGT OIL PRESSURE . 576
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 576
TEST FUEL PRESSURE 578
METHOD FOR TESTING FUEL PRESSURE 579
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 586
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 587
BLEED AIR FROM FUEL SYSTEM 594
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 594
TEST FUEL CIRCUIT FOR LEAKAGE . 595
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 595
HANDLE CYLINDER CUT-OUT MODE OPERATION 597
HANDLE NO-INJECTION CRANKING OPERATION 598
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 599
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT . 599
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 599
TEST COOLING FAN SPEED 601
METHOD FOR TESTING COOLING FAN SPEED 601
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 602
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 602
TEST SCR RELATED FUNCTIONS 603
TEST AdBlue/DEF PUMP RAISED PRESSURE 606
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 609
TEST AdBlue/DEF LINE HEATER RELAY 1 . 613
TEST AdBlue/DEF LINE HEATER RELAY 2 . 615
TEST AdBlue/DEF PUMP HEATER RELAY . 618
TEST AdBlue/DEF TANK HEATER VALVE . 621
TEST DENITRATION EFFICIENCY OF SCR 624
CLEAN AdBlue/DEF TANK . 628
METHOD FOR CLEANING AdBlue/DEF TANK . 628
HYBRID SYSTEM . 633
PRECAUTIONS FOR USING HYBRID SYSTEMS 633
DRAIN, REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT . 634
METHOD FOR DRAINING THE HYBRID SYSTEM COOLANT . 635
REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT 638
WATER PRESSURE TEST OF THE HYBRID SYSTEM COOLANT 640
METHOD FOR TESTING THE WATER PRESSURE OF THE HYBRID SYSTEM COOLANT 640
TEST LUBRICATION CIRCUIT OIL PRESSURE OF HYBRID SYSTEM 642
TEST LUBRICATION CIRCUIT OIL PRESSURE OF ELECTRIC SWING MOTOR CASE 642
TEST LUBRICATION CIRCUIT OIL PRESSURE OF MOTOR-GENERATOR OIL CASE . 642
TEST SWING PARKING BRAKE PRESSURE . 644
METHOD FOR TESTING THE SWING PARKING BRAKE PRESSURE . 644
TEST AND CLEAN DELIVERY FILTER OF SWING MOTOR . 646
METHOD FOR CHECKING AND CLEANING ELECTRIC SWING MOTOR COOLING OIL DELIVERY FILTER . 646
POWER TRAIN . 647
TEST SWING CIRCLE BEARING CLEARANCE . 647
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 647
UNDERCARRIAGE AND FRAME . 648
TEST AND ADJUST TRACK TENSION . 648
METHOD FOR TESTING TRACK TENSION 648
METHOD FOR ADJUSTING TRACK TENSION 648
HYDRAULIC SYSTEM 650
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 650
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK . 650
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT . 650
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT . 655
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUITS 656
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, AND TRAVEL CIRCUITS 657
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,AND TRAVEL CIRCUITS . 662
TEST OIL PRESSURE OF CONTROL CIRCUIT 665
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 665
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 667
METHOD FOR TESTING PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 667
METHOD FOR TESTING PC-EPC VALVE OUTLET PRESSURE . 668
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 669
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 671
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR 671
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE . 672
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) . 674
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE . 676
METHOD FOR ADJUSTING LS VALVE . 676
TEST OUTLET PRESSURE OF SOLENOID VALVE 678
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 678
OPERATING CONDITION OF SOLENOID VALVE . 679
TEST PPC VALVE OUTPUT PRESSURE 682
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE 682
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 684
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 684
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 685
TEST PUMP SWASH PLATE SENSOR 687
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 687
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 688
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 688
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 688
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 689
TEST OIL LEAKAGE 690
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 690
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 691
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 691
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 692
BLEED AIR FROM HYDRAULIC CIRCUIT 693
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 693
CAB AND ITS ATTACHMENTS . 696
TEST CAB TIPPING STOPPER 696
METHOD FOR TESTING CAB TIPPING STOPPER 696
METHOD FOR ADJUSTING MIRRORS 697
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 697
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 698
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 699
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 700
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 701
ELECTRICAL SYSTEM . 703
SET AND OPERATE MACHINE MONITOR . 703
OPERATOR MODE . 706
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 707
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 707
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 708
CHECKING FUNCTION OF SERVICE METER 708
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 708
SERVICE MODE 711
METHOD FOR OPERATING SERVICE MODE . 711
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 713
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 722
ABNORMALITY RECORD MENU . 735
METHOD FOR CONFIRMING MAINTENANCE RECORD 740
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 741
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 744
DEFAULT MENU 745
DIAGNOSTIC TESTS MENU . 757
ADJUSTMENT MENU . 771
METHOD FOR PERFORMING NO-INJECTION CRANKING . 791
KOMTRAX SETTINGS MENU . 792
METHOD FOR DISPLAYING SERVICE MESSAGE . 794
METHOD FOR STARTING UP KOMTRAX TERMINAL . 796
ADJUST REARVIEW CAMERA ANGLE 801
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE . 801
ADJUST KomVision CAMERA ANGLE . 804
METHOD FOR ADJUSTING KomVision CAMERA ANGLE . 805
ADJUST KomVision RELATED ITEMS 809
SETTING OF KomVision (MAIN SETTING) . 809
SETTING OF KomVision (CAMERA SETTING) . 811
SETTING OF KomVision (CAMERA CALIBRATION) . 813
KomVision screen – Check 12 m visibility 826
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 829
HANDLE BATTERY DISCONNECT SWITCH 830
TEST DIODES . 831
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 831
METHOD FOR TESTING DIODE USING ANALOG TESTER 831
Pm CLINIC . 832
Pm CLINIC SERVICE . 832
Pm CLINIC CHECK SHEET:HB365LC-3E0, HB365NLC-3E0 . 833
40 TROUBLESHOOTING 845
CONTENTS 846
ABBREVIATION LIST . 859
RELATED INFORMATION ON TROUBLESHOOTING 865
GENERAL TROUBLESHOOTING POINTS 865
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 866
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 878
PRECAUTIONS FOR USING HYBRID SYSTEMS, TROUBLESHOOTING FOR HIGH-VOLTAGE EQUIPMENT 880
TABLE OF SELF-DEFINE MONITORING ITEMS AND CHECK SHEET FOR HYBRID COMPONENTS . 887
CHECKS BEFORE TROUBLESHOOTING . 893
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 895
WALK-AROUND CHECK . 895
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 897
CHECK FUEL LEVEL AND TYPE . 897
CHECK IMPURE INGREDIENT IN FUEL . 898
CHECK FUEL PREFILTER 898
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 898
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 899
CHECK MAIN FILTER . 902
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 904
CHECK OIL LEVEL IN MOTOR-GENERATOR CASE . 905
CHECK COOLANT LEVEL (RESERVOIR TANK) 906
CHECK CLOGGING OF AIR CLEANER . 907
OUTER ELEMENT – CLEAN . 908
ELEMENTS – REPLACE 910
CHECK HYDRAULIC OIL LEVEL . 912
CHECK HYDRAULIC OIL STRAINER 913
CHECK HYDRAULIC FILTER 914
CHECK CAPACITOR . 915
CHECK OIL LEVEL IN ELECTRIC SWING MOTOR CASE 915
CHECK OIL LEVEL IN SWING MACHINERY CASE . 916
CHECK OIL LEVEL IN FINAL DRIVE CASE . 917
BLEED AIR FROM FUEL SYSTEM 918
BLEED AIR FROM HYDRAULIC SYSTEM . 918
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod 918
AUTOMATIC GREASE SYSTEM . 923
FINDING MALFUNCTIONS 923
MALFUNCTION FINDING PROCEDURES 927
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 929
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR 929
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER 929
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER 930
PREPARATION FOR TROUBLESHOOTING OF GATEWAY TERMINAL . 930
PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER . 930
PREPARATION FOR TROUBLESHOOTING OF INVERTER (HYBRID CONTROLLER) . 931
DISCONNECT AND CONNECT CONNECTOR WITH A SPECIAL LOCK 931
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 935
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 938
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 942
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 944
CONNECTOR LIST AND LAYOUT . 947
CONNECTOR CONTACT IDENTIFICATION 961
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE .1001
FUSE LOCATION TABLE (MACHINE WITH KOMTRAX TERMINAL) .1007
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) .1010
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) .1014
FAILURE CODES TABLE .1016
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .1038
FAILURE CODE [879AKA] .1038
FAILURE CODE [879AKB] .1039
FAILURE CODE [879BKA] .1040
FAILURE CODE [879BKB] .1042
FAILURE CODE [879CKA] .1044
FAILURE CODE [879CKB] .1045
FAILURE CODE [879DKZ] .1046
FAILURE CODE [879EMC] .1048
FAILURE CODE [879FMC] .1049
FAILURE CODE [879GKX] .1050
FAILURE CODE [989L00] .1052
FAILURE CODE [989M00] .1053
FAILURE CODE [989N00] .1054
FAILURE CODE [A1U0N3] .1055
FAILURE CODE [A1U0N4] .1057
FAILURE CODE [A900FR] .1059
FAILURE CODE [A900N6] .1060
FAILURE CODE [A900NY] .1061
FAILURE CODE [AA10NX] .1062
FAILURE CODE [AB00KE] .1064
FAILURE CODE [AQ10N3] .1066
FAILURE CODE [AS00N3] .1068
FAILURE CODE [AS00R2] .1070
FAILURE CODE [AS00R3] .1071
FAILURE CODE [AS00R4] .1072
FAILURE CODE [AS00R5] .1073
FAILURE CODE [AS00R6] .1074
FAILURE CODE [AS00ZK] .1075
FAILURE CODE [AS10KM] .1076
FAILURE CODE [AS10NR] .1077
FAILURE CODE [AS10NT] .1078
FAILURE CODE [B@BAZG] .1079
FAILURE CODE [B@BAZK] .1080
FAILURE CODE [B@BCNS] .1082
FAILURE CODE [B@BCZK] .1083
FAILURE CODE [B@HANS] .1084
FAILURE CODE [CA115] 1085
FAILURE CODE [CA122] 1086
FAILURE CODE [CA123] 1088
FAILURE CODE [CA131] 1090
FAILURE CODE [CA132] 1092
FAILURE CODE [CA144] 1094
FAILURE CODE [CA145] 1096
FAILURE CODE [CA153] 1098
FAILURE CODE [CA154] 1101
FAILURE CODE [CA187] 1104
FAILURE CODE [CA221] 1106
FAILURE CODE [CA222] 1108
FAILURE CODE [CA227] 1110
FAILURE CODE [CA234] 1111
FAILURE CODE [CA238] 1112
FAILURE CODE [CA239] 1114
FAILURE CODE [CA249] 1116
FAILURE CODE [CA256] 1118
FAILURE CODE [CA271] 1120
FAILURE CODE [CA272] 1122
FAILURE CODE [CA281] 1124
FAILURE CODE [CA322] 1125
FAILURE CODE [CA323] 1127
FAILURE CODE [CA324] 1129
FAILURE CODE [CA325] 1131
FAILURE CODE [CA331] 1133
FAILURE CODE [CA332] 1135
FAILURE CODE [CA343] 1137
FAILURE CODE [CA351] 1138
FAILURE CODE [CA352] 1139
FAILURE CODE [CA356] 1142
FAILURE CODE [CA357] 1144
FAILURE CODE [CA386] 1146
FAILURE CODE [CA428] 1147
FAILURE CODE [CA429] 1149
FAILURE CODE [CA435] 1151
FAILURE CODE [CA441] 1153
FAILURE CODE [CA442] 1155
FAILURE CODE [CA449] 1156
FAILURE CODE [CA451] 1159
FAILURE CODE [CA452] 1162
FAILURE CODE [CA488] 1164
FAILURE CODE [CA515] 1165
FAILURE CODE [CA516] 1167
FAILURE CODE [CA553] 1169
FAILURE CODE [CA555] 1170
FAILURE CODE [CA556] 1171
FAILURE CODE [CA559] 1172
FAILURE CODE [CA595] 1176
FAILURE CODE [CA687] 1177
FAILURE CODE [CA689] 1179
FAILURE CODE [CA691] 1184
FAILURE CODE [CA692] 1186
FAILURE CODE [CA697] 1188
FAILURE CODE [CA698] 1189
FAILURE CODE [CA731] 1190
FAILURE CODE [CA778] 1192
FAILURE CODE [CA1117] .1197
FAILURE CODE [CA1664] .1198
FAILURE CODE [CA1669] .1200
FAILURE CODE [CA1673] .1201
FAILURE CODE [CA1677] .1202
FAILURE CODE [CA1678] .1203
FAILURE CODE [CA1682] .1204
FAILURE CODE [CA1683] .1206
FAILURE CODE [CA1684] .1208
FAILURE CODE [CA1686] .1210
FAILURE CODE [CA1691] .1211
FAILURE CODE [CA1694] .1214
FAILURE CODE [CA1695] .1217
FAILURE CODE [CA1696] .1218
FAILURE CODE [CA1712] .1220
FAILURE CODE [CA1713] .1223
FAILURE CODE [CA1714] .1225
FAILURE CODE [CA1715] .1226
FAILURE CODE [CA1776] .1227
FAILURE CODE [CA1777] .1230
FAILURE CODE [CA1843] .1233
FAILURE CODE [CA1844] .1235
FAILURE CODE [CA1879] .1237
FAILURE CODE [CA1881] .1240
FAILURE CODE [CA1883] .1242
FAILURE CODE [CA1885] .1245
FAILURE CODE [CA1887] .1247
FAILURE CODE [CA1921] .1249
FAILURE CODE [CA1922] .1252
FAILURE CODE [CA1942] .1257
FAILURE CODE [CA1993] .1258
FAILURE CODE [CA2185] .1261
FAILURE CODE [CA2186] .1262
FAILURE CODE [CA2249] .1264
FAILURE CODE [CA2265] .1265
FAILURE CODE [CA2266] .1267
FAILURE CODE [CA2271] .1269
FAILURE CODE [CA2272] .1271
FAILURE CODE [CA2288] .1274
FAILURE CODE [CA2311] .1275
FAILURE CODE [CA2349] .1276
FAILURE CODE [CA2353] .1279
FAILURE CODE [CA2357] .1281
FAILURE CODE [CA2381] .1282
FAILURE CODE [CA2382] .1284
FAILURE CODE [CA2383] .1287
FAILURE CODE [CA2386] .1290
FAILURE CODE [CA2387] .1292
FAILURE CODE [CA2555] .1293
FAILURE CODE [CA2556] .1296
FAILURE CODE [CA2637] .1299
FAILURE CODE [CA2639] .1301
FAILURE CODE [CA2771] .1304
FAILURE CODE [CA2777] .1310
FAILURE CODE [CA2976] .1313
FAILURE CODE [CA3133] .1315
FAILURE CODE [CA3134] .1317
FAILURE CODE [CA3135] .1319
FAILURE CODE [CA3142] .1322
FAILURE CODE [CA3143] .1323
FAILURE CODE [CA3144] .1324
FAILURE CODE [CA3146] .1326
FAILURE CODE [CA3147] .1327
FAILURE CODE [CA3148] .1328
FAILURE CODE [CA3151] .1330
FAILURE CODE [CA3165] .1337
FAILURE CODE [CA3229] .1339
FAILURE CODE [CA3231] .1341
FAILURE CODE [CA3232] .1343
FAILURE CODE [CA3235] .1347
FAILURE CODE [CA3239] .1349
FAILURE CODE [CA3241] .1352
FAILURE CODE [CA3242] .1355
FAILURE CODE [CA3251] .1358
FAILURE CODE [CA3253] .1360
FAILURE CODE [CA3254] .1363
FAILURE CODE [CA3255] .1366
FAILURE CODE [CA3256] .1370
FAILURE CODE [CA3311] .1372
FAILURE CODE [CA3312] .1374
FAILURE CODE [CA3313] .1377
FAILURE CODE [CA3314] .1378
FAILURE CODE [CA3315] .1379
FAILURE CODE [CA3316] .1381
FAILURE CODE [CA3317] .1382
FAILURE CODE [CA3318] .1383
FAILURE CODE [CA3319] .1385
FAILURE CODE [CA3321] .1386
FAILURE CODE [CA3322] .1388
FAILURE CODE [CA3419] .1390
FAILURE CODE [CA3421] .1392
FAILURE CODE [CA3497] .1394
FAILURE CODE [CA3498] .1395
FAILURE CODE [CA3543] .1396
FAILURE CODE [CA3545] .1402
FAILURE CODE [CA3547] .1404
FAILURE CODE [CA3558] .1405
FAILURE CODE [CA3559] .1407
FAILURE CODE [CA3562] .1409
FAILURE CODE [CA3563] .1411
FAILURE CODE [CA3567] .1414
FAILURE CODE [CA3568] .1417
FAILURE CODE [CA3571] .1421
FAILURE CODE [CA3572] .1423
FAILURE CODE [CA3574] .1425
FAILURE CODE [CA3575] .1427
FAILURE CODE [CA3577] .1429
FAILURE CODE [CA3578] .1431
FAILURE CODE [CA3582] .1433
FAILURE CODE [CA3583] .1439
FAILURE CODE [CA3596] .1441
FAILURE CODE [CA3649] .1444
FAILURE CODE [CA3681] .1446
FAILURE CODE [CA3682] .1451
FAILURE CODE [CA3713] .1456
FAILURE CODE [CA3717] .1459
FAILURE CODE [CA3718] .1460
FAILURE CODE [CA3725] .1461
FAILURE CODE [CA3741] .1464
FAILURE CODE [CA3748] .1465
FAILURE CODE [CA3751] .1468
FAILURE CODE [CA3755] .1470
FAILURE CODE [CA3866] .1472
FAILURE CODE [CA3867] .1476
FAILURE CODE [CA3868] .1479
FAILURE CODE [CA3899] .1483
FAILURE CODE [CA3911] .1485
FAILURE CODE [CA3912] .1489
FAILURE CODE [CA3932] .1491
FAILURE CODE [CA3933] .1493
FAILURE CODE [CA3934] .1495
FAILURE CODE [CA3935] .1498
FAILURE CODE [CA3936] .1500
FAILURE CODE [CA4151] .1502
FAILURE CODE [CA4152] .1506
FAILURE CODE [CA4155] .1510
FAILURE CODE [CA4156] .1512
FAILURE CODE [CA4157] .1515
FAILURE CODE [CA4158] .1517
FAILURE CODE [CA4159] .1518
FAILURE CODE [CA4161] .1519
FAILURE CODE [CA4162] .1522
FAILURE CODE [CA4163] .1525
FAILURE CODE [CA4164] .1527
FAILURE CODE [CA4165] .1529
FAILURE CODE [CA4166] .1531
FAILURE CODE [CA4168] .1533
FAILURE CODE [CA4169] .1536
FAILURE CODE [CA4171] .1538
FAILURE CODE [CA4249] .1541
FAILURE CODE [CA4251] .1543
FAILURE CODE [CA4259] .1545
FAILURE CODE [CA4261] .1548
FAILURE CODE [CA4277] .1551
FAILURE CODE [CA4281] .1555
FAILURE CODE [CA4459] .1559
FAILURE CODE [CA4461] .1562
FAILURE CODE [CA4658] .1565
FAILURE CODE [CA4731] .1569
FAILURE CODE [CA4732] .1570
FAILURE CODE [CA4739] .1571
FAILURE CODE [CA4768] .1572
FAILURE CODE [CA4769] .1574
FAILURE CODE [CA4842] .1576
FAILURE CODE [CA4952] .1580
FAILURE CODE [CA5115] .1582
FAILURE CODE [CA5179] .1585
FAILURE CODE [CA5181] .1587
FAILURE CODE [CA5383] .1589
FAILURE CODE [D110KB] .1591
FAILURE CODE [D19JKZ] .1593
FAILURE CODE [D811MC] .1596
FAILURE CODE [D862KA] .1597
FAILURE CODE [D8ALKA] .1599
FAILURE CODE [D8ALKB] .1602
FAILURE CODE [D8AQKR] .1604
FAILURE CODE [D8G1KT] .1611
FAILURE CODE [DA20MC] .1612
FAILURE CODE [DA22KK] .1613
FAILURE CODE [DA25KP] .1616
FAILURE CODE [DA26KP] .1618
FAILURE CODE [DA29KQ] .1621
FAILURE CODE [DA2LKA] .1623
FAILURE CODE [DA2LKB] .1626
FAILURE CODE [DA2QKR] .1628
FAILURE CODE [DA2RKR] .1637
FAILURE CODE [DAF0KM] .1642
FAILURE CODE [DAF0MB] .1643
FAILURE CODE [DAF0MC] .1644
FAILURE CODE [DAF8KB] .1645
FAILURE CODE [DAF9KQ] .1647
FAILURE CODE [DAFGMC] .1648
FAILURE CODE [DAFLKA] .1649
FAILURE CODE [DAFLKB] .1652
FAILURE CODE [DAFQKR] .1654
FAILURE CODE [DAZ9KQ] .1662
FAILURE CODE [DAZQKR] .1663
FAILURE CODE [DB2QKR] .1670
FAILURE CODE [DB2RKR] .1678
FAILURE CODE [DBP0KM] .1683
FAILURE CODE [DBP0KT] .1684
FAILURE CODE [DBPQKR] .1685
FAILURE CODE [DDNRKA] .1693
FAILURE CODE [DDNRKY] .1695
FAILURE CODE [DDNS00] .1697
FAILURE CODE [DFB1KZ] .1699
FAILURE CODE [DFB2KZ] .1701
FAILURE CODE [DFB3L8] .1703
FAILURE CODE [DFB4L8] .1705
FAILURE CODE [DFB5KZ] .1707
FAILURE CODE [DFB6KZ] .1709
FAILURE CODE [DGH2KA] .1711
FAILURE CODE [DGH2KB] .1713
FAILURE CODE [DHA4KA] .1715
FAILURE CODE [DHAAMA] .1717
FAILURE CODE [DHACMA] .1719
FAILURE CODE [DHPAMA] .1721
FAILURE CODE [DHPBMA] .1723
FAILURE CODE [DHS3MA] .1725
FAILURE CODE [DHS4MA] .1727
FAILURE CODE [DHS8MA] .1729
FAILURE CODE [DHS9MA] .1731
FAILURE CODE [DHSAKZ] .1733
FAILURE CODE [DHSBKZ] .1735
FAILURE CODE [DHSCMA] .1737
FAILURE CODE [DHSDMA] .1739
FAILURE CODE [DHSFMA] .1741
FAILURE CODE [DHSGMA] .1743
FAILURE CODE [DHSHMA] .1745
FAILURE CODE [DHSJMA] .1747
FAILURE CODE [DHVAKZ] .1749
FAILURE CODE [DHVAL8] .1751
FAILURE CODE [DHVAMA] .1753
FAILURE CODE [DHVBKZ] .1754
FAILURE CODE [DHVBL8] .1756
FAILURE CODE [DHVBMA] .1758
FAILURE CODE [DHZAMA] .1759
FAILURE CODE [DHZCL8] .1763
FAILURE CODE [DKR0MA] .1764
FAILURE CODE [DKR1MA] .1766
FAILURE CODE [DKULKA] .1768
FAILURE CODE [DKULKB] .1770
FAILURE CODE [DKULKY] .1772
FAILURE CODE [DLM5KA] .1773
FAILURE CODE [DLM5MB] .1775
FAILURE CODE [DR10KA] .1777
FAILURE CODE [DR21KX] .1780
FAILURE CODE [DUMBKA] .1782
FAILURE CODE [DUMBKB] .1785
FAILURE CODE [DV00KA] .1787
FAILURE CODE [DV00KB] .1788
FAILURE CODE [DV20KB] .1789
FAILURE CODE [DW43KA] .1791
FAILURE CODE [DW43KB] .1793
FAILURE CODE [DW43KY] .1794
FAILURE CODE [DW45KA] .1795
FAILURE CODE [DW45KB] .1798
FAILURE CODE [DW45KK] .1801
FAILURE CODE [DW45KY] .1803
FAILURE CODE [DW4CKY] .1805
FAILURE CODE [DW91KA] .1806
FAILURE CODE [DW91KB] .1808
FAILURE CODE [DW91KY] .1809
FAILURE CODE [DWA2KA] .1810
FAILURE CODE [DWA2KB] .1812
FAILURE CODE [DWA2KY] .1813
FAILURE CODE [DWK0KA] .1814
FAILURE CODE [DWK0KB] .1816
FAILURE CODE [DWK0KY] .1818
FAILURE CODE [DWK2KA] .1819
FAILURE CODE [DWK2KB] .1821
FAILURE CODE [DWK2KY] .1823
FAILURE CODE [DWN5KA] .1824
FAILURE CODE [DWN5KB] .1827
FAILURE CODE [DWN5KY] .1829
FAILURE CODE [DWPUKA] .1830
FAILURE CODE [DWPUKB] .1832
FAILURE CODE [DWPUKY] .1834
FAILURE CODE [DXA8KA] .1836
FAILURE CODE [DXA8KB] .1839
FAILURE CODE [DXA9KA] .1841
FAILURE CODE [DXA9KB] .1844
FAILURE CODE [DXE0KA] .1846
FAILURE CODE [DXE0KB] .1848
FAILURE CODE [DXE4KA] .1849
FAILURE CODE [DXE4KB] .1851
FAILURE CODE [DXE4KY] .1852
FAILURE CODE [DXE5KA] .1853
FAILURE CODE [DXE5KB] .1855
FAILURE CODE [DXE6KA] .1857
FAILURE CODE [DXE6KB] .1859
FAILURE CODE [DXE7KA] .1861
FAILURE CODE [DXE7KB] .1863
FAILURE CODE [DXE7KY] .1865
FAILURE CODE [DXE8KA] .1867
FAILURE CODE [DXE8KB] .1869
FAILURE CODE [DXE8KY] .1871
FAILURE CODE [DXE9KA] .1873
FAILURE CODE [DXE9KB] .1875
FAILURE CODE [DXE9KY] .1877
FAILURE CODE [DXEAKA] .1879
FAILURE CODE [DXEAKB] .1881
FAILURE CODE [DXEAKY] .1883
FAILURE CODE [DXEKKA] .1885
FAILURE CODE [DXEKKB] .1887
FAILURE CODE [DXEKKY] .1889
FAILURE CODE [DXELKA] .1891
FAILURE CODE [DXELKB] .1893
FAILURE CODE [DXELKY] .1895
FAILURE CODE [DY20KA] .1897
FAILURE CODE [DY20MA] .1899
FAILURE CODE [DY2CKB] .1901
FAILURE CODE [DY2DKB] .1903
FAILURE CODE [DY2EKB] .1905
FAILURE CODE [F313KA] .1907
FAILURE CODE [F313KB] .1909
FAILURE CODE [F318KB] .1912
FAILURE CODE [F318KY] .1915
FAILURE CODE [GA00NS] .1917
FAILURE CODE [GA01KA] .1918
FAILURE CODE [GA02KZ] .1920
FAILURE CODE [GA04KG] .1923
FAILURE CODE [GA05KG] .1926
FAILURE CODE [GA05KP] .1929
FAILURE CODE [GA06KZ] .1932
FAILURE CODE [GA08KG] .1933
FAILURE CODE [GA09KG] .1941
FAILURE CODE [GA09KP] .1949
FAILURE CODE [GA0AKZ] .1950
FAILURE CODE [GA0BKZ] .1951
FAILURE CODE [GA10MA] .1958
FAILURE CODE [GA10MC] .1965
FAILURE CODE [GA12NK] .1966
FAILURE CODE [GA13KP] .1972
FAILURE CODE [GA13KY] .1974
FAILURE CODE [GA15KZ] .1976
FAILURE CODE [GA17KR] .1984
FAILURE CODE [GA17MB] .1985
FAILURE CODE [GA18MC] .1986
FAILURE CODE [GA19KR] .1991
FAILURE CODE [GA19KT] .1992
FAILURE CODE [GA1BMA] .1993
FAILURE CODE [GA1FKR] .1995
FAILURE CODE [GA1FMA] .1996
FAILURE CODE [GA1GKR] .1999
FAILURE CODE [GA1GKT] .2000
FAILURE CODE [GA1GMB] .2001
FAILURE CODE [GA1HKZ] .2002
FAILURE CODE [GA1JKZ] .2003
FAILURE CODE [GA1KKZ] .2004
FAILURE CODE [GA1LKZ] .2005
FAILURE CODE [GA1MKZ] .2006
FAILURE CODE [GA1NNS] .2007
FAILURE CODE [GA1SFS] .2008
FAILURE CODE [GA1SMC] .2009
FAILURE CODE [GA1TKP] .2010
FAILURE CODE [GA1TNS] .2013
FAILURE CODE [GA1UKZ] .2016
FAILURE CODE [GA1VFS] .2019
FAILURE CODE [GA1VMC] .2020
FAILURE CODE [GA1XKZ] .2021
FAILURE CODE [GA1YNS] .2022
FAILURE CODE [GA1ZKZ] .2023
FAILURE CODE [GA1ZNS] .2024
FAILURE CODE [GA22NS] .2025
FAILURE CODE [GA23KZ] .2026
FAILURE CODE [GA24KZ] .2027
FAILURE CODE [GA25MA] .2028
FAILURE CODE [GA25NS] .2033
FAILURE CODE [GA26MA] .2034
FAILURE CODE [GA26NS] .2039
FAILURE CODE [GA27KZ] .2040
FAILURE CODE [GA2QKR] .2041
FAILURE CODE [GA2RKR] .2046
FAILURE CODE [GA60MC] .2051
FAILURE CODE [GA60N1] .2053
FAILURE CODE [GA61KZ] .2055
FAILURE CODE [GA61NS] .2057
FAILURE CODE [GA62KY] .2058
FAILURE CODE [GA62KZ] .2063
FAILURE CODE [GA62MA] .2067
FAILURE CODE [GA63KY] .2068
FAILURE CODE [GA63KZ] .2073
FAILURE CODE [GA63MA] .2077
FAILURE CODE [GA64KY] .2078
FAILURE CODE [GA64KZ] .2083
FAILURE CODE [GA64MA] .2087
FAILURE CODE [GA70KB] .2088
FAILURE CODE [GA70MD] .2091
FAILURE CODE [GA70NS] .2093
FAILURE CODE [GA71KZ] .2094
FAILURE CODE [GA72MA] .2096
FAILURE CODE [GA72MC] .2098
FAILURE CODE [GA81KZ] .2100
FAILURE CODE [GAA0KB] .2103
FAILURE CODE [GAA2KB] .2105
FAILURE CODE [GAA6KP] .2107
FAILURE CODE [GAA6KY] .2109
FAILURE CODE [GACA00] .2111
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .2112
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .2112
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 2118
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .2121
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .2123
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .2125
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 2128
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 2129
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .2130
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 2131
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .2132
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2133
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2134
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2135
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2136
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2137
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .2138
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .2139
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .2141
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .2142
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 2143
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2144
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .2146
E-23 MONITOR TEMPERATURE GAUGE OF HYBRID SYSTEMS DOES NOT INDICATE CORRECT TEMPERATURE 2147
E-24 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .2148
E-25 FUNCTION SWITCH DOES NOT OPERATE .2149
E-26 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .2150
E-27 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 2151
E-28 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 2152
E-29 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .2153
E-30 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 2154
E-31 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .2155
E-32 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 2156
E-33 ALARM BUZZER CANNOT BE CANCELED 2157
E-34 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .2158
E-35 SERVICE MODE CANNOT BE SELECTED 2159
E-36 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 2160
E-37 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .2162
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .2163
E-39 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .2166
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .2168
E-41 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .2170
E-42 ALARM DOES NOT SOUND DURING TRAVEL .2171
E-43 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 2173
E-44 HORN DOES NOT SOUND 2174
E-45 HORN DOES NOT STOP SOUNDING 2177
E-46 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .2179
E-47 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .2180
E-48 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 2182
E-49 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2183
E-50 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2184
E-51 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .2185
E-52 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2186
E-53 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .2187
E-54 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .2188
E-55 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .2189
E-56 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2190
E-57 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .2191
E-58 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .2193
E-59 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .2194
E-60 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED 2195
E-61 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 2197
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .2198
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .2198
FAILURE MODE AND CAUSE TABLE 2199
H-1 ALL WORK EQUIPMENTS OR TRAVEL DOES NOT OPERATE 2210
H-2 ALL WORK EQUIPMENT AND TRAVEL SPEED OR POWER IS LOW .2211
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 2213
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .2214
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2215
H-6 SPEED OR POWER OF BOOM IS LOW .2217
H-7 ARM SPEED OR POWER IS LOW .2223
H-8 BUCKET SPEED OR POWER IS LOW 2228
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 2232
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .2233
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 2235
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .2237
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .2238
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 2239
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .2240
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 2241
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED .2242
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .2243
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 2244
H-20 MACHINE DOES NOT TRAVEL STRAIGHT .2245
H-21 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .2247
H-22 TRAVEL SPEED IS LOW 2250
H-23 ONE OF TRACKS DOES NOT RUN .2252
H-24 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2254
H-25 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) .2255
H-26 UNUSUAL NOISE IS HEARD FROM AROUND FAN .2256
H-27 Quick coupler cylinder will not extend .2257
H-28 Quick coupler cylinder will not retract (but buzzer doesnot sound) .2259
H-29 Buzzer does not sound (but quick coupler cylinder doesretract) .2261
H-30 Quick coupler cylinder extends and retracts slowly .2263
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .2264
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2265
TROUBLESHOOTING OF ENGINE (S-MODE) 2266
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .2266
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2267
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2268
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2269
S-4 ENGINE STARTABILITY IS POOR .2271
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2273
S-6 ENGINE STOPS DURING OPERATION .2275
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2277
S-8 ENGINE LACKS POWER 2278
S-9 KDPF GETS CLOGGED IN A SHORT TIME .2280
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2282
S-11 OIL BECOMES CONTAMINATED QUICKLY .2283
S-12 FUEL CONSUMPTION IS EXCESSIVE 2284
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2285
S-14 OIL PRESSURE DROPS .2286
S-15 FUEL MIXES INTO ENGINE OIL .2288
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2289
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2290
S-18 UNUSUAL NOISE IS HEARD .2291
S-19 VIBRATION IS EXCESSIVE .2292
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .2293
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2294
S-22 ACTIVE REGENERATION TAKES TIME .2296
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2297
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2298
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2300
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2301
TROUBLESHOOTING FOR HYBRID SYSTEMS (Y MODE) .2302
PRECAUTIONS FOR USING HYBRID SYSTEMS 2302
Y-1 HYBRID MONITOR DOES NOT GO OUT 2303
Y-2 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT .2305
Y-3 UPPER STRUCTURE SWINGS ONLY TO THE RIGHT OR LEFT 2306
Y-4 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 2307
Y-5 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS LOW IN ONLY ONE DIRECTION 2308
Y-6 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) .2309
Y-7 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (EITHER RIGHT OR LEFT) 2310
Y-8 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 2311
Y-9 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 2312
Y-10 SWING DRIFT ON A SLOPE IS LARGE (WHILE PARKING BRAKE IS APPLIED) .2313
Y-11 SWING DRIFT ON A SLOPE IS LARGE (WHILE PARKING BRAKE IS RELEASED) 2314
Y-12 ELECTRIC SWING MOTOR TEMPERATURE INCREASES ABNORMALLY 2315
Y-13 MOTOR-GENERATOR TEMPERATURE INCREASES ABNORMALLY .2318
Y-14 INVERTER TEMPERATURE INCREASES ABNORMALLY 2320
Y-15 CAPACITOR TEMPERATURE INCREASES ABNORMALLY .2322
50 DISASSEMBLY AND ASSEMBLY .2325
CONTENTS 2326
ABBREVIATION LIST .2331
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2337
HOW TO READ THIS MANUAL .2337
COATING MATERIALS LIST 2339
SPECIAL TOOLS LIST 2343
SKETCHES OF SPECIAL TOOLS .2362
ENGINE AND COOLING SYSTEM .2370
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2370
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2370
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2374
REMOVE AND INSTALL INJECTOR ASSEMBLY 2382
METHOD FOR REMOVING INJECTOR ASSEMBLY .2382
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2388
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2400
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2400
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2409
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2426
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2426
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2427
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2429
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2429
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2430
REMOVE AND INSTALL STARTER ASSEMBLY .2432
METHOD FOR REMOVING STARTER ASSEMBLY 2432
METHOD FOR INSTALLING STARTER ASSEMBLY 2433
REMOVE AND INSTALL ALTERNATOR BELT 2434
METHOD FOR REMOVING ALTERNATOR BELT .2434
METHOD FOR INSTALLING ALTERNATOR BELT .2437
REMOVE AND INSTALL RADIATOR ASSEMBLY 2440
METHOD FOR REMOVING RADIATOR ASSEMBLY .2440
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2443
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2446
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2446
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2450
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2453
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2453
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2455
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 2457
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY .2457
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY .2461
REMOVE AND INSTALL FAN 2464
METHOD FOR INSTALLING FAN .2464
METHOD FOR REMOVING FAN .2464
REMOVE AND INSTALL ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY 2465
METHOD FOR REMOVING ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY .2466
METHOD FOR INSTALLING ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY .2475
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2487
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2487
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2489
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2491
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2491
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2492
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2500
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2500
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2502
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2505
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2505
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2508
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2511
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2511
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2517
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2522
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2522
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2529
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2533
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2533
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2533
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2540
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2540
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2540
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2541
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2541
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2543
REMOVE AND INSTALL KDPF ASSEMBLY 2546
METHOD FOR REMOVING KDPF ASSEMBLY .2546
METHOD FOR INSTALLING KDPF ASSEMBLY .2549
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2552
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2553
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2556
REMOVE AND INSTALL SCR ASSEMBLY .2561
METHOD FOR REMOVING SCR ASSEMBLY 2561
METHOD FOR INSTALLING SCR ASSEMBLY 2564
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2567
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2568
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2574
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2579
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2579
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2582
REMOVE AND INSTALL KCCV ASSEMBLY 2586
METHOD FOR REMOVING KCCV ASSEMBLY .2586
METHOD FOR INSTALLING KCCV ASSEMBLY .2587
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2589
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2590
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2593
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2597
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2597
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2600
REMOVE AND INSTALL AdBlue/DEF PUMP 2604
METHOD FOR REMOVING AdBlue/DEF PUMP .2604
METHOD FOR INSTALLING AdBlue/DEF PUMP .2607
REMOVE AND INSTALL AdBlue/DEF HOSE 2610
METHOD FOR REMOVING AdBlue/DEF HOSE .2611
METHOD FOR INSTALLING AdBlue/DEF HOSE .2617
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2625
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2625
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2627
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2630
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2630
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2631
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2633
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2633
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2634
HYBRID SYSTEM .2637
REMOVE AND INSTALL HYBRID RADIATOR ASSEMBLY .2637
METHOD FOR REMOVING HYBRID RADIATOR ASSEMBLY 2637
METHOD FOR INSTALLING HYBRID RADIATOR ASSEMBLY 2639
REMOVE AND INSTALL HYBRID WATER PUMP ASSEMBLY .2641
METHOD FOR REMOVING HYBRID WATER PUMP ASSEMBLY 2641
METHOD FOR INSTALLING HYBRID WATER PUMP ASSEMBLY 2643
REMOVE AND INSTALL INVERTER ASSEMBLY 2646
METHOD FOR REMOVING INVERTER ASSEMBLY .2646
METHOD FOR INSTALLING INVERTER ASSEMBLY .2650
REMOVE AND INSTALL INVERTER AND CAPACITOR ASSEMBLY 2655
METHOD FOR REMOVING INVERTER AND CAPACITOR ASSEMBLY .2655
METHOD FOR INSTALLING INVERTER AND CAPACITOR ASSEMBLY .2660
REMOVE AND INSTALL MOTOR-GENERATOR AND HOUSING ASSEMBLY .2665
METHOD FOR REMOVING MOTOR-GENERATOR AND HOUSING ASSEMBLY 2665
METHOD FOR INSTALLING MOTOR-GENERATOR AND HOUSING ASSEMBLY 2669
REMOVE AND INSTALL ELECTRIC SWING MOTOR .2675
METHOD FOR REMOVING ELECTRIC SWING MOTOR 2675
METHOD FOR INSTALLING ELECTRIC SWING MOTOR 2679
POWER TRAIN .2685
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2685
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2685
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2686
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2688
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2689
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2693
REMOVE AND INSTALL ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY 2701
METHOD FOR REMOVING ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY .2701
METHOD FOR INSTALLING ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY .2705
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2710
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2710
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2717
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2730
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2730
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2730
UNDERCARRIAGE AND FRAME .2732
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2732
METHOD FOR SEPARATING TRACK ASSEMBLY 2732
METHOD FOR INSTALLING TRACK ASSEMBLY 2734
REMOVE AND INSTALL SPROCKET .2737
METHOD FOR REMOVING SPROCKET 2737
METHOD FOR INSTALLING SPROCKET 2738
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2739
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2739
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2740
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2741
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2741
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2742
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2746
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2747
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2747
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2749
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2750
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2751
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2753
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2753
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2755
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2758
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2758
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2760
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2763
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2763
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2764
HYDRAULIC SYSTEM 2767
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2767
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2767
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2769
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2772
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2773
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2774
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2775
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2775
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2778
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2782
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2782
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2785
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2788
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2788
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2795
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2802
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2802
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2804
REMOVE AND INSTALL ATT BYPASS SOLENOID 2809
REMOVE ATT BYPASS SOLENOID 2809
INSTALL ATT BYPASS SOLENOID .2812
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2814
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2814
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2815
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2817
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2817
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2818
REMOVE AND INSTALL QUICK COUPLER VALVE 2820
WORK EQUIPMENT 2822
REMOVE AND INSTALL BUCKET ASSEMBLY 2822
METHOD FOR REMOVING BUCKET ASSEMBLY .2822
METHOD FOR INSTALLING BUCKET ASSEMBLY .2822
REMOVE AND INSTALL ARM ASSEMBLY .2824
METHOD FOR REMOVING ARM ASSEMBLY 2824
METHOD FOR INSTALLING ARM ASSEMBLY 2825
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2827
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2827
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2829
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2832
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2832
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2835
CAB AND ITS ATTACHMENTS .2842
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2842
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY .2842
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY .2849
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2857
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2859
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2859
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2869
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2869
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2872
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2878
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2878
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2883
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2888
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2888
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2893
REMOVE AND INSTALL OPERATOR’S SEAT 2899
METHOD FOR REMOVING OPERATOR’S SEAT .2899
METHOD FOR INSTALLING OPERATOR’S SEAT .2901
REMOVE AND INSTALL SEAT BELT 2904
METHOD FOR REMOVING SEAT BELT .2904
METHOD FOR INSTALLING SEAT BELT .2904
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2906
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2906
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2911
ELECTRICAL SYSTEM .2920
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2920
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2920
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2922
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2926
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2926
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2929
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2932
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2932
METHOD FOR INSTALLING KomVision CONTROLLER 2933
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2934
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2934
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2936
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2940
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2940
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2940
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2942
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2942
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2943
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2945
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2945
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2945
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2947
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2947
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2948
REMOVE AND INSTALL KomVision CAMERA .2950
METHOD FOR REMOVING KomVision CAMERA 2950
METHOD FOR INSTALLING KomVision CAMERA 2951
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY .2953
METHOD FOR REMOVING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2953
METHOD FOR INSTALLING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2958
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 2963
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS .2963
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS .2971
REMOVE AND INSTALL COMMUNICATION TERMINAL .2980
METHOD FOR REMOVING COMMUNICATION TERMINAL 2980
METHOD FOR INSTALLING COMMUNICATION TERMINAL 2982
60 MAINTENANCE STANDARD .2985
CONTENTS 2986
ABBREVIATION LIST .2987
ENGINE AND COOLING SYSTEM .2993
MAINTENANCE STANDARD OF ENGINE MOUNT 2993
MAINTENANCE STANDARD OF COOLING SYSTEM 2995
POWER TRAIN .2997
MAINTENANCE STANDARD OF SWING CIRCLE 2997
MAINTENANCE STANDARD OF SWING MACHINERY WITH SWING PARKING BRAKE 2998
MAINTENANCE STANDARD OF FINAL DRIVE .3000
MAINTENANCE STANDARD OF SPROCKET 3002
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .3003
UNDERCARRIAGE AND FRAME .3005
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .3005
MAINTENANCE STANDARD OF IDLER .3007
MAINTENANCE STANDARD OF TRACK ROLLER 3009
MAINTENANCE STANDARD OF CARRIER ROLLER 3011
MAINTENANCE STANDARD OF TRACK SHOE 3012
MAINTENANCE STANDARD OF TRIPLE SHOE .3015
HYDRAULIC SYSTEM 3016
MAINTENANCE STANDARD OF HYDRAULIC TANK 3016
MAINTENANCE STANDARD OF MAIN PUMP .3017
MAINTENANCE STANDARD OF MAIN PUMP LS-EPC VALVE 3019
MAINTENANCE STANDARD OF MAIN PUMP PC-EPC VALVE 3020
MAINTENANCE STANDARD OF TRAVEL MOTOR 3021
MAINTENANCE STANDARD OF CONTROL VALVE .3024
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 3036
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM .3038
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 3040
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 3043
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 3046
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 3048
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE .3049
MAINTENANCE STANDARD OF SOLENOID VALVE 3051
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE .3052
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .3053
WORK EQUIPMENT 3054
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 3054
DIMENSION OF ARM 3059
DIMENSIONS OF BUCKET 3061
MAINTENANCE STANDARD OF BOOM CYLINDER .3063
MAINTENANCE STANDARD OF ARM CYLINDER 3064
MAINTENANCE STANDARD OF BUCKET CYLINDER .3065
80 APPENDIX .3067
CONTENTS 3068
ABBREVIATION LIST .3070
AIR CONDITIONER SYSTEM 3076
PRECAUTIONS FOR REFRIGERANT .3076
AIR CONDITIONER COMPONENT .3077
SPECIFICATIONS OF AIR CONDITIONER .3079
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .3080
OUTLINE OF REFRIGERATION CYCLE 3081
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .3083
AIR CONDITIONER UNIT 3083
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .3083
FUNCTION OF AIR CONDITIONER UNIT 3085
COMPONENT PARTS OF AIR CONDITIONER UNIT .3087
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3088
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .3088
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .3088
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .3088
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3089
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .3089
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .3089
FUNCTION OF DUAL PRESSURE SWITCH 3090
AIR CONDITIONER CONTROLLER 3091
STRUCTURE OF AIR CONDITIONER CONTROLLER .3091
COMPRESSOR 3092
STRUCTURE OF COMPRESSOR .3092
SPECIFICATIONS OF COMPRESSOR 3092
FUNCTION OF COMPRESSOR 3092
CONDENSER .3093
STRUCTURE OF CONDENSER 3093
SPECIFICATIONS OF CONDENSER .3093
FUNCTION OF CONDENSER .3093
RECEIVER DRIER 3094
STRUCTURE OF RECEIVER DRIER .3094
SPECIFICATIONS OF RECEIVER DRIER 3094
FUNCTION OF RECEIVER DRIER 3094
SENSORS FOR AIR CONDITIONER SYSTEM 3095
STRUCTURE OF SUNLIGHT SENSOR 3095
FUNCTION OF SUNLIGHT SENSOR .3095
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .3095
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3095
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .3097
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .3099
AIR CONDITIONER SYSTEM DIAGRAM 3101
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3102
FUNCTION OF AIR CONDITIONER CONTROLLER 3103
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .3104
TESTING AIR LEAKAGE (DUCT) 3108
METHOD FOR TESTING AIR LEAKAGE (DUCT) .3108
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .3110
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3111
TEST VENT (MODE) CHANGEOVER .3112
METHOD FOR TESTING VENT (MODE) CHANGEOVER .3112
TESTING FRESH/RECIRC AIR CHANGEOVER .3114
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3114
TEST SUNLIGHT SENSOR 3115
METHOD FOR TESTING SUNLIGHT SENSOR 3115
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .3116
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .3116
TEST RELAYS .3117
METHOD FOR TESTING RELAYS .3117
AIR CONDITIONER TROUBLESHOOTING CHART 1 .3118
AIR CONDITIONER TROUBLESHOOTING CHART 2 .3119
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3122
FAILURE CODE [879AKA] .3124
FAILURE CODE [879AKB] .3125
FAILURE CODE [879BKA] .3126
FAILURE CODE [879BKB] .3128
FAILURE CODE [879CKA] .3130
FAILURE CODE [879CKB] .3131
FAILURE CODE [879DKZ] .3132
FAILURE CODE [879EMC] .3134
FAILURE CODE [879FMC] .3135
FAILURE CODE [879GKX] .3136
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3138
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .3140
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3143
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .3145
TROUBLESHOOTING USING GAUGE PRESSURE 3147
CONNECTION OF SERVICE TOOL 3150
METHOD FOR CONNECTING SERVICE TOOL 3150
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .3152
HANDLE COMPRESSOR OIL .3154
90 CIRCUIT DIAGRAMS .3157
CONTENTS 3158
ABBREVIATION LIST .3159
HYDRAULIC CIRCUIT DIAGRAM .3165
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .3165
HYDRAULIC CIRCUIT DIAGRAM (1/2) .3169
HYDRAULIC CIRCUIT DIAGRAM (2/2) .3171
ELECTRICAL CIRCUIT DIAGRAM 3173
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3173
ELECTRICAL CIRCUIT DIAGRAM (1/12) .3177
ELECTRICAL CIRCUIT DIAGRAM (2/12) .3179
ELECTRICAL CIRCUIT DIAGRAM (3/12) .3181
ELECTRICAL CIRCUIT DIAGRAM (4/12) .3183
ELECTRICAL CIRCUIT DIAGRAM (5/12) .3185
ELECTRICAL CIRCUIT DIAGRAM (6/12) .3187
ELECTRICAL CIRCUIT DIAGRAM (7/12) .3189
ELECTRICAL CIRCUIT DIAGRAM (8/12) .3191
ELECTRICAL CIRCUIT DIAGRAM (9/12) .3193
ELECTRICAL CIRCUIT DIAGRAM (10/12) 3195
ELECTRICAL CIRCUIT DIAGRAM (11/12) 3197
ELECTRICAL CIRCUIT DIAGRAM (12/12) 3199
HYDRAULIC CIRCUIT DIAGRAM GATEWAY .3201
HYDRAULIC CIRCUIT DIAGRAM (1/3) .3203
HYDRAULIC CIRCUIT DIAGRAM (2/3) .3205
HYDRAULIC CIRCUIT DIAGRAM (3/3) .3207
WIRING DIAGRAM (BEFORE GATEWAY) .3209
WIRING DIAGRAM (1/12) .3211
WIRING DIAGRAM (2/12) .3213
WIRING DIAGRAM (3/12) .3215
WIRING DIAGRAM (4/12) .3217
WIRING DIAGRAM (5/12) .3219
WIRING DIAGRAM (6/12) .3221
WIRING DIAGRAM (7/12) .3223
WIRING DIAGRAM (8/12) .3225
WIRING DIAGRAM (9/12) .3227
WIRING DIAGRAM (10/12) 3229
WIRING DIAGRAM (11/12) 3231
WIRING DIAGRAM (12/12) 3233
WIRING DIAGRAM (AFTER GATEWAY) 3235
WIRING DIAGRAM (1/13) .3237
WIRING DIAGRAM (2/13) .3239
WIRING DIAGRAM (3/13) .3241
WIRING DIAGRAM (4/13) .3243
WIRING DIAGRAM (5/13) .3245
WIRING DIAGRAM (6/13) .3247
WIRING DIAGRAM (7/13) .3249
WIRING DIAGRAM (8/13) .3251
WIRING DIAGRAM (9/13) .3253
WIRING DIAGRAM (10/13) 3255
WIRING DIAGRAM (11/13) 3257
WIRING DIAGRAM (12/13) 3259
WIRING DIAGRAM (13/13) 3261
INDEX 3263

DESCRIPTION:

Komatsu HB365LC-3,HB365NLC-3 Hydraulic Excavator Shop Manual UENBM00523 – PDF DOWNLOAD

SERIAL NUMBERS

• 5001 and up
• K70001 and up

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

G.B 29/12/24