UENBM00451

HYDRAULIC HB365LC-3
EXCAVATOR HB365NLC-3

SERIAL NUMBERS 5001 and up

K70001 and up
 00 INDEX AND FOREWORD

HB365LC-3 00-1
INDEX 00 INDEX AND FOREWORD

INDEX (ALL-A-0310-001-10-B)
00 INDEX AND FOREWORD ........................................................................................................................ 00-1
ABBREVIATION LIST ........................................................................................................................... 00-21
FOREWORD, SAFETY, BASIC INFORMATION ................................................................................... 00-27
HOW TO READ THE SHOP MANUAL........................................................................................... 00-27
SAFETY NOTICE FOR OPERATION............................................................................................. 00-29
PRECAUTIONS PARTICULARLY FOR HYBRID MACHINES........................................................ 00-37
PRECAUTIONS TO PREVENT FIRE............................................................................................. 00-38
ACTIONS IF FIRE OCCURS ......................................................................................................... 00-40
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS ........................................................ 00-41
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...................................................... 00-42
PRECAUTIONS FOR DEF............................................................................................................. 00-43
STORE AdBlue/DEF ...................................................................................................................... 00-44
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT ...................................................... 00-45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS................................ 00-48
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT..................................................... 00-55
PRECAUTIONS FOR MAINTENANCE OF HYBRID SYSTEM ...................................................... 00-57
PRECAUTIONS AGAINST HIGH VOLTAGE AND HIGH TEMPERATURE .................................... 00-58
PRECAUTIONS FOR NORMAL CHECK AND MAINTENANCE .................................................... 00-59
PRECAUTIONS FOR THE MACHINE NOT TO BE TIPPED OVER AND FOR HYBRID COMPO-
NENTS NOT TO BE DAMAGED ................................................................................................ 00-60
PRECAUTIONS FOR THE MACHINE NOT TO BE SUBMERGED................................................ 00-61
PRECAUTIONS FOR THE COLD SEASON .................................................................................. 00-62
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT .................................................. 00-63
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT .............................................. 00-64
PRACTICAL USE OF KOMTRAX .................................................................................................. 00-65
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER ................................................... 00-66
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS ..................... 00-70
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR ..................... 00-74
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR ....... 00-75
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL ... 00-77
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH .. 00-78
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE .
................................................................................................................................................... 00-80
HOW TO READ THE CODES (SYMBOLS) FOR ELECTRIC CABLE ............................................ 00-81
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD.................................................... 00-87
STANDARD TIGHTENING TORQUE TABLE................................................................................. 00-90
CONVERSION TABLE ................................................................................................................... 00-97
01 SPECIFICATIONS .................................................................................................................................... 01-1
CONTENTS ............................................................................................................................................ 01-2
ABBREVIATION LIST ............................................................................................................................. 01-3
SPECIFICATIONS .................................................................................................................................. 01-9
SPECIFICATION DRAWING............................................................................................................ 01-9
WORKING RANGE DRAWINGS ................................................................................................... 01-10
SPECIFICATIONS ..........................................................................................................................01-11
WEIGHT TABLE ............................................................................................................................ 01-15
TABLE OF FUEL, COOLANT, AND LUBRICANTS ........................................................................ 01-17
10 STRUCTURE AND FUNCTION ................................................................................................................ 10-1
CONTENTS ............................................................................................................................................ 10-2
ABBREVIATION LIST ............................................................................................................................. 10-6
UREA SCR SYSTEM............................................................................................................................ 10-12
LAYOUT DRAWING OF UREA SCR SYSTEM .............................................................................. 10-12
UREA SCR SYSTEM DIAGRAM ................................................................................................... 10-16
FUNCTION OF UREA SCR SYSTEM............................................................................................ 10-17
COMPONENT PARTS OF UREA SCR SYSTEM........................................................................... 10-37
BOOT-UP SYSTEM .............................................................................................................................. 10-46
LAYOUT DRAWING OF BOOT-UP SYSTEM................................................................................. 10-46

00-2 HB365LC-3
00 INDEX AND FOREWORD INDEX

SYSTEM OPERATING LAMP SYSTEM ........................................................................................ 10-48

BATTERY DISCONNECT SWITCH ............................................................................................... 10-50
ENGINE SYSTEM ................................................................................................................................ 10-51
LAYOUT DRAWING OF ENGINE SYSTEM ................................................................................... 10-51
ENGINE CONTROL SYSTEM ....................................................................................................... 10-53
AUTO-DECELERATION SYSTEM ................................................................................................. 10-56
ENGINE AUTOMATIC WARM-UP SYSTEM .................................................................................. 10-58
OVERHEAT PREVENTION SYSTEM ............................................................................................ 10-60
TURBOCHARGER PROTECTION SYSTEM ................................................................................. 10-63
AUTOMATIC IDLE STOP SYSTEM ............................................................................................... 10-65
COMPONENT PARTS OF ENGINE SYSTEM ............................................................................... 10-69
COOLING SYSTEM.............................................................................................................................. 10-85
LAYOUT DRAWING OF COOLING SYSTEM ................................................................................ 10-85
HYBRID SYSTEM................................................................................................................................. 10-87
LAYOUT DRAWING OF HYBRID SYSTEM ................................................................................... 10-87
SYSTEM DIAGRAM OF HYBRID SYSTEM ................................................................................... 10-88
STRUCTURE OF HYBRID SYSTEM ............................................................................................. 10-89
HYBRID PROTECTION SYSTEM.................................................................................................. 10-90
COOLING SYSTEM OF HYBRID COMPONENTS ........................................................................ 10-92
INTERLOCK SYSTEM OF HYBRID COMPONENTS .................................................................... 10-93
WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID COMPONENTS ......
................................................................................................................................................... 10-94
COMPONENT PARTS OF HYBRID SYSTEM ............................................................................... 10-96
CONTROL SYSTEM............................................................................................................................10-103
LAYOUT DRAWING OF CONTROL SYSTEM ..............................................................................10-103
MACHINE MONITOR SYSTEM ....................................................................................................10-106
KomVision SYSTEM .....................................................................................................................10-108
KomVision SYSTEM .....................................................................................................................10-109
KOMTRAX SYSTEM.....................................................................................................................10-113
PPC LEVERS ...............................................................................................................................10-114
AUTOMATIC GREASE SYSTEM ..................................................................................................10-116
COMPONENT PARTS OF CONTROL SYSTEM...........................................................................10-131
HYDRAULIC SYSTEM.........................................................................................................................10-165
LAYOUT DRAWING OF HYDRAULIC SYSTEM ...........................................................................10-165
CLSS ............................................................................................................................................10-168
ENGINE AND PUMP COMBINED CONTROL SYSTEM...............................................................10-187
PUMP AND VALVE CONTROL SYSTEM .....................................................................................10-193
COMPONENT PARTS OF HYDRAULIC SYSTEM .......................................................................10-196
WORK EQUIPMENT SYSTEM ............................................................................................................10-279
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM ..............................................................10-279
STRUCTURE OF VALVE CONTROL............................................................................................10-285
ONE-TOUCH POWER MAXIMIZING SYSTEM ............................................................................10-286
MACHINE PUSH-UP SYSTEM .....................................................................................................10-288
PPC LOCK SYSTEM ....................................................................................................................10-290
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM ..............................................10-291
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT.................................................................10-293
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM ...........................................................10-295
SWING SYSTEM .................................................................................................................................10-321
LAYOUT DRAWING OF SWING SYSTEM ...................................................................................10-321
SWING CONTROL SYSTEM DIAGRAM ......................................................................................10-324
COMPONENT PARTS OF SWING SYSTEM................................................................................10-327
TRAVEL SYSTEM................................................................................................................................10-331
LAYOUT DRAWING OF TRAVEL SYSTEM ..................................................................................10-331
TRAVEL CONTROL SYSTEM DIAGRAM .....................................................................................10-335
COMPONENT PARTS OF TRAVEL SYSTEM ..............................................................................10-337
UNDERCARRIAGE AND FRAME........................................................................................................10-358
LAYOUT DRAWING OF UNDERCARRIAGE ................................................................................10-358
WORK EQUIPMENT............................................................................................................................10-360

HB365LC-3 00-3
INDEX 00 INDEX AND FOREWORD

STRUCTURE OF WORK EQUIPMENT ........................................................................................10-360

FUNCTION OF WORK EQUIPMENT ...........................................................................................10-361
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM............................................................10-362
BUCKET CLEARANCE ADJUSTMENT SHIM ..............................................................................10-363
CAB AND ITS ATTACHMENTS ...........................................................................................................10-364
ROPS CAB ...................................................................................................................................10-364
CAB MOUNT ................................................................................................................................10-365
CAB TIPPING STOPPER .............................................................................................................10-366
20 STANDARD VALUE TABLE ...................................................................................................................... 20-1
CONTENTS ............................................................................................................................................ 20-2
ABBREVIATION LIST ............................................................................................................................. 20-3
STANDARD VALUE TABLE FOR ENGINE ............................................................................................. 20-9
STANDARD VALUE TABLE FOR ENGINE:HB365LC-3................................................................... 20-9
STANDARD VALUE TABLE FOR MACHINE......................................................................................... 20-15
STANDARD VALUE TABLE FOR MACHINE: HB365LC-3 ............................................................. 20-15
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ......................... 20-32
30 TESTING AND ADJUSTING ..................................................................................................................... 30-1
CONTENTS ............................................................................................................................................ 30-2
ABBREVIATION LIST ............................................................................................................................. 30-5
RELATED INFORMATION ON TESTING AND ADJUSTING .................................................................30-11
TOOLS FOR TESTING AND ADJUSTING......................................................................................30-11
SKETCH OF TOOLS FOR TESTING AND ADJUSTING ............................................................... 30-18
ENGINE AND COOLING SYSTEM....................................................................................................... 30-20
TEST ENGINE SPEED .................................................................................................................. 30-20
TEST BOOST PRESSURE............................................................................................................ 30-23
TEST EXHAUST GAS COLOR ...................................................................................................... 30-25
TEST AND ADJUST VALVE CLEARANCE .................................................................................... 30-28
TEST COMPRESSION PRESSURE.............................................................................................. 30-31
TEST BLOWBY PRESSURE ......................................................................................................... 30-34
TEST ENGINE OIL PRESSURE .................................................................................................... 30-36
TEST EGR VALVE AND VGT OIL PRESSURE ............................................................................. 30-38
TEST FUEL PRESSURE ............................................................................................................... 30-40
TEST FUEL DISCHARGE, RETURN AND LEAKAGE ................................................................... 30-48
BLEED AIR FROM FUEL SYSTEM ............................................................................................... 30-56
TEST FUEL CIRCUIT FOR LEAKAGE .......................................................................................... 30-57
HANDLE CYLINDER CUT-OUT MODE OPERATION.................................................................... 30-59
HANDLE NO-INJECTION CRANKING OPERATION ..................................................................... 30-60
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION ................................. 30-61
TEST COOLING FAN SPEED ...................................................................................................... 30-63
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER ................ 30-64
TEST SCR RELATED FUNCTIONS............................................................................................... 30-65
CLEAN AdBlue/DEF TANK ............................................................................................................ 30-90
HYBRID SYSTEM................................................................................................................................. 30-95
PRECAUTIONS FOR USING HYBRID SYSTEMS ........................................................................ 30-95
DRAIN, REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT ....................................... 30-96
WATER PRESSURE TEST OF THE HYBRID SYSTEM COOLANT .............................................30-102
TEST LUBRICATION CIRCUIT OIL PRESSURE OF HYBRID SYSTEM ......................................30-104
TEST SWING PARKING BRAKE PRESSURE..............................................................................30-106
TEST AND CLEAN DELIVERY FILTER OF SWING MOTOR .......................................................30-108
POWER TRAIN....................................................................................................................................30-109
TEST SWING CIRCLE BEARING CLEARANCE ..........................................................................30-109
UNDERCARRIAGE AND FRAME........................................................................................................30-110
TEST AND ADJUST TRACK TENSION........................................................................................30-110
HYDRAULIC SYSTEM.........................................................................................................................30-112
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM............................................30-112
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUITS ...........30-116
TEST OIL PRESSURE OF CONTROL CIRCUIT ..........................................................................30-125
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT ...................................30-127

00-4 HB365LC-3
00 INDEX AND FOREWORD INDEX

TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT....................................30-131

TEST OUTLET PRESSURE OF SOLENOID VALVE ....................................................................30-138
TEST PPC VALVE OUTPUT PRESSURE.....................................................................................30-142
ADJUST WORK EQUIPMENT AND SWING PPC VALVES ..........................................................30-144
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE...30-145
TEST PUMP SWASH PLATE SENSOR........................................................................................30-147
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT................................30-148
TEST OIL LEAKAGE ....................................................................................................................30-150
BLEED AIR FROM HYDRAULIC CIRCUIT ...................................................................................30-153
CAB AND ITS ATTACHMENTS ...........................................................................................................30-156
TEST CAB TIPPING STOPPER ...................................................................................................30-156
METHOD FOR ADJUSTING MIRRORS .......................................................................................30-157
ELECTRICAL SYSTEM .......................................................................................................................30-163
SET AND OPERATE MACHINE MONITOR..................................................................................30-163
METHOD FOR STARTING UP KOMTRAX TERMINAL ................................................................30-253
ADJUST REARVIEW CAMERA ANGLE .......................................................................................30-258
ADJUST KomVision CAMERA ANGLE .........................................................................................30-261
ADJUST KomVision RELATED ITEMS .........................................................................................30-266
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER .........................................................30-286
HANDLE BATTERY DISCONNECT SWITCH ...............................................................................30-287
TEST DIODES ..............................................................................................................................30-288
Pm CLINIC...........................................................................................................................................30-289
Pm CLINIC SERVICE ...................................................................................................................30-289
40 TROUBLESHOOTING .............................................................................................................................. 40-1
CONTENTS ............................................................................................................................................ 40-2
ABBREVIATION LIST ........................................................................................................................... 40-15
RELATED INFORMATION ON TROUBLESHOOTING ......................................................................... 40-21
GENERAL TROUBLESHOOTING POINTS ................................................................................... 40-21
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM.......................................................... 40-23
SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................... 40-35
PRECAUTIONS FOR USING HYBRID SYSTEMS, TROUBLESHOOTING FOR HIGH-VOLTAGE
EQUIPMENT .............................................................................................................................. 40-37
TABLE OF SELF-DEFINE MONITORING ITEMS AND CHECK SHEET FOR HYBRID COMPONENTS.
................................................................................................................................................... 40-44
CHECKS BEFORE TROUBLESHOOTING .................................................................................... 40-50
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ..................................................... 40-52
TESTING IN ACCORDANCE WITH TESTING PROCEDURE....................................................... 40-54
AUTOMATIC GREASE SYSTEM ................................................................................................... 40-80
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM..................................... 40-84
PROCEDURE FOR TESTING AND TROUBLESHOOTING .......................................................... 40-90
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS ............................................. 40-93
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE.................................................... 40-97
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SEN-
SOR SYSTEM............................................................................................................................ 40-99
CONNECTOR LIST AND LAYOUT ...............................................................................................40-102
CONNECTOR CONTACT IDENTIFICATION ................................................................................40-116
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE ..................................................................40-156
FUSE LOCATION TABLE .............................................................................................................40-162
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)..........................40-164
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883]
AND [CA3135])..........................................................................................................................40-168
FAILURE CODES TABLE .............................................................................................................40-170
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .....................................................40-191
FAILURE CODE [879AKA]............................................................................................................40-191
FAILURE CODE [879AKB]............................................................................................................40-192
FAILURE CODE [879BKA]............................................................................................................40-193
FAILURE CODE [879BKB]............................................................................................................40-195
FAILURE CODE [879CKA]............................................................................................................40-197

HB365LC-3 00-5
INDEX 00 INDEX AND FOREWORD

FAILURE CODE [879CKB]............................................................................................................40-198

FAILURE CODE [879DKZ]............................................................................................................40-199
FAILURE CODE [879EMC] ...........................................................................................................40-201
FAILURE CODE [879FMC] ...........................................................................................................40-202
FAILURE CODE [879GKX] ...........................................................................................................40-203
FAILURE CODE [989L00] .............................................................................................................40-205
FAILURE CODE [989M00] ............................................................................................................40-206
FAILURE CODE [989N00] ............................................................................................................40-207
FAILURE CODE [A1U0N3] ...........................................................................................................40-208
FAILURE CODE [A1U0N4] ...........................................................................................................40-210
FAILURE CODE [A900FR]............................................................................................................40-212
FAILURE CODE [A900N6] ............................................................................................................40-213
FAILURE CODE [A900NY]............................................................................................................40-214
FAILURE CODE [AA10NX] ...........................................................................................................40-215
FAILURE CODE [AB00KE] ...........................................................................................................40-217
FAILURE CODE [AQ10N3] ...........................................................................................................40-219
FAILURE CODE [AS00N3]............................................................................................................40-221
FAILURE CODE [AS00R2]............................................................................................................40-223
FAILURE CODE [AS00R3]............................................................................................................40-224
FAILURE CODE [AS00R4]............................................................................................................40-225
FAILURE CODE [AS00R5]............................................................................................................40-226
FAILURE CODE [AS00R6]............................................................................................................40-227
FAILURE CODE [AS00ZK]............................................................................................................40-228
FAILURE CODE [AS10KM]...........................................................................................................40-229
FAILURE CODE [AS10NR] ...........................................................................................................40-230
FAILURE CODE [AS10NT] ...........................................................................................................40-231
FAILURE CODE [B@BAZG] .........................................................................................................40-232
FAILURE CODE [B@BAZK]..........................................................................................................40-233
FAILURE CODE [B@BCNS] .........................................................................................................40-235
FAILURE CODE [B@BCZK] .........................................................................................................40-236
FAILURE CODE [B@HANS] .........................................................................................................40-237
FAILURE CODE [CA115] ..............................................................................................................40-238
FAILURE CODE [CA122] ..............................................................................................................40-239
FAILURE CODE [CA123] ..............................................................................................................40-241
FAILURE CODE [CA131] ..............................................................................................................40-243
FAILURE CODE [CA132] ..............................................................................................................40-245
FAILURE CODE [CA144] ..............................................................................................................40-247
FAILURE CODE [CA145] ..............................................................................................................40-249
FAILURE CODE [CA153] ..............................................................................................................40-251
FAILURE CODE [CA154] ..............................................................................................................40-254
FAILURE CODE [CA187] ..............................................................................................................40-257
FAILURE CODE [CA221] ..............................................................................................................40-259
FAILURE CODE [CA222] ..............................................................................................................40-261
FAILURE CODE [CA227] ..............................................................................................................40-263
FAILURE CODE [CA234] ..............................................................................................................40-264
FAILURE CODE [CA238] ..............................................................................................................40-265
FAILURE CODE [CA239] ..............................................................................................................40-267
FAILURE CODE [CA249] ..............................................................................................................40-269
FAILURE CODE [CA256] ..............................................................................................................40-271
FAILURE CODE [CA271] ..............................................................................................................40-273
FAILURE CODE [CA272] ..............................................................................................................40-275
FAILURE CODE [CA281] ..............................................................................................................40-277
FAILURE CODE [CA322] ..............................................................................................................40-278
FAILURE CODE [CA323] ..............................................................................................................40-280
FAILURE CODE [CA324] ..............................................................................................................40-282
FAILURE CODE [CA325] ..............................................................................................................40-284
FAILURE CODE [CA331] ..............................................................................................................40-286
FAILURE CODE [CA332] ..............................................................................................................40-288

00-6 HB365LC-3
00 INDEX AND FOREWORD INDEX

FAILURE CODE [CA343] ..............................................................................................................40-290

FAILURE CODE [CA351] ..............................................................................................................40-291
FAILURE CODE [CA352] ..............................................................................................................40-292
FAILURE CODE [CA356] ..............................................................................................................40-295
FAILURE CODE [CA357] ..............................................................................................................40-297
FAILURE CODE [CA386] ..............................................................................................................40-299
FAILURE CODE [CA428] ..............................................................................................................40-300
FAILURE CODE [CA429] ..............................................................................................................40-302
FAILURE CODE [CA435] ..............................................................................................................40-304
FAILURE CODE [CA441] ..............................................................................................................40-306
FAILURE CODE [CA442] ..............................................................................................................40-308
FAILURE CODE [CA449] ..............................................................................................................40-309
FAILURE CODE [CA451] ..............................................................................................................40-312
FAILURE CODE [CA452] ..............................................................................................................40-315
FAILURE CODE [CA488] ..............................................................................................................40-317
FAILURE CODE [CA515] ..............................................................................................................40-318
FAILURE CODE [CA516] ..............................................................................................................40-320
FAILURE CODE [CA553] ..............................................................................................................40-322
FAILURE CODE [CA555] ..............................................................................................................40-323
FAILURE CODE [CA556] ..............................................................................................................40-324
FAILURE CODE [CA559] ..............................................................................................................40-325
FAILURE CODE [CA595] ..............................................................................................................40-329
FAILURE CODE [CA687] ..............................................................................................................40-330
FAILURE CODE [CA689] ..............................................................................................................40-332
FAILURE CODE [CA691] ..............................................................................................................40-337
FAILURE CODE [CA692] ..............................................................................................................40-339
FAILURE CODE [CA697] ..............................................................................................................40-341
FAILURE CODE [CA698] ..............................................................................................................40-342
FAILURE CODE [CA731] ..............................................................................................................40-343
FAILURE CODE [CA778] ..............................................................................................................40-345
FAILURE CODE [CA1117] ............................................................................................................40-350
FAILURE CODE [CA1664] ............................................................................................................40-351
FAILURE CODE [CA1669] ............................................................................................................40-353
FAILURE CODE [CA1673] ............................................................................................................40-354
FAILURE CODE [CA1677] ............................................................................................................40-355
FAILURE CODE [CA1678] ............................................................................................................40-356
FAILURE CODE [CA1682] ............................................................................................................40-357
FAILURE CODE [CA1683] ............................................................................................................40-359
FAILURE CODE [CA1684] ............................................................................................................40-361
FAILURE CODE [CA1686] ............................................................................................................40-363
FAILURE CODE [CA1691] ............................................................................................................40-364
FAILURE CODE [CA1694] ............................................................................................................40-367
FAILURE CODE [CA1695] ............................................................................................................40-370
FAILURE CODE [CA1696] ............................................................................................................40-371
FAILURE CODE [CA1712] ............................................................................................................40-373
FAILURE CODE [CA1713] ............................................................................................................40-376
FAILURE CODE [CA1714] ............................................................................................................40-378
FAILURE CODE [CA1715] ............................................................................................................40-379
FAILURE CODE [CA1776] ............................................................................................................40-380
FAILURE CODE [CA1777] ............................................................................................................40-383
FAILURE CODE [CA1843] ............................................................................................................40-386
FAILURE CODE [CA1844] ............................................................................................................40-388
FAILURE CODE [CA1879] ............................................................................................................40-390
FAILURE CODE [CA1881] ............................................................................................................40-393
FAILURE CODE [CA1883] ............................................................................................................40-395
FAILURE CODE [CA1885] ............................................................................................................40-398
FAILURE CODE [CA1887] ............................................................................................................40-400
FAILURE CODE [CA1921] ............................................................................................................40-402

HB365LC-3 00-7
INDEX 00 INDEX AND FOREWORD

FAILURE CODE [CA1922] ............................................................................................................40-405

FAILURE CODE [CA1942] ............................................................................................................40-410
FAILURE CODE [CA1993] ............................................................................................................40-411
FAILURE CODE [CA2185] ............................................................................................................40-414
FAILURE CODE [CA2186] ............................................................................................................40-415
FAILURE CODE [CA2249] ............................................................................................................40-417
FAILURE CODE [CA2265] ............................................................................................................40-418
FAILURE CODE [CA2266] ............................................................................................................40-420
FAILURE CODE [CA2271] ............................................................................................................40-422
FAILURE CODE [CA2272] ............................................................................................................40-424
FAILURE CODE [CA2288] ............................................................................................................40-427
FAILURE CODE [CA2311] ............................................................................................................40-428
FAILURE CODE [CA2349] ............................................................................................................40-429
FAILURE CODE [CA2353] ............................................................................................................40-432
FAILURE CODE [CA2357] ............................................................................................................40-434
FAILURE CODE [CA2381] ............................................................................................................40-435
FAILURE CODE [CA2382] ............................................................................................................40-437
FAILURE CODE [CA2383] ............................................................................................................40-440
FAILURE CODE [CA2386] ............................................................................................................40-443
FAILURE CODE [CA2387] ............................................................................................................40-445
FAILURE CODE [CA2555] ............................................................................................................40-446
FAILURE CODE [CA2556] ............................................................................................................40-449
FAILURE CODE [CA2637] ............................................................................................................40-452
FAILURE CODE [CA2639] ............................................................................................................40-454
FAILURE CODE [CA2771] ............................................................................................................40-457
FAILURE CODE [CA2777] ............................................................................................................40-463
FAILURE CODE [CA2976] ............................................................................................................40-466
FAILURE CODE [CA3133] ............................................................................................................40-468
FAILURE CODE [CA3134] ............................................................................................................40-470
FAILURE CODE [CA3135] ............................................................................................................40-472
FAILURE CODE [CA3142] ............................................................................................................40-475
FAILURE CODE [CA3143] ............................................................................................................40-476
FAILURE CODE [CA3144] ............................................................................................................40-477
FAILURE CODE [CA3146] ............................................................................................................40-479
FAILURE CODE [CA3147] ............................................................................................................40-480
FAILURE CODE [CA3148] ............................................................................................................40-481
FAILURE CODE [CA3151] ............................................................................................................40-483
FAILURE CODE [CA3165] ............................................................................................................40-489
FAILURE CODE [CA3229] ............................................................................................................40-491
FAILURE CODE [CA3231] ............................................................................................................40-493
FAILURE CODE [CA3232] ............................................................................................................40-495
FAILURE CODE [CA3235] ............................................................................................................40-499
FAILURE CODE [CA3239] ............................................................................................................40-501
FAILURE CODE [CA3241] ............................................................................................................40-504
FAILURE CODE [CA3242] ............................................................................................................40-507
FAILURE CODE [CA3251] ............................................................................................................40-510
FAILURE CODE [CA3253] ............................................................................................................40-512
FAILURE CODE [CA3254] ............................................................................................................40-515
FAILURE CODE [CA3255] ............................................................................................................40-518
FAILURE CODE [CA3256] ............................................................................................................40-522
FAILURE CODE [CA3311] ............................................................................................................40-524
FAILURE CODE [CA3312] ............................................................................................................40-526
FAILURE CODE [CA3313] ............................................................................................................40-529
FAILURE CODE [CA3314] ............................................................................................................40-530
FAILURE CODE [CA3315] ............................................................................................................40-531
FAILURE CODE [CA3316] ............................................................................................................40-533
FAILURE CODE [CA3317] ............................................................................................................40-534
FAILURE CODE [CA3318] ............................................................................................................40-535

00-8 HB365LC-3
00 INDEX AND FOREWORD INDEX

FAILURE CODE [CA3319] ............................................................................................................40-537

FAILURE CODE [CA3321] ............................................................................................................40-538
FAILURE CODE [CA3322] ............................................................................................................40-540
FAILURE CODE [CA3419] ............................................................................................................40-542
FAILURE CODE [CA3421] ............................................................................................................40-544
FAILURE CODE [CA3497] ............................................................................................................40-546
FAILURE CODE [CA3498] ............................................................................................................40-547
FAILURE CODE [CA3543] ............................................................................................................40-548
FAILURE CODE [CA3545] ............................................................................................................40-554
FAILURE CODE [CA3547] ............................................................................................................40-556
FAILURE CODE [CA3558] ............................................................................................................40-557
FAILURE CODE [CA3559] ............................................................................................................40-559
FAILURE CODE [CA3562] ............................................................................................................40-561
FAILURE CODE [CA3563] ............................................................................................................40-563
FAILURE CODE [CA3567] ............................................................................................................40-566
FAILURE CODE [CA3568] ............................................................................................................40-569
FAILURE CODE [CA3571] ............................................................................................................40-573
FAILURE CODE [CA3572] ............................................................................................................40-575
FAILURE CODE [CA3574] ............................................................................................................40-577
FAILURE CODE [CA3575] ............................................................................................................40-579
FAILURE CODE [CA3577] ............................................................................................................40-581
FAILURE CODE [CA3578] ............................................................................................................40-583
FAILURE CODE [CA3582] ............................................................................................................40-585
FAILURE CODE [CA3583] ............................................................................................................40-591
FAILURE CODE [CA3596] ............................................................................................................40-593
FAILURE CODE [CA3649] ............................................................................................................40-596
FAILURE CODE [CA3681] ............................................................................................................40-598
FAILURE CODE [CA3682] ............................................................................................................40-603
FAILURE CODE [CA3713] ............................................................................................................40-608
FAILURE CODE [CA3717] ............................................................................................................40-611
FAILURE CODE [CA3718] ............................................................................................................40-612
FAILURE CODE [CA3725] ............................................................................................................40-613
FAILURE CODE [CA3741] ............................................................................................................40-616
FAILURE CODE [CA3748] ............................................................................................................40-617
FAILURE CODE [CA3751] ............................................................................................................40-620
FAILURE CODE [CA3755] ............................................................................................................40-622
FAILURE CODE [CA3866] ............................................................................................................40-624
FAILURE CODE [CA3867] ............................................................................................................40-628
FAILURE CODE [CA3868] ............................................................................................................40-631
FAILURE CODE [CA3899] ............................................................................................................40-635
FAILURE CODE [CA3911] ............................................................................................................40-637
FAILURE CODE [CA3912] ............................................................................................................40-641
FAILURE CODE [CA3932] ............................................................................................................40-643
FAILURE CODE [CA3933] ............................................................................................................40-645
FAILURE CODE [CA3934] ............................................................................................................40-647
FAILURE CODE [CA3935] ............................................................................................................40-650
FAILURE CODE [CA3936] ............................................................................................................40-652
FAILURE CODE [CA4151] ............................................................................................................40-654
FAILURE CODE [CA4152] ............................................................................................................40-658
FAILURE CODE [CA4155] ............................................................................................................40-662
FAILURE CODE [CA4156] ............................................................................................................40-664
FAILURE CODE [CA4157] ............................................................................................................40-667
FAILURE CODE [CA4158] ............................................................................................................40-669
FAILURE CODE [CA4159] ............................................................................................................40-670
FAILURE CODE [CA4161] ............................................................................................................40-671
FAILURE CODE [CA4162] ............................................................................................................40-674
FAILURE CODE [CA4163] ............................................................................................................40-677
FAILURE CODE [CA4164] ............................................................................................................40-679

HB365LC-3 00-9
INDEX 00 INDEX AND FOREWORD

FAILURE CODE [CA4165] ............................................................................................................40-681

FAILURE CODE [CA4166] ............................................................................................................40-683
FAILURE CODE [CA4168] ............................................................................................................40-685
FAILURE CODE [CA4169] ............................................................................................................40-688
FAILURE CODE [CA4171] ............................................................................................................40-690
FAILURE CODE [CA4249] ............................................................................................................40-693
FAILURE CODE [CA4251] ............................................................................................................40-695
FAILURE CODE [CA4259] ............................................................................................................40-697
FAILURE CODE [CA4261] ............................................................................................................40-700
FAILURE CODE [CA4277] ............................................................................................................40-703
FAILURE CODE [CA4281] ............................................................................................................40-707
FAILURE CODE [CA4459] ............................................................................................................40-711
FAILURE CODE [CA4461] ............................................................................................................40-714
FAILURE CODE [CA4658] ............................................................................................................40-717
FAILURE CODE [CA4731] ............................................................................................................40-721
FAILURE CODE [CA4732] ............................................................................................................40-722
FAILURE CODE [CA4739] ............................................................................................................40-723
FAILURE CODE [CA4768] ............................................................................................................40-724
FAILURE CODE [CA4769] ............................................................................................................40-726
FAILURE CODE [CA4842] ............................................................................................................40-728
FAILURE CODE [CA4952] ............................................................................................................40-732
FAILURE CODE [CA5115] ............................................................................................................40-734
FAILURE CODE [CA5179] ............................................................................................................40-737
FAILURE CODE [CA5181] ............................................................................................................40-739
FAILURE CODE [CA5383] ............................................................................................................40-741
FAILURE CODE [D110KB]............................................................................................................40-743
FAILURE CODE [D19JKZ] ............................................................................................................40-745
FAILURE CODE [D811MC] ...........................................................................................................40-748
FAILURE CODE [D862KA]............................................................................................................40-749
FAILURE CODE [D8ALKA] ...........................................................................................................40-750
FAILURE CODE [D8ALKB] ...........................................................................................................40-752
FAILURE CODE [D8AQKR] ..........................................................................................................40-754
FAILURE CODE [DA20MC] ..........................................................................................................40-759
FAILURE CODE [DA22KK] ...........................................................................................................40-760
FAILURE CODE [DA25KP] ...........................................................................................................40-763
FAILURE CODE [DA26KP] ...........................................................................................................40-765
FAILURE CODE [DA29KQ]...........................................................................................................40-768
FAILURE CODE [DA2LKA] ...........................................................................................................40-770
FAILURE CODE [DA2LKB] ...........................................................................................................40-772
FAILURE CODE [DA2QKR] ..........................................................................................................40-774
FAILURE CODE [DA2RKR] ..........................................................................................................40-779
FAILURE CODE [DAF0KM] ..........................................................................................................40-784
FAILURE CODE [DAF0MB] ..........................................................................................................40-785
FAILURE CODE [DAF0MC] ..........................................................................................................40-786
FAILURE CODE [DAF8KB] ...........................................................................................................40-787
FAILURE CODE [DAF9KQ]...........................................................................................................40-789
FAILURE CODE [DAFGMC] .........................................................................................................40-790
FAILURE CODE [DAFLKA] ...........................................................................................................40-791
FAILURE CODE [DAFLKB] ...........................................................................................................40-793
FAILURE CODE [DAFQKR] ..........................................................................................................40-795
FAILURE CODE [DAZ9KQ]...........................................................................................................40-799
FAILURE CODE [DAZQKR] ..........................................................................................................40-800
FAILURE CODE [DB2QKR] ..........................................................................................................40-804
FAILURE CODE [DB2RKR] ..........................................................................................................40-809
FAILURE CODE [DBP0KM] ..........................................................................................................40-814
FAILURE CODE [DBP0KT] ...........................................................................................................40-815
FAILURE CODE [DBPQKR]..........................................................................................................40-816
FAILURE CODE [DDNRKA]..........................................................................................................40-821

00-10 HB365LC-3
00 INDEX AND FOREWORD INDEX

FAILURE CODE [DDNRKY]..........................................................................................................40-823

FAILURE CODE [DDNS00]...........................................................................................................40-825
FAILURE CODE [DGH2KA] ..........................................................................................................40-827
FAILURE CODE [DGH2KB] ..........................................................................................................40-829
FAILURE CODE [DHA4KA]...........................................................................................................40-831
FAILURE CODE [DHAAMA]..........................................................................................................40-833
FAILURE CODE [DHACMA] .........................................................................................................40-835
FAILURE CODE [DHPAMA]..........................................................................................................40-837
FAILURE CODE [DHPBMA]..........................................................................................................40-839
FAILURE CODE [DHS3MA] ..........................................................................................................40-841
FAILURE CODE [DHS4MA] ..........................................................................................................40-843
FAILURE CODE [DHS8MA] ..........................................................................................................40-845
FAILURE CODE [DHS9MA] ..........................................................................................................40-847
FAILURE CODE [DHSAKZ] ..........................................................................................................40-849
FAILURE CODE [DHSBKZ] ..........................................................................................................40-851
FAILURE CODE [DHSCMA] .........................................................................................................40-853
FAILURE CODE [DHSDMA] .........................................................................................................40-855
FAILURE CODE [DHSFMA]..........................................................................................................40-857
FAILURE CODE [DHSGMA] .........................................................................................................40-859
FAILURE CODE [DHSHMA] .........................................................................................................40-861
FAILURE CODE [DHSJMA] ..........................................................................................................40-863
FAILURE CODE [DHVAKZ]...........................................................................................................40-865
FAILURE CODE [DHVAL8] ...........................................................................................................40-867
FAILURE CODE [DHVAMA]..........................................................................................................40-869
FAILURE CODE [DHVBKZ] ..........................................................................................................40-870
FAILURE CODE [DHVBL8] ...........................................................................................................40-872
FAILURE CODE [DHVBMA]..........................................................................................................40-874
FAILURE CODE [DKR0MA] ..........................................................................................................40-875
FAILURE CODE [DKR1MA] ..........................................................................................................40-877
FAILURE CODE [DKULKA]...........................................................................................................40-879
FAILURE CODE [DKULKB]...........................................................................................................40-881
FAILURE CODE [DKULKY]...........................................................................................................40-883
FAILURE CODE [DLM5KA]...........................................................................................................40-884
FAILURE CODE [DLM5MB] ..........................................................................................................40-886
FAILURE CODE [DR10KA] ...........................................................................................................40-888
FAILURE CODE [DR21KX] ...........................................................................................................40-891
FAILURE CODE [DUMBKA]..........................................................................................................40-893
FAILURE CODE [DUMBKB]..........................................................................................................40-895
FAILURE CODE [DV20KB] ...........................................................................................................40-897
FAILURE CODE [DW43KA] ..........................................................................................................40-899
FAILURE CODE [DW43KB] ..........................................................................................................40-901
FAILURE CODE [DW43KY] ..........................................................................................................40-902
FAILURE CODE [DW45KA] ..........................................................................................................40-903
FAILURE CODE [DW45KB] ..........................................................................................................40-906
FAILURE CODE [DW45KK] ..........................................................................................................40-909
FAILURE CODE [DW45KY] ..........................................................................................................40-911
FAILURE CODE [DW4CKY]..........................................................................................................40-913
FAILURE CODE [DW91KA] ..........................................................................................................40-914
FAILURE CODE [DW91KB] ..........................................................................................................40-916
FAILURE CODE [DW91KY] ..........................................................................................................40-917
FAILURE CODE [DWA2KA] ..........................................................................................................40-918
FAILURE CODE [DWA2KB] ..........................................................................................................40-920
FAILURE CODE [DWA2KY] ..........................................................................................................40-921
FAILURE CODE [DWK0KA]..........................................................................................................40-922
FAILURE CODE [DWK0KB]..........................................................................................................40-924
FAILURE CODE [DWK0KY]..........................................................................................................40-926
FAILURE CODE [DWK2KA]..........................................................................................................40-927
FAILURE CODE [DWK2KB]..........................................................................................................40-929

HB365LC-3 00-11
INDEX 00 INDEX AND FOREWORD

FAILURE CODE [DWK2KY]..........................................................................................................40-931

FAILURE CODE [DWN5KA]..........................................................................................................40-932
FAILURE CODE [DWN5KB]..........................................................................................................40-934
FAILURE CODE [DWN5KY]..........................................................................................................40-935
FAILURE CODE [DXA8KA]...........................................................................................................40-936
FAILURE CODE [DXA8KB]...........................................................................................................40-939
FAILURE CODE [DXA9KA]...........................................................................................................40-941
FAILURE CODE [DXA9KB]...........................................................................................................40-944
FAILURE CODE [DXE0KA]...........................................................................................................40-946
FAILURE CODE [DXE0KB]...........................................................................................................40-948
FAILURE CODE [DXE4KA]...........................................................................................................40-949
FAILURE CODE [DXE4KB]...........................................................................................................40-951
FAILURE CODE [DXE4KY]...........................................................................................................40-952
FAILURE CODE [DXE5KA]...........................................................................................................40-953
FAILURE CODE [DXE5KB]...........................................................................................................40-955
FAILURE CODE [DXE6KA]...........................................................................................................40-957
FAILURE CODE [DXE6KB]...........................................................................................................40-959
FAILURE CODE [DXE7KA]...........................................................................................................40-961
FAILURE CODE [DXE7KB]...........................................................................................................40-963
FAILURE CODE [DXE7KY]...........................................................................................................40-965
FAILURE CODE [DXE8KA]...........................................................................................................40-967
FAILURE CODE [DXE8KB]...........................................................................................................40-969
FAILURE CODE [DXE8KY]...........................................................................................................40-971
FAILURE CODE [DXE9KA]...........................................................................................................40-973
FAILURE CODE [DXE9KB]...........................................................................................................40-975
FAILURE CODE [DXE9KY]...........................................................................................................40-977
FAILURE CODE [DXEAKA] ..........................................................................................................40-979
FAILURE CODE [DXEAKB] ..........................................................................................................40-981
FAILURE CODE [DXEAKY] ..........................................................................................................40-983
FAILURE CODE [DY20KA] ...........................................................................................................40-985
FAILURE CODE [DY20MA]...........................................................................................................40-987
FAILURE CODE [DY2CKB]...........................................................................................................40-989
FAILURE CODE [DY2DKB]...........................................................................................................40-991
FAILURE CODE [DY2EKB]...........................................................................................................40-993
FAILURE CODE [GA00NS]...........................................................................................................40-995
FAILURE CODE [GA01KA] ...........................................................................................................40-996
FAILURE CODE [GA02KZ] ...........................................................................................................40-998
FAILURE CODE [GA04KG].........................................................................................................40-1001
FAILURE CODE [GA05KG].........................................................................................................40-1004
FAILURE CODE [GA05KP] .........................................................................................................40-1007
FAILURE CODE [GA06KZ] .........................................................................................................40-1010
FAILURE CODE [GA08KG].........................................................................................................40-1011
FAILURE CODE [GA09KG].........................................................................................................40-1019
FAILURE CODE [GA09KP] .........................................................................................................40-1027
FAILURE CODE [GA0AKZ].........................................................................................................40-1028
FAILURE CODE [GA0BKZ].........................................................................................................40-1029
FAILURE CODE [GA10MA] ........................................................................................................40-1036
FAILURE CODE [GA10MC] ........................................................................................................40-1043
FAILURE CODE [GA12NK].........................................................................................................40-1044
FAILURE CODE [GA13KP] .........................................................................................................40-1050
FAILURE CODE [GA13KY] .........................................................................................................40-1052
FAILURE CODE [GA15KZ] .........................................................................................................40-1054
FAILURE CODE [GA17KR].........................................................................................................40-1062
FAILURE CODE [GA17MB] ........................................................................................................40-1063
FAILURE CODE [GA18MC] ........................................................................................................40-1064
FAILURE CODE [GA19KR].........................................................................................................40-1069
FAILURE CODE [GA19KT] .........................................................................................................40-1070
FAILURE CODE [GA1BMA] ........................................................................................................40-1071

00-12 HB365LC-3
00 INDEX AND FOREWORD INDEX

FAILURE CODE [GA1FKR].........................................................................................................40-1073

FAILURE CODE [GA1FMA] ........................................................................................................40-1074
FAILURE CODE [GA1GKR] ........................................................................................................40-1077
FAILURE CODE [GA1GKT] ........................................................................................................40-1078
FAILURE CODE [GA1GMB]........................................................................................................40-1079
FAILURE CODE [GA1HKZ].........................................................................................................40-1080
FAILURE CODE [GA1JKZ] .........................................................................................................40-1081
FAILURE CODE [GA1KKZ].........................................................................................................40-1082
FAILURE CODE [GA1LKZ] .........................................................................................................40-1083
FAILURE CODE [GA1MKZ] ........................................................................................................40-1084
FAILURE CODE [GA1NNS] ........................................................................................................40-1085
FAILURE CODE [GA1SFS].........................................................................................................40-1086
FAILURE CODE [GA1SMC]........................................................................................................40-1087
FAILURE CODE [GA1TKP].........................................................................................................40-1088
FAILURE CODE [GA1TNS].........................................................................................................40-1091
FAILURE CODE [GA1UKZ].........................................................................................................40-1094
FAILURE CODE [GA1VFS].........................................................................................................40-1097
FAILURE CODE [GA1VMC]........................................................................................................40-1098
FAILURE CODE [GA1XKZ].........................................................................................................40-1099
FAILURE CODE [GA1YNS] ........................................................................................................40-1100
FAILURE CODE [GA1ZKZ] .........................................................................................................40-1101
FAILURE CODE [GA1ZNS].........................................................................................................40-1102
FAILURE CODE [GA22NS].........................................................................................................40-1103
FAILURE CODE [GA23KZ] .........................................................................................................40-1104
FAILURE CODE [GA24KZ] .........................................................................................................40-1105
FAILURE CODE [GA25MA] ........................................................................................................40-1106
FAILURE CODE [GA25NS]......................................................................................................... 40-1110
FAILURE CODE [GA26MA] ........................................................................................................ 40-1111
FAILURE CODE [GA26NS]......................................................................................................... 40-1115
FAILURE CODE [GA27KZ] ......................................................................................................... 40-1116
FAILURE CODE [GA2QKR] ........................................................................................................ 40-1117
FAILURE CODE [GA2RKR] ........................................................................................................40-1122
FAILURE CODE [GA60MC] ........................................................................................................40-1127
FAILURE CODE [GA60N1] .........................................................................................................40-1129
FAILURE CODE [GA61KZ] .........................................................................................................40-1131
FAILURE CODE [GA61NS].........................................................................................................40-1133
FAILURE CODE [GA62KY] .........................................................................................................40-1134
FAILURE CODE [GA62KZ] .........................................................................................................40-1139
FAILURE CODE [GA62MA] ........................................................................................................40-1143
FAILURE CODE [GA63KY] .........................................................................................................40-1144
FAILURE CODE [GA63KZ] .........................................................................................................40-1149
FAILURE CODE [GA63MA] ........................................................................................................40-1153
FAILURE CODE [GA64KY] .........................................................................................................40-1154
FAILURE CODE [GA64KZ] .........................................................................................................40-1159
FAILURE CODE [GA64MA] ........................................................................................................40-1163
FAILURE CODE [GA70KB] .........................................................................................................40-1164
FAILURE CODE [GA70MD] ........................................................................................................40-1167
FAILURE CODE [GA70NS].........................................................................................................40-1169
FAILURE CODE [GA71KZ] .........................................................................................................40-1170
FAILURE CODE [GA72MA] ........................................................................................................40-1172
FAILURE CODE [GA72MC] ........................................................................................................40-1174
FAILURE CODE [GA81KZ] .........................................................................................................40-1176
FAILURE CODE [GAA0KB].........................................................................................................40-1179
FAILURE CODE [GAA2KB].........................................................................................................40-1181
FAILURE CODE [GAA6KP].........................................................................................................40-1183
FAILURE CODE [GAA6KY].........................................................................................................40-1185
FAILURE CODE [GACA00].........................................................................................................40-1187
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .........................................................40-1188

HB365LC-3 00-13
INDEX 00 INDEX AND FOREWORD

E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) ..............................................40-1188
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK........................................................40-1194
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK ..................................................40-1197
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP..... 40-1199
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS
NOTHING................................................................................................................................40-1201
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), EN-
GINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW ...........................................................40-1204
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIA-
TOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW .................................................40-1205
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUN-
NING .......................................................................................................................................40-1206
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUN-
NING .......................................................................................................................................40-1207
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING...
................................................................................................................................................40-1208
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..............40-1209
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING....................40-1210
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ...... 40-1211
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING .......................................................................................................................................40-1212
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 40-1213
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-
NING .......................................................................................................................................40-1214
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .................40-1215
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL...............................40-1217
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM
OR MAXIMUM.........................................................................................................................40-1218
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOL-
ANT TEMPERATURE..............................................................................................................40-1219
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR
MAXIMUM ...............................................................................................................................40-1220
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEM-
PERATURE .............................................................................................................................40-1222
E-23 MONITOR TEMPERATURE GAUGE OF HYBRID SYSTEMS DOES NOT INDICATE CORRECT
TEMPERATURE......................................................................................................................40-1223
E-24 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED ......................40-1224
E-25 FUNCTION SWITCH DOES NOT OPERATE .....................................................................40-1225
E-26 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)..................40-1226
E-27 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR
DOES NOT LIGHT UP OR DOES NOT GO OFF ....................................................................40-1227
E-28 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER ....................40-1228
E-29 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS
NOT DISPLAYED ....................................................................................................................40-1229
E-30 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS
NOT CHANGED ......................................................................................................................40-1230
E-31 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT
CHANGE .................................................................................................................................40-1231
E-32 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT
CHANGE .................................................................................................................................40-1232
E-33 ALARM BUZZER CANNOT BE CANCELED ......................................................................40-1233
E-34 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION.........
................................................................................................................................................40-1234
E-35 SERVICE MODE CANNOT BE SELECTED .......................................................................40-1235
E-36 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE ....40-1236
E-37 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK........40-1238
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT
SWING ....................................................................................................................................40-1239

00-14 HB365LC-3
00 INDEX AND FOREWORD INDEX

E-39 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING
BRAKE DOES NOT OPERATE ...............................................................................................40-1242
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDI-
CATOR NOT DISPLAYED ON MONITOR ...............................................................................40-1244
E-41 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED ...........................40-1246
E-42 ALARM DOES NOT SOUND DURING TRAVEL ................................................................40-1247
E-43 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED..........................40-1249
E-44 HORN DOES NOT SOUND................................................................................................40-1250
E-45 HORN DOES NOT STOP SOUNDING...............................................................................40-1253
E-46 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .
................................................................................................................................................40-1255
E-47 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE...40-1256
E-48 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPER-
ATE .........................................................................................................................................40-1258
E-49 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ...
................................................................................................................................................40-1259
E-50 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .
................................................................................................................................................40-1260
E-51 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION..........
................................................................................................................................................40-1261
E-52 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 40-1262
E-53 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION
................................................................................................................................................40-1263
E-54 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .
................................................................................................................................................40-1264
E-55 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.40-1265
E-56 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION40-1266
E-57 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ..........
................................................................................................................................................40-1267
E-58 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED.......................................40-1269
E-59 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .................................................40-1270
E-60 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED .............................................40-1271
E-61 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE..................................................40-1273
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .....................40-1274
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)...............................40-1274
FAILURE MODE AND CAUSE TABLE........................................................................................40-1275
H-1 ALL WORK EQUIPMENTS OR TRAVEL DOES NOT OPERATE.........................................40-1285
H-2 ALL WORK EQUIPMENT AND TRAVEL SPEED OR POWER IS LOW ...............................40-1286
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR............................................40-1288
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP ..................................40-1289
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS ..................................................40-1290
H-6 SPEED OR POWER OF BOOM IS LOW .............................................................................40-1292
H-7 ARM SPEED OR POWER IS LOW ......................................................................................40-1298
H-8 BUCKET SPEED OR POWER IS LOW................................................................................40-1303
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION .....................................40-1306
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE ........................................................................40-1307
H-11 HYDRAULIC DRIFT OF ARM IS LARGE ...........................................................................40-1309
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE.....................................................................40-1311
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIP-
MENT MOVES ........................................................................................................................40-1312
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE .................................................................40-1313
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .........................40-1314
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE..................................................40-1315
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED............................................................40-1316
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .....................................40-1317
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD
MOVES SLOWER ...................................................................................................................40-1318
H-20 MACHINE DOES NOT TRAVEL STRAIGHT ......................................................................40-1319

HB365LC-3 00-15
INDEX 00 INDEX AND FOREWORD

H-21 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW.............................40-1321

H-22 TRAVEL SPEED IS LOW ...................................................................................................40-1324
H-23 ONE OF TRACKS DOES NOT RUN ..................................................................................40-1326
H-24 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST ..40-1328
H-25 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) ............................40-1329
H-26 UNUSUAL NOISE IS HEARD FROM AROUND FAN .........................................................40-1330
H-27 Quick coupler cylinder will not extend.................................................................................40-1331
H-28 Quick coupler cylinder will not retract (but buzzer doesnot sound) .....................................40-1333
H-29 Buzzer does not sound (but quick coupler cylinder doesretract) .........................................40-1335
H-30 Quick coupler cylinder extends and retracts slowly.............................................................40-1337
TROUBLESHOOTING OF ENGINE (S-MODE) .................................................................................40-1338
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)...............................40-1338
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION.......
................................................................................................................................................40-1339
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT .................................................40-1340
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS
BUT DOES NOT START) ........................................................................................................40-1341
S-4 ENGINE STARTABILITY IS POOR.......................................................................................40-1343
S-5 ENGINE DOES NOT PICK UP SMOOTHLY ........................................................................40-1345
S-6 ENGINE STOPS DURING OPERATION ..............................................................................40-1347
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE ........................................................................40-1349
S-8 ENGINE LACKS POWER.....................................................................................................40-1350
S-9 KDPF GETS CLOGGED IN A SHORT TIME ........................................................................40-1352
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE ..................................................................40-1354
S-11 OIL BECOMES CONTAMINATED QUICKLY ......................................................................40-1355
S-12 FUEL CONSUMPTION IS EXCESSIVE .............................................................................40-1356
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) .......
................................................................................................................................................40-1357
S-14 OIL PRESSURE DROPS ...................................................................................................40-1358
S-15 FUEL MIXES INTO ENGINE OIL........................................................................................40-1360
S-16 WATER MIXES INTO ENGINE OIL (MILKY) ......................................................................40-1361
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) ....................................40-1362
S-18 UNUSUAL NOISE IS HEARD.............................................................................................40-1364
S-19 VIBRATION IS EXCESSIVE ...............................................................................................40-1365
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT.................................................................40-1366
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY ................................................40-1367
S-22 ACTIVE REGENERATION TAKES TIME............................................................................40-1369
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION..............................40-1370
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE ...................................................................40-1371
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) ..........................................................40-1373
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES).........................40-1374
TROUBLESHOOTING FOR HYBRID SYSTEMS (Y MODE) .............................................................40-1375
PRECAUTIONS FOR USING HYBRID SYSTEMS .....................................................................40-1375
Y-1 HYBRID MONITOR DOES NOT GO OUT ............................................................................40-1376
Y-2 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT....................40-1378
Y-3 UPPER STRUCTURE SWINGS ONLY TO THE RIGHT OR LEFT .......................................40-1379
Y-4 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS LOW IN BOTH DI-
RECTIONS (RIGHT AND LEFT) .............................................................................................40-1380
Y-5 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS LOW IN ONLY ONE
DIRECTION.............................................................................................................................40-1381
Y-6 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT
AND LEFT)..............................................................................................................................40-1382
Y-7 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (EITHER
RIGHT OR LEFT) ....................................................................................................................40-1383
Y-8 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING................................40-1384
Y-9 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING ..40-1385
Y-10 SWING DRIFT ON A SLOPE IS LARGE (WHILE PARKING BRAKE IS APPLIED) ............40-1386
Y-11 SWING DRIFT ON A SLOPE IS LARGE (WHILE PARKING BRAKE IS RELEASED).........40-1387

00-16 HB365LC-3
00 INDEX AND FOREWORD INDEX

Y-12 ELECTRIC SWING MOTOR TEMPERATURE INCREASES ABNORMALLY .....................40-1388

Y-13 MOTOR-GENERATOR TEMPERATURE INCREASES ABNORMALLY..............................40-1391
Y-14 INVERTER TEMPERATURE INCREASES ABNORMALLY ................................................40-1393
Y-15 CAPACITOR TEMPERATURE INCREASES ABNORMALLY..............................................40-1395
50 DISASSEMBLY AND ASSEMBLY............................................................................................................. 50-1
CONTENTS ............................................................................................................................................ 50-2
ABBREVIATION LIST ............................................................................................................................. 50-7
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY ........................................................ 50-13
HOW TO READ THIS MANUAL..................................................................................................... 50-13
COATING MATERIALS LIST.......................................................................................................... 50-15
SPECIAL TOOLS LIST .................................................................................................................. 50-19
SKETCHES OF SPECIAL TOOLS................................................................................................. 50-38
ENGINE AND COOLING SYSTEM....................................................................................................... 50-46
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .................................................................. 50-46
REMOVE AND INSTALL INJECTOR ASSEMBLY ......................................................................... 50-58
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .............................................................. 50-76
REMOVE AND INSTALL EGR VALVE ASSEMBLY.......................................................................50-102
REMOVE AND INSTALL EGR COOLER ASSEMBLY...................................................................50-105
REMOVE AND INSTALL STARTER ASSEMBLY ..........................................................................50-108
REMOVE AND INSTALL ALTERNATOR BELT .............................................................................50-110
REMOVE AND INSTALL RADIATOR ASSEMBLY ........................................................................50-116
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY ...............................................50-122
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY................................................................50-129
REMOVE AND INSTALL FAN CLUTCH ASSEMBLY ....................................................................50-133
REMOVE AND INSTALL FAN .......................................................................................................50-140
REMOVE AND INSTALL ENGINE, MOTOR-GENERATOR, AND MAIN PUMP ASSEMBLY ........50-141
REMOVE AND INSTALL ENGINE FRONT OIL SEAL ..................................................................50-163
REMOVE AND INSTALL ENGINE REAR OIL SEAL.....................................................................50-167
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .................................................................50-176
REMOVE AND INSTALL FUEL TANK ASSEMBLY .......................................................................50-180
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY ............................................................50-186
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY..............................50-197
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR ................................................................50-208
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .............................................................50-210
REMOVE AND INSTALL KDPF ASSEMBLY.................................................................................50-211
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY ............................................................50-217
REMOVE AND INSTALL SCR ASSEMBLY...................................................................................50-226
REMOVE AND INSTALL KDPF, SCR ASSEMBLY........................................................................50-232
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET ......................................................50-244
REMOVE AND INSTALL KCCV ASSEMBLY ................................................................................50-251
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE ..................................................................50-254
REMOVE AND INSTALL AdBlue/DEF INJECTOR........................................................................50-262
REMOVE AND INSTALL AdBlue/DEF PUMP ...............................................................................50-268
REMOVE AND INSTALL AdBlue/DEF HOSE ...............................................................................50-274
REMOVE AND INSTALL AIR CLEANER ASSEMBLY...................................................................50-289
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY ................................50-294
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY ...................................50-297
HYBRID SYSTEM................................................................................................................................50-301
REMOVE AND INSTALL HYBRID RADIATOR ASSEMBLY..........................................................50-301
REMOVE AND INSTALL HYBRID WATER PUMP ASSEMBLY ....................................................50-305
REMOVE AND INSTALL INVERTER ASSEMBLY ........................................................................50-310
REMOVE AND INSTALL INVERTER AND CAPACITOR ASSEMBLY...........................................50-319
REMOVE AND INSTALL MOTOR-GENERATOR AND HOUSING ASSEMBLY ............................50-329
REMOVE AND INSTALL ELECTRIC SWING MOTOR .................................................................50-340
POWER TRAIN....................................................................................................................................50-350
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY ...............................50-350
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY......................................................50-353
REMOVE AND INSTALL ELECTRIC SWING MOTOR AND SWING MACHINERY ASSEMBLY ..50-366

HB365LC-3 00-17
INDEX 00 INDEX AND FOREWORD

DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .........................................50-375

REMOVE AND INSTALL SWING CIRCLE ASSEMBLY ................................................................50-395
UNDERCARRIAGE AND FRAME........................................................................................................50-397
SEPARATION AND CONNECTION OF TRACK ASSEMBLY........................................................50-397
REMOVE AND INSTALL SPROCKET ..........................................................................................50-402
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY...........................................50-404
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .................................................................50-407
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY ..........................................50-412
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY ................................................50-415
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .............................................50-419
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY ........................................................50-424
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY...........................................................50-429
HYDRAULIC SYSTEM.........................................................................................................................50-433
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY ..................................................50-433
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY ...................................50-438
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY............................................................50-441
REMOVE AND INSTALL MAIN PUMP ASSEMBLY ......................................................................50-448
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .............................................................50-454
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY ..............................................50-468
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY ......................50-475
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY ..........................................50-478
REMOVE AND INSTALL QUICK COUPLER VALVE.....................................................................50-481
WORK EQUIPMENT............................................................................................................................50-483
REMOVE AND INSTALL BUCKET ASSEMBLY............................................................................50-483
REMOVE AND INSTALL ARM ASSEMBLY ..................................................................................50-485
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY .........................................................50-488
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY........................50-493
CAB AND ITS ATTACHMENTS ...........................................................................................................50-503
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY ...........................................................50-503
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) ....................................50-518
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY .............................................................50-531
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY.................................................................50-540
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY .................................................50-550
REMOVE AND INSTALL OPERATOR'S SEAT .............................................................................50-561
REMOVE AND INSTALL SEAT BELT ...........................................................................................50-566
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .................................................................50-568
ELECTRICAL SYSTEM .......................................................................................................................50-582
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY ...................................................50-582
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY.......................................................50-588
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY ................................................50-594
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY ........................................................50-596
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR ..........................................................50-602
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR ..............................50-604
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR.........................................50-607
REMOVE AND INSTALL SCR TEMPERATURE SENSOR ...........................................................50-609
REMOVE AND INSTALL KomVision CAMERA .............................................................................50-612
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY......................................................50-615
60 MAINTENANCE STANDARD.................................................................................................................... 60-1
CONTENTS ............................................................................................................................................ 60-2
ABBREVIATION LIST ............................................................................................................................. 60-3
ENGINE AND COOLING SYSTEM......................................................................................................... 60-9
MAINTENANCE STANDARD OF ENGINE MOUNT ........................................................................ 60-9
MAINTENANCE STANDARD OF COOLING SYSTEM ...................................................................60-11
POWER TRAIN..................................................................................................................................... 60-13
MAINTENANCE STANDARD OF SWING CIRCLE ........................................................................ 60-13
MAINTENANCE STANDARD OF SWING MACHINERY WITH SWING PARKING BRAKE ........... 60-14
MAINTENANCE STANDARD OF FINAL DRIVE ............................................................................ 60-16
MAINTENANCE STANDARD OF SPROCKET .............................................................................. 60-18

00-18 HB365LC-3
00 INDEX AND FOREWORD INDEX

MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING......... 60-19

UNDERCARRIAGE AND FRAME......................................................................................................... 60-21
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION.................................... 60-21
MAINTENANCE STANDARD OF IDLER ....................................................................................... 60-23
MAINTENANCE STANDARD OF TRACK ROLLER....................................................................... 60-25
MAINTENANCE STANDARD OF CARRIER ROLLER ................................................................... 60-27
MAINTENANCE STANDARD OF TRACK SHOE ........................................................................... 60-28
MAINTENANCE STANDARD OF TRIPLE SHOE........................................................................... 60-31
HYDRAULIC SYSTEM.......................................................................................................................... 60-32
MAINTENANCE STANDARD OF HYDRAULIC TANK ................................................................... 60-32
MAINTENANCE STANDARD OF MAIN PUMP.............................................................................. 60-33
MAINTENANCE STANDARD OF TRAVEL MOTOR ...................................................................... 60-37
MAINTENANCE STANDARD OF CONTROL VALVE..................................................................... 60-40
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM .............................................. 60-52
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM ................................................. 60-54
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE ....................... 60-56
MAINTENANCE STANDARD OF TRAVEL PPC VALVE ................................................................ 60-59
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)...... 60-62
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE ..................................... 60-65
MAINTENANCE STANDARD OF SOLENOID VALVE.................................................................... 60-67
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE ........................... 60-68
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .......................................................... 60-69
WORK EQUIPMENT............................................................................................................................. 60-70
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE................................................. 60-70
MAINTENANCE STANDARD OF BOOM CYLINDER .................................................................... 60-79
MAINTENANCE STANDARD OF ARM CYLINDER ....................................................................... 60-80
MAINTENANCE STANDARD OF BUCKET CYLINDER................................................................. 60-81
80 APPENDIX................................................................................................................................................ 80-1
CONTENTS ............................................................................................................................................ 80-2
ABBREVIATION LIST ............................................................................................................................. 80-4
AIR CONDITIONER SYSTEM .............................................................................................................. 80-10
PRECAUTIONS FOR REFRIGERANT .......................................................................................... 80-10
AIR CONDITIONER COMPONENT ................................................................................................80-11
SPECIFICATIONS OF AIR CONDITIONER ................................................................................... 80-13
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE ............................................. 80-14
OUTLINE OF REFRIGERATION CYCLE ....................................................................................... 80-15
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .................................................................... 80-17
AIR CONDITIONER UNIT.............................................................................................................. 80-17
COMPONENT PARTS OF AIR CONDITIONER UNIT.................................................................... 80-21
AIR CONDITIONER CONTROLLER .............................................................................................. 80-25
COMPRESSOR ............................................................................................................................. 80-26
CONDENSER ................................................................................................................................ 80-27
RECEIVER DRIER......................................................................................................................... 80-28
SENSORS FOR AIR CONDITIONER SYSTEM............................................................................. 80-29
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER......
.......................................................................................................................................................... 80-31
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER ......... 80-33
AIR CONDITIONER SYSTEM DIAGRAM ............................................................................................. 80-35
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER .................................... 80-36
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS ..
.......................................................................................................................................................... 80-38
TESTING AIR LEAKAGE (DUCT)......................................................................................................... 80-42
METHOD FOR TESTING AIR LEAKAGE (DUCT) ......................................................................... 80-42
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION................................................ 80-44
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE
OF THE MACHINE MONITOR .......................................................................................................... 80-45
TEST VENT (MODE) CHANGEOVER .................................................................................................. 80-46
METHOD FOR TESTING VENT (MODE) CHANGEOVER ............................................................ 80-46

HB365LC-3 00-19
INDEX 00 INDEX AND FOREWORD

TESTING FRESH/RECIRC AIR CHANGEOVER.................................................................................. 80-48

METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER .................................................. 80-48
TEST SUNLIGHT SENSOR.................................................................................................................. 80-49
METHOD FOR TESTING SUNLIGHT SENSOR............................................................................ 80-49
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT.................................................................. 80-50
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT............................ 80-50
TEST RELAYS...................................................................................................................................... 80-52
METHOD FOR TESTING RELAYS ................................................................................................ 80-52
AIR CONDITIONER TROUBLESHOOTING CHART 1 ......................................................................... 80-53
AIR CONDITIONER TROUBLESHOOTING CHART 2 ......................................................................... 80-55
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE........................................................... 80-58
FAILURE CODE [879AKA].................................................................................................................... 80-60
FAILURE CODE [879AKB].................................................................................................................... 80-61
FAILURE CODE [879BKA].................................................................................................................... 80-62
FAILURE CODE [879BKB].................................................................................................................... 80-64
FAILURE CODE [879CKA].................................................................................................................... 80-66
FAILURE CODE [879CKB].................................................................................................................... 80-67
FAILURE CODE [879DKZ].................................................................................................................... 80-68
FAILURE CODE [879EMC] ................................................................................................................... 80-70
FAILURE CODE [879FMC] ................................................................................................................... 80-71
FAILURE CODE [879GKX] ................................................................................................................... 80-72
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE).
.......................................................................................................................................................... 80-74
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)...
.......................................................................................................................................................... 80-76
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS
ABNORMAL) ..................................................................................................................................... 80-79
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER............................................... 80-81
TROUBLESHOOTING USING GAUGE PRESSURE............................................................................ 80-83
CONNECTION OF SERVICE TOOL ..................................................................................................... 80-86
METHOD FOR CONNECTING SERVICE TOOL ........................................................................... 80-86
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITION-
ER PIPINGS...................................................................................................................................... 80-88
HANDLE COMPRESSOR OIL .............................................................................................................. 80-90
90 CIRCUIT DIAGRAMS ............................................................................................................................... 90-1
CONTENTS ............................................................................................................................................ 90-2
ABBREVIATION LIST ............................................................................................................................. 90-3
HYDRAULIC CIRCUIT DIAGRAM .......................................................................................................... 90-9
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .................................................................. 90-9
HYDRAULIC CIRCUIT DIAGRAM (1/2) ......................................................................................... 90-13
HYDRAULIC CIRCUIT DIAGRAM (2/2) ......................................................................................... 90-15
ELECTRICAL CIRCUIT DIAGRAM ....................................................................................................... 90-17
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM............................................................... 90-17
ELECTRICAL CIRCUIT DIAGRAM (1/12)...................................................................................... 90-21
ELECTRICAL CIRCUIT DIAGRAM (2/12)...................................................................................... 90-23
ELECTRICAL CIRCUIT DIAGRAM (3/12)...................................................................................... 90-25
ELECTRICAL CIRCUIT DIAGRAM (4/12)...................................................................................... 90-27
ELECTRICAL CIRCUIT DIAGRAM (5/12)...................................................................................... 90-29
ELECTRICAL CIRCUIT DIAGRAM (6/12)...................................................................................... 90-31
ELECTRICAL CIRCUIT DIAGRAM (7/12)...................................................................................... 90-33
ELECTRICAL CIRCUIT DIAGRAM (8/12)...................................................................................... 90-35
ELECTRICAL CIRCUIT DIAGRAM (9/12)...................................................................................... 90-37
ELECTRICAL CIRCUIT DIAGRAM (10/12) .................................................................................... 90-39
ELECTRICAL CIRCUIT DIAGRAM (11/12) .................................................................................... 90-41
ELECTRICAL CIRCUIT DIAGRAM (12/12).................................................................................... 90-43
INDEX..................................................................................................................................................................1

00-20 HB365LC-3
00 INDEX AND FOREWORD ABBREVIATION LIST

ABBREVIATION LIST (ALL-A-0360-005-00-B)

• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).

HB365LC-3 00-21
ABBREVIATION LIST 00 INDEX AND FOREWORD

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
This is an electronic control device that send the
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.

00-22 HB365LC-3
00 INDEX AND FOREWORD ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.

HB365LC-3 00-23
ABBREVIATION LIST 00 INDEX AND FOREWORD

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a service that allows transmission and re-
Multimedia Messaging
MMS Communication ception of short messages consisting of charac-
Service
ters or voice or images between cell phones.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NC Normally Closed circuits. Circuit is normally closed if it is not actu-
system
ated, and it opens when it is actuated.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NO Normally Open circuits. Circuit is normally open if it is not actuat-
system
ed, and it closes when it is actuated.
This is a hydraulic system that can operate multi-
Open-center Load
OLSS Hydraulic system ple actuators at the same time regardless of the
Sensing System
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
Steering This is a function that electrically controls the en-
Palm command control gine and transmission in an optimal way with the
PCCS
system (D Series) controller instantly analyzing data from levers,
pedals, and dials.
This is a valve that adjusts the fuel intake amount
PCV Pre-stroke Control Valve Engine at the pump inlet in order to control fuel dis-
charged volume of supply pump.
Proportional Pressure This is a system that operates actuators in pro-
PPC Hydraulic system
Control portion to the oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Work equipment This is a function that performs hydraulic control
Power Tilt and power
PTP of the tilt and pitch of the dozer blade of the bull-
Pitch dozer (D Series) dozer.
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
Roll-Over Protective crushed when the machine rolls over. (Roll-over
ROPS Cab and canopy
Structure protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
Selective Catalytic Re- less nitrogen and water by oxidation-reduction re-
SCR Urea SCR system
duction action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
Le Systeme Internation- Abbreviation for "International System of Units" It
SI al d' Unites (Internation- Unit is the universal unit system and "a single unit for
al unit system) a single quantity" is the basic principle applied.
This is an actuator that consists of a solenoid and
SOL Solenoid Electrical system an iron core that is operated by the magnetic
force when the solenoid is energized.

00-24 HB365LC-3
00 INDEX AND FOREWORD ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.

*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection

HB365LC-3 00-25
ABBREVIATION LIST 00 INDEX AND FOREWORD

Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

00-26 HB365LC-3
00 INDEX AND FOREWORD HOW TO READ THE SHOP MANUAL

FOREWORD, SAFETY, BASIC INFORMATION (ALL-A-0370-001-00-B)

HOW TO READ THE SHOP MANUAL (ALL_E-A-0320-010-00-B)

• 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. "STRUC-
TURE 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 ad-
justing 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, instal-
lation, 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.
Symbols
Important safety and quality portions are marked with the following symbols so that shop manual is used effec-
tively.

HB365LC-3 00-27
HOW TO READ THE SHOP MANUAL 00 INDEX AND FOREWORD

Symbol Item Remark

This signal indicates an extremely hazardous situation which will result in
Danger
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Warning
death or serious injury if it is not avoided.
This signal indicates a potentially hazardous situation which will result in
Caution
injury or property damage around the machine if it is not avoided.
This signal indicates the weight of parts and components, and items which
Weight requires great attention to a selection of wires and working posture for
slinging work.
This signal indicates the tightening torque for portions which requires spe-
Tightening torque
cial care in assembling work.
This signal indicates a place to be coated with adhesive, grease, etc. in
Coat
assembling work.

Oil and coolant This signal indicates a place to supply oil, coolant, etc. and the quantity.

Draining This signal indicates a place to drain oil, coolant, etc. and the quantity.

Signal word
Signal word for notice and remark describes the following.
Symbol Item Remark
If the precaution of this signal word is not observed, the machine damage
NOTICE Notice
or shortening of service life may occur.
REMARK Remark This signal word contains useful information to know.

Unit
International System of Units (SI) is used in this manual. For reference, units that have been used in the past
are given in { }.

00-28 HB365LC-3
00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION

SAFETY NOTICE FOR OPERATION (ALL-A-1120-012-00-B)

• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop
manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of
the servicing and repair methods require the use of special tools designed by Komatsu for special purpos-
es.

• The symbol mark is indicated for such matters that require special precautions. The work indicated with
this warning mark should be performed according to the instructions with special attention. Should a
hazardous situation occurs or be anticipated during such work, be sure to keep safe first and take every
necessary measures.
Safety matters
• Well organized work place
• Correct work clothes
• Observance of work standard
• Enforcement of hand signals
• Prohibition against unlicensed persons operating and handling the machine
• Safety check before starting work
• Wear of dust glasses (for cleaning or grinding work)
• Wear of welding goggles and protectors (for welding work)
• Being in good physical condition, and good preparation
• Always be alert and careful.
General precautions
k If the machine is handled incorrectly, it is dangerous. Read and understand what is described in the
operation and maintenance manual before operation. Read and understand what is described in this
manual before operation.
• Read and understand the meaning of all the safety labels stuck to the machine before performing any
greasing or repairs. For the locations of the safety labels and detailed explanation of precautions, see Oper-
ation and Maintenance Manual.
• Tools and removed parts in the workshop should be well organized. Always keep the tools and parts in their
correct places. Always keep the work area clean and make sure that there is no dust, dirt, oil, or water on
the floor. Smoke only in the designated areas. Never smoke while working.
• Keep all tools in good condition, learn the correct way to use them, and use the proper ones. Check the
tools, machine, forklift truck, service car, etc. thoroughly before starting the work.
• Always wear safety shoes and helmet when performing
any operation. Do not wear loose clothes, or clothes with
buttons missing.

HB365LC-3 00-29
SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD

• Always wear the protective eyeglasses when hitting parts

with a hammer.
• Always wear the protective eyeglasses when grinding
parts with a grinder, etc.
• When performing any operation with multiple workers, al-
ways agree on the operating procedure before starting. Be
clear in verbal communication, and observe hand signals.
Hang "UNDER REPAIR" warning tag in the operator's
compartment Before starting work. ,&
• Work and operation which require license or qualification
should be performed by qualified workers.
• Welding repairs should be performed by trained and experienced welders. When performing welding work,
always wear welding gloves, apron, welding goggles, cap and other clothes suited for welding work.
• Warm up before starting the work with exercise which increases alertness and the range of motion in order
to prevent injury.
• Avoid prolonged work, and take a rest at times to keep up a good condition. Take a rest at designated safe
area.
Precautions for preparatory work
• Place the machine on a firm and level ground, and apply the parking brake and chock the wheels or tracks
to prevent the machine from moving before adding oil or making any repairs.
• Lower the work equipment (blade, ripper, bucket, etc.) to the ground before starting work. If this is not pos-
sible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to
lock all the control levers and hang "UNDER REPAIR" warning tag on them.
• When performing the disassembling or assembling work, support the machine securely with blocks, jacks,
or stands before starting the work.
• Remove all mud and oil from the steps or other places for
going up and down on the machine. Always use the hand-
rails, ladders or steps when for going up and down on the
machine. Never jump on or off the machine. When the
scaffold is not provided, use steps or stepladder to secure
your footing. Do not use handrails, ladders, or steps if they
are damaged or deformed. Repair it or replace it immedi-
ately.

,&

Precautions during work

• For the machine with the battery disconnect switch, check before starting the work that the system operat-
ing lamp is not lit. Then, turn the battery disconnect switch to OFF (○) position.
REMARK
Remove the key after it is turned to OFF (○) position if the battery disconnect switch is a switch key type.
For the machine without the battery disconnect switch, turn the starting switch to OFF position, wait for two
minutes or more before starting the work. Disconnect the battery cable by starting from the negative (-) ter-
minal first.
• For the machine with the quick release battery terminal (-), check before starting the work that the system
operating lamp is not lit. Then, disconnect the quick release battery terminal (-).
REMARK
For the machine without the system operating lamp, turn the starting switch to OFF position, wait for two
minutes or more before starting the work. Disconnect the quick release battery terminal (-).

00-30 HB365LC-3
00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION

• Release the remaining pressure from the circuit before starting the work of disconnecting and removing of
oil, fuel, water, or air from the circuit. When removing the cap of oil filter, drain plug, or oil pressure plug, it
should be done slowly otherwise the oil spills.
• When removing or installing the checking plug or the piping in the fuel circuit, wait 30 seconds or longer
after the engine is shut down and start the work after the remaining pressure is released from the fuel cir-
cuit.
• The coolant and oil in the circuits are hot when the engine
is shut down. Be careful not to get scalded. Wait for the oil
and coolant to cool before performing any work on the oil
or coolant circuits.

• Before starting work, shut down the engine. When working

on or around a rotating part, in particular, shut down the
engine. When checking the machine without shutting down
the engine (measuring oil pressure, revolving speed, tem-
perature, etc.), take extreme care not to get caught in ro-
tating parts or moving parts.
• When raising a heavy component (heavier than 25 kg),
use a hoist or crane. Before starting work, check that the
slings (wire ropes, webbing slings, chains, and hooks) are
free from damage. Always use slings which have ample
capacity and install them to proper places. Operate the
hoist or crane slowly to prevent the component from hitting
any other part. Do not work with any part still raised by the
hoist or crane.
• When removing a part which is under internal pressure or
under reaction force of a spring, always leave 2 bolts in di-
agonal positions. Loosen those 2 bolts gradually and alter-
nately to release the pressure, and then remove the part.
• When removing components, do not break or damage the
electrical wiring. Damaged wiring may cause a fire.
,&
• When removing piping, do not spill the fuel or oil. If any
fuel or oil drips onto the floor, wipe it off immediately. Fuel
or oil on the floor can cause you to slip and can even cause fires.
• Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in partic-
ular.

HB365LC-3 00-31
SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD

• Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which
must not be reused with new parts. When installing hoses and wiring harnesses, be sure that they will not
be damaged by contact with other parts when the machine is operated.
• When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and
tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In
addition, check that high pressure hoses and tubes are correctly installed.
• When assembling or installing parts, always tighten them to the specified torques. When installing protec-
tive parts such as guards, or parts which vibrate violently or rotate at high speed, check again that they are
installed correctly.
• Never insert your fingers or hand when aligning 2 holes. Be careful not to get your fingers caught in a hole.
• Check that the measuring tools are correctly installed when measuring hydraulic pressure.
• Take care when removing or installing the tracks of track-type machines. Since the track shoe may sepa-
rate suddenly when you remove it, never let anyone stand at either end of the track shoe.
• If the engine is operated for a long time in a closed place
with poor ventilation, it may cause gas poisoning. Open
the windows and doors to ventilate the place well.

,&

Precautions for slinging work and making signals

• Only one appointed worker must make signals and co-workers must communicate with each other fre-
quently. The appointed signaler must make specified signals clearly at a place where he is well seen from
the operator's seat and where he can see the working condition easily. The signaler must always stand in
front of the load and guide the operator safely.
k Never stand under the load.
k Do not move a load over a person.
k Never step on the load.
k Do not prevent the load from swinging or falling down by holding it simply with the hands.
k The sling workers and assistant workers other than the guide must move to a place where they
are not caught between the load and materials or equipment on the ground or hit by the load
even if the crane starts abruptly.
• Check the slings before starting sling work.
• Keep putting on gloves during sling work. (Put on leather gloves, if available.)
• Measure the weight of the load by the eye and check its center of gravity.
• Use proper sling corresponding to the weight of the load and method of slinging. If too thick wire ropes are
used to sling a light load, the load may slip and fall.
• Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install
2 or more wire ropes symmetrically.
k Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or
slipping of the rope from its original slinging position on the load, which can result in a danger-
ous accident.
• Hanging angle must be 60 ° or smaller as a rule.
• When slinging a heavy load (25 kg or heavier), the hanging angle of the rope must be narrower than that of
the hook.

00-32 HB365LC-3
00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION

REMARK
When slinging a load with 2 or more ropes, the force sub-
jected to each rope increases with the hanging angle. The
figure below shows the variation of allowable load in kN
{kg} when slinging is made with 2 ropes, each of which is
allowed to sling up to 9.8 kN {1000 kg} vertically, at vari-
ous hanging angles. When the 2 ropes sling a load verti-
cally, they can sling up to 2000 kg of total weight. This
weight is reduced to 1000 kg when the 2 ropes make a
hanging angle of 120 °. If the 2 ropes sling a 2000 kg load
at a hanging angle of 150 °, each rope is subjected to a
force as large as 39.2 kN {4000 kg} .
• When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery,
apply proper material to prevent the wire rope from slipping.
• Use the specified eye bolts and fix wire ropes, chains, etc. to them with shackles, etc.
• Apply wire ropes to the middle part of the hook.
k Do not use hooks if it does not have a latch sys-
tem.
k Slinging near the tip of the hook may cause the
rope to slip off the hook during hoisting.
REMARK
The strength of the hook is maximum at its central part.

• Never use a wire rope which has breaks in strands (A), re-
duced diameter (B), or kinks (C). There is a danger that
the rope may break during the towing operation.
Precautions for slinging up
• Wind in the crane slowly until wire ropes are stretched.
When settling the wire ropes with the hand, do not grasp
them but press them from above. If you grasp them, your
fingers may be caught.
• After the wire ropes are stretched, stop the crane and
check the condition of the slung load, wire ropes, and
pads.
• If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again.
• Do not lift up the load at an angle.
Precautions for slinging down
• When slinging down a load, stop it temporarily at 30 cm above the floor, and then lower it slowly.
• Check that the load is stable, and then remove the sling.
• Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified
place.
Precautions for using mobile crane
REMARK
Read Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
Precautions for using overhead traveling crane
k When raising a heavy component (heavier than 25 kg), use a hoist or crane.

HB365LC-3 00-33
SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD

REMARK

Weight of component whose weight is heavier than 25 kg is shown with symbol in "DISASSEMBLY AND
ASSEMBLY".
• Before starting work, check the wire ropes, brake, clutch, controller, rails, over winding prevention device,
ground fault circuit interrupter for electric shock prevention, crane collision prevention device, and energiz-
ing caution lamp, and check the following safety items.
• Observe the signals for sling work.
• Operate the hoist at a safe place.
• Be sure to check the directions of the direction indication plate (north, south, east and west) and the
operating button.
• Do not sling a load at an angle. Do not move the crane while the slung load is swinging.
• Do not raise or lower a load while the crane is moving longitudinally or laterally.
• Do not drag a sling.
• When lifting up a load, stop it just after it becomes off the ground, check the safety, and then lift it up.
• Consider the travel route in advance and lift up a load to a safe height.
• Place the control switch in a position where it is not an obstacle to work and passage.
• After operating the hoist, do not swing the control switch.
• Remember the position of the main switch so that you can turn off the power immediately in an emer-
gency.
• If the hoist stops because of a power failure, turn off the main switch. When turning on a switch after it
is turned off by the ground fault circuit interrupter, check that the devices related to that switch are not
in operating condition.
• If you find an obstacle around the hoist, stop the operation.
• After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 m above
the floor. Do not leave the sling installed to the hook.
Selecting wire ropes
Select adequate ropes depending on the weight of the parts to be hoisted referring to the table below.
REMARK
The allowable load is calculated with one sixth (safety factor 6) of the breaking load of the rope.

Wire rope (JIS G3525 6x37-A type) (Standard Z twist wire ropes without galvanizing)
Nominal diameter of rope ( mm) Allowable load ( kN { t} )
10 8.8 {0.9}
12 12.7 {1.3}
14 17.3 {1.7}
16 22.6 {2.3}
18 28.6 {2.9}
20 35.3 {3.6}
25 55.3 {5.6}
30 79.6 {8.1}
40 141.6 {14.4}
50 221.6 {22.6}
60 318.3 {32.4}

00-34 HB365LC-3
00 INDEX AND FOREWORD SAFETY NOTICE FOR OPERATION

Precautions for disconnecting air conditioner piping

NOTICE
When replacing the air conditioner unit, air conditioner compressor, condenser or receiver drier, etc.,
collect the refrigerant (air conditioner gas: R134a) from the air conditioner circuit before disconnecting
the air conditioner hoses.
REMARK
• Ask a qualified person for collecting, adding and filling operations of the refrigerant (air conditioner gas:
R134a).
• Never release the refrigerant (air conditioner gas: R134a) to the atmosphere.
k Put on the protective eyeglasses, gloves and working clothes with long sleeves while you are col-
lecting or filling the refrigerant. Otherwise, when refrigerant gas (R134a) gets in your eyes, you may
lose your sight, and when it touches your skin, you may suffer from frostbite.
• When loosening the nuts fixing air conditioner hoses and tubes, be sure to use 2 wrenches; use one
wrench to fix and use the other one to loosen the nut.
Precautions for air conditioner piping
• When installing the air conditioner piping, be careful so that dirt, dusts and water do not enter the hose.
• Check that the O-rings are fitted to the joints when connecting the air conditioner piping.
• Do not reuse an O-ring because it is deformed and deteriorated if it is used once.
• When removing the O-rings, use a soft tool so that the piping is not damaged.
• Check that the O-ring is not damaged or deteriorated.
• Apply compressor oil for refrigerant (R134a) to O-ring.
REMARK
Do not apply oil to the threaded portion of a bolt, nut or union.
Manufacturer Part name
DENSO ND-OIL8
VALEO THERMAL SYSTEMS ZXL100PG (PAG46 or equivalent)
SANDEN SP-10

When tightening nuts of the air conditioner hoses and tubes, be sure to use 2 wrenches. Use one wrench to fix
and tighten the nut with the other wrench to the specified torque (Use a torque wrench for tightening).

HB365LC-3 00-35
SAFETY NOTICE FOR OPERATION 00 INDEX AND FOREWORD

REMARK
• The figure shows an example of fitting of O-ring.
• An O-ring is fitted to every joint of the air conditioner piping.
For tightening torques, see THE OTHER INFORMATION, "Pre-
cautions for disconnection and connection of air conditioner
piping".

00-36 HB365LC-3
00 INDEX AND FOREWORD PRECAUTIONS PARTICULARLY FOR HYBRID MACHINES

PRECAUTIONS PARTICULARLY FOR HYBRID MACHINES (HB335_3-A-1120-012-00-B)

Precautions particularly for hybrid machines

k This machine is equipped with the hybrid system which combines the electrical motor and diesel en-
gine. Read "FOREWORD", "SAFETY" in the Operation and Maintenance Manual, and STRUCTURE
AND OPERATION “HYBRID SYSTEM” in this SHOP MANUAL to get a better understanding of the hy-
brid system.
k Observe the legislation to the electricity always when performing the removal and installing work of
hybrid components (motor-generator, capacitor, inverter, electric swing motor) or high voltage wir-
ing.
k Do not touch the devices or wirings carelessly, otherwise serious injury or death may occur by elec-
tric shock with high voltage accumulated inside the devices or wiring.
k Once disassembled hybrid components and high voltage wiring cannot be guaranteed. Never disas-
semble them.
k Replace the hybrid devices and high voltage wiring (with conduit wiring in orange color) as a unit.
k Perform discharging of the capacitor completely before handling the hybrid components. For detail,
see "TESTING AND ADJUSTING", “Diagnostic Tests menu (Capacitor Discharge)”.
k Observe the following items for handling the hybrid components and high voltage wirings.
k Handling inverter and capacitor
k Controller has been assembled with electronic circuits for control including microcomputers. These
electronic circuits inside of the controller must be handled with care since they control the machine.
k Precautions for arc welding
k Disconnect all the connectors and ground cables of the wiring harness connecting to the inverter
and capacitor when the arc welding is to be performed for repair, etc., of the machine. Set the ground
cable for the arc welding near the portion to be welded.
k When handling the hybrid components and high voltage wiring, see the inspection window in the
contactor box on the capacitor. the LED display indicating the charging state of the capacitor that it
shows "not yet charged state". Check that LED display function operates normally by the following
procedures before performing discharging the capacitor.
k 1. Both 2 LEDs are lit one minute after the engine is started.
k 2. Only one LED is lit after the starting switch is turned off. (Another LED goes out when the start-
ing switch is turned off.)
There may be a failure of LED display function in indicating the capacitor charging state, if the above checks are
not satisfied despite that the hybrid system error is not occurring. Replace the capacitor by referring to “PRE-
CAUTIONS FOR NORMAL CHECK AND MAINTENANCE (00-59)”

HB365LC-3 00-37
PRECAUTIONS TO PREVENT FIRE 00 INDEX AND FOREWORD

PRECAUTIONS TO PREVENT FIRE (ALL-K-11U0-17B-01-B)

Fire caused by fuel, oil, coolant or window washer fluid

Do not bring any open flame close to fuel, oil, coolant or win-
dow washer fluid. Always observe the following.
• Do not smoke or use any open flame near fuel or other
flammable substances.
• Shut down the engine before adding fuel.
• Do not leave the machine when adding fuel or oil.
• Tighten all the fuel and oil caps securely.
• Be careful not to spill fuel on overheated surfaces or on
,&
parts of the electrical system.
• After adding fuel or oil, wipe up any spilled fuel or oil.
• Put greasy rags and other flammable materials into a safe
container to maintain safety at the workplace.
• When washing parts with oil, use a non-flammable oil. Do
not use diesel oil or gasoline.There is danger that they
may catch fire.
• Do not weld or use a cutting torch to cut any pipes or tubes
that contain flammable liquids.
• Determine well-ventilated areