Komatsu HB365LC-3,HB365NLC-3 Hydraulic Excavator Shop Manual UENBM00640 PDF

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Komatsu HB365LC-3,HB365NLC-3 Hydraulic Excavator Shop Manual UENBM00640 – PDF DOWNLOAD

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Komatsu HB365LC-3,HB365NLC-3 Hydraulic Excavator Shop Manual UENBM00640 – PDF DOWNLOAD

Language : English
Pages : 3234
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu HB365LC-3,HB365NLC-3 Hydraulic Excavator Shop Manual UENBM00640 – PDF DOWNLOAD

SERIAL NUMBERS

• HB365LC-3E0 K75222 and up
• HB365NLC-3E0 K75222 and up

00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 24
FOREWORD, SAFETY, BASIC INFORMATION . 30
HOW TO READ THE SHOP MANUAL . 30
SAFETY NOTICE FOR OPERATION . 32
PRECAUTIONS PARTICULARLY FOR HYBRID MACHINES 40
PRECAUTIONS TO PREVENT FIRE . 41
ACTIONS IF FIRE OCCURS 43
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 44
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 45
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 2349
SKETCHES OF SPECIAL TOOLS .2368
ENGINE AND COOLING SYSTEM .2376
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2376
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2376
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2380
REMOVE AND INSTALL INJECTOR ASSEMBLY 2388
METHOD FOR REMOVING INJECTOR ASSEMBLY .2388
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2394
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2406
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2406
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2415
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2432
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2432
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2433
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2435
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2435
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2436
REMOVE AND INSTALL STARTER ASSEMBLY .2438
METHOD FOR REMOVING STARTER ASSEMBLY 2438
METHOD FOR INSTALLING STARTER ASSEMBLY 2439
REMOVE AND INSTALL ALTERNATOR BELT 2440
METHOD FOR REMOVING ALTERNATOR BELT .2440
METHOD FOR INSTALLING ALTERNATOR BELT .2443
REMOVE AND INSTALL RADIATOR ASSEMBLY 2446
METHOD FOR REMOVING RADIATOR ASSEMBLY .2446
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2449
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2452
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2452
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2456
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2459
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2459
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2461
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY 2463
METHOD FOR REMOVING FAN CLUTCH ASSEMBLY .2463
METHOD FOR INSTALLING FAN CLUTCH ASSEMBLY .2467
REMOVE AND INSTALL FAN 2470
METHOD FOR INSTALLING FAN .2470
METHOD FOR REMOVING FAN .2470
REMOVE AND INSTALL ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY 2471
METHOD FOR REMOVING ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY .2472
METHOD FOR INSTALLING ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY .2481
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2493
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2493
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2495
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2497
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2497
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2498
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2506
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2506
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2508
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2511
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2511
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2514
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2517
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2517
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2523
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2528
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2528
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2535
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2539
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2539
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2539
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2546
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2546
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2546
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2547
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2547
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2549
REMOVE AND INSTALL KDPF ASSEMBLY 2552
METHOD FOR REMOVING KDPF ASSEMBLY .2552
METHOD FOR INSTALLING KDPF ASSEMBLY .2555
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2558
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2559
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2562
REMOVE AND INSTALL SCR ASSEMBLY .2567
METHOD FOR REMOVING SCR ASSEMBLY 2567
METHOD FOR INSTALLING SCR ASSEMBLY 2570
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2573
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2574
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2580
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2585
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2585
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2588
REMOVE AND INSTALL KCCV ASSEMBLY 2592
METHOD FOR REMOVING KCCV ASSEMBLY .2592
METHOD FOR INSTALLING KCCV ASSEMBLY .2593
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2595
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2596
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2599
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2603
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2603
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2606
REMOVE AND INSTALL AdBlue/DEF PUMP 2610
METHOD FOR REMOVING AdBlue/DEF PUMP .2610
METHOD FOR INSTALLING AdBlue/DEF PUMP .2613
REMOVE AND INSTALL AdBlue/DEF HOSE 2616
METHOD FOR REMOVING AdBlue/DEF HOSE .2617
METHOD FOR INSTALLING AdBlue/DEF HOSE .2623
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2631
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2631
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2633
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2636
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2636
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2637
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2639
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2639
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2640
HYBRID SYSTEM .2643
REMOVE AND INSTALL HYBRID RADIATOR ASSEMBLY .2643
METHOD FOR REMOVING HYBRID RADIATOR ASSEMBLY 2643
METHOD FOR INSTALLING HYBRID RADIATOR ASSEMBLY 2645
REMOVE AND INSTALL HYBRID WATER PUMP ASSEMBLY .2647
METHOD FOR REMOVING HYBRID WATER PUMP ASSEMBLY 2647
METHOD FOR INSTALLING HYBRID WATER PUMP ASSEMBLY 2649
REMOVE AND INSTALL INVERTER ASSEMBLY 2652
METHOD FOR REMOVING INVERTER ASSEMBLY .2652
METHOD FOR INSTALLING INVERTER ASSEMBLY .2656
REMOVE AND INSTALL INVERTER AND CAPACITOR ASSEMBLY 2661
METHOD FOR REMOVING INVERTER AND CAPACITOR ASSEMBLY .2661
METHOD FOR INSTALLING INVERTER AND CAPACITOR ASSEMBLY .2666
REMOVE AND INSTALL MOTOR-GENERATOR AND HOUSING ASSEMBLY .2671
METHOD FOR REMOVING MOTOR-GENERATOR AND HOUSING ASSEMBLY 2671
METHOD FOR INSTALLING MOTOR-GENERATOR AND HOUSING ASSEMBLY 2675
REMOVE AND INSTALL ELECTRIC SWING MOTOR .2681
METHOD FOR REMOVING ELECTRIC SWING MOTOR 2681
METHOD FOR INSTALLING ELECTRIC SWING MOTOR 2685
POWER TRAIN .2691
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2691
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2691
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2692
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2694
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2695
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2699
REMOVE AND INSTALL ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY 2707
METHOD FOR REMOVING ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY .2707
METHOD FOR INSTALLING ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY .2711
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2716
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2716
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2723
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2736
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2736
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2736
UNDERCARRIAGE AND FRAME .2738
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2738
METHOD FOR SEPARATING TRACK ASSEMBLY 2738
METHOD FOR INSTALLING TRACK ASSEMBLY 2740
REMOVE AND INSTALL SPROCKET .2743
METHOD FOR REMOVING SPROCKET 2743
METHOD FOR INSTALLING SPROCKET 2744
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2745
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2745
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2746
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2747
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2747
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2748
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2752
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2753
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2753
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2755
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2756
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2757
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2759
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2759
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2761
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2764
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2764
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2766
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2769
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2769
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2770
HYDRAULIC SYSTEM 2773
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2773
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2773
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2775
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2778
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2779
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2780
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2781
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2781
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2784
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2788
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2788
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2791
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2794
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2794
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2801
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2808
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2808
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2810
REMOVE AND INSTALL ATT BYPASS SOLENOID 2815
REMOVE ATT BYPASS SOLENOID 2815
INSTALL ATT BYPASS SOLENOID .2818
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2820
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2820
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2821
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2823
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2823
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2824
REMOVE AND INSTALL QUICK COUPLER VALVE 2826
WORK EQUIPMENT 2828
REMOVE AND INSTALL BUCKET ASSEMBLY 2828
METHOD FOR REMOVING BUCKET ASSEMBLY .2828
METHOD FOR INSTALLING BUCKET ASSEMBLY .2828
REMOVE AND INSTALL ARM ASSEMBLY .2830
METHOD FOR REMOVING ARM ASSEMBLY 2830
METHOD FOR INSTALLING ARM ASSEMBLY 2831
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2833
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2833
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2835
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2838
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2838
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2841
CAB AND ITS ATTACHMENTS .2848
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2848
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY .2848
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY .2855
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2863
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2865
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2865
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2875
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2875
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2878
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2884
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2884
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2889
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2894
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2894
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2899
REMOVE AND INSTALL OPERATOR’S SEAT 2905
METHOD FOR REMOVING OPERATOR’S SEAT .2905
METHOD FOR INSTALLING OPERATOR’S SEAT .2907
REMOVE AND INSTALL SEAT BELT 2910
METHOD FOR REMOVING SEAT BELT .2910
METHOD FOR INSTALLING SEAT BELT .2910
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2912
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2912
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2917
ELECTRICAL SYSTEM .2926
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2926
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2926
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2928
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2932
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2932
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2935
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2938
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY .2938
METHOD FOR INSTALLING KomVision CONTROLLER 2939
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2940
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2940
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2942
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2946
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2946
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2946
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2948
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2948
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2949
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2951
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2951
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2951
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2953
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2953
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2954
REMOVE AND INSTALL KomVision CAMERA .2956
METHOD FOR REMOVING KomVision CAMERA 2956
METHOD FOR INSTALLING KomVision CAMERA 2957
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY .2959
METHOD FOR REMOVING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2959
METHOD FOR INSTALLING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2964
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 2969
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS .2969
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS .2977
REMOVE AND INSTALL COMMUNICATION TERMINAL .2986
METHOD FOR REMOVING COMMUNICATION TERMINAL 2986
METHOD FOR INSTALLING COMMUNICATION TERMINAL 2988
60 MAINTENANCE STANDARD .2991
CONTENTS 2992
ABBREVIATION LIST .2993
ENGINE AND COOLING SYSTEM .2999
MAINTENANCE STANDARD OF ENGINE MOUNT 2999
MAINTENANCE STANDARD OF COOLING SYSTEM 3001
POWER TRAIN .3003
MAINTENANCE STANDARD OF SWING CIRCLE 3003
MAINTENANCE STANDARD OF SWING MACHINERY WITH SWING PARKING BRAKE 3004
MAINTENANCE STANDARD OF FINAL DRIVE .3006
MAINTENANCE STANDARD OF SPROCKET 3008
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .3009
UNDERCARRIAGE AND FRAME .3011
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .3011
MAINTENANCE STANDARD OF IDLER .3013
MAINTENANCE STANDARD OF TRACK ROLLER 3015
MAINTENANCE STANDARD OF CARRIER ROLLER 3017
MAINTENANCE STANDARD OF TRACK SHOE 3018
MAINTENANCE STANDARD OF TRIPLE SHOE .3021
HYDRAULIC SYSTEM 3022
MAINTENANCE STANDARD OF HYDRAULIC TANK 3022
MAINTENANCE STANDARD OF MAIN PUMP .3023
MAINTENANCE STANDARD OF MAIN PUMP LS-EPC VALVE 3025
MAINTENANCE STANDARD OF MAIN PUMP PC-EPC VALVE 3026
MAINTENANCE STANDARD OF TRAVEL MOTOR 3027
MAINTENANCE STANDARD OF CONTROL VALVE .3030
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 3042
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM .3044
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 3046
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 3049
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 3052
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 3054
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE .3055
MAINTENANCE STANDARD OF SOLENOID VALVE 3057
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE .3058
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .3059
WORK EQUIPMENT 3060
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 3060
DIMENSION OF ARM 3065
DIMENSIONS OF BUCKET 3067
MAINTENANCE STANDARD OF BOOM CYLINDER .3069
MAINTENANCE STANDARD OF ARM CYLINDER 3070
MAINTENANCE STANDARD OF BUCKET CYLINDER .3071
80 APPENDIX .3073
CONTENTS 3074
ABBREVIATION LIST .3076
AIR CONDITIONER SYSTEM 3082
PRECAUTIONS FOR REFRIGERANT .3082
AIR CONDITIONER COMPONENT .3083
SPECIFICATIONS OF AIR CONDITIONER .3085
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .3086
OUTLINE OF REFRIGERATION CYCLE 3087
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .3089
AIR CONDITIONER UNIT 3089
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .3089
FUNCTION OF AIR CONDITIONER UNIT 3091
COMPONENT PARTS OF AIR CONDITIONER UNIT .3093
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 3094
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .3094
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .3094
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .3094
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 3095
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .3095
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .3095
FUNCTION OF DUAL PRESSURE SWITCH 3096
AIR CONDITIONER CONTROLLER 3097
STRUCTURE OF AIR CONDITIONER CONTROLLER .3097
COMPRESSOR 3098
STRUCTURE OF COMPRESSOR .3098
SPECIFICATIONS OF COMPRESSOR 3098
FUNCTION OF COMPRESSOR 3098
CONDENSER .3099
STRUCTURE OF CONDENSER 3099
SPECIFICATIONS OF CONDENSER .3099
FUNCTION OF CONDENSER .3099
RECEIVER DRIER 3100
STRUCTURE OF RECEIVER DRIER .3100
SPECIFICATIONS OF RECEIVER DRIER 3100
FUNCTION OF RECEIVER DRIER 3100
SENSORS FOR AIR CONDITIONER SYSTEM 3101
STRUCTURE OF SUNLIGHT SENSOR 3101
FUNCTION OF SUNLIGHT SENSOR .3101
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .3101
FUNCTION OF AMBIENT TEMPERATURE SENSOR 3101
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .3103
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .3105
AIR CONDITIONER SYSTEM DIAGRAM 3107
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 3108
FUNCTION OF AIR CONDITIONER CONTROLLER 3109
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .3110
TESTING AIR LEAKAGE (DUCT) 3114
METHOD FOR TESTING AIR LEAKAGE (DUCT) .3114
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .3116
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 3117
TEST VENT (MODE) CHANGEOVER .3118
METHOD FOR TESTING VENT (MODE) CHANGEOVER .3118
TESTING FRESH/RECIRC AIR CHANGEOVER .3120
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 3120
TEST SUNLIGHT SENSOR 3121
METHOD FOR TESTING SUNLIGHT SENSOR 3121
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .3122
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .3122
TEST RELAYS .3123
METHOD FOR TESTING RELAYS .3123
AIR CONDITIONER TROUBLESHOOTING CHART 1 .3124
AIR CONDITIONER TROUBLESHOOTING CHART 2 .3125
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 3128
FAILURE CODE [879AKA] .3130
FAILURE CODE [879AKB] .3131
FAILURE CODE [879BKA] .3132
FAILURE CODE [879BKB] .3134
FAILURE CODE [879CKA] .3136
FAILURE CODE [879CKB] .3137
FAILURE CODE [879DKZ] .3138
FAILURE CODE [879EMC] .3140
FAILURE CODE [879FMC] .3141
FAILURE CODE [879GKX] .3142
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 3144
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .3146
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3149
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .3151
TROUBLESHOOTING USING GAUGE PRESSURE 3153
CONNECTION OF SERVICE TOOL 3156
METHOD FOR CONNECTING SERVICE TOOL 3156
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .3158
HANDLE COMPRESSOR OIL .3160
90 CIRCUIT DIAGRAMS .3163
CONTENTS 3164
ABBREVIATION LIST .3165
HYDRAULIC CIRCUIT DIAGRAM .3171
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .3171
HYDRAULIC CIRCUIT DIAGRAM (1/3) .3175
HYDRAULIC CIRCUIT DIAGRAM (2/3) .3177
HYDRAULIC CIRCUIT DIAGRAM (3/3) .3179
ELECTRICAL CIRCUIT DIAGRAM 3181
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3181
ELECTRICAL CIRCUIT DIAGRAM 3185
ELECTRICAL CIRCUIT DIAGRAM (1/13) .3187
ELECTRICAL CIRCUIT DIAGRAM (2/13) .3189
ELECTRICAL CIRCUIT DIAGRAM (3/13) .3191
ELECTRICAL CIRCUIT DIAGRAM (4/13) .3193
ELECTRICAL CIRCUIT DIAGRAM (5/13) .3195
ELECTRICAL CIRCUIT DIAGRAM (6/13) .3197
ELECTRICAL CIRCUIT DIAGRAM (7/13) .3199
ELECTRICAL CIRCUIT DIAGRAM (8/13) .3201
ELECTRICAL CIRCUIT DIAGRAM (9/13) .3203
ELECTRICAL CIRCUIT DIAGRAM (10/13) 3205
ELECTRICAL CIRCUIT DIAGRAM (11/13) 3207
ELECTRICAL CIRCUIT DIAGRAM (12/13) 3209
ELECTRICAL CIRCUIT DIAGRAM (13/13) 3211
INDEX 3213

DESCRIPTION:

Komatsu HB365LC-3,HB365NLC-3 Hydraulic Excavator Shop Manual UENBM00640 – PDF DOWNLOAD

SERIAL NUMBERS

• HB365LC-3E0 K75222 and up
• HB365NLC-3E0 K75222 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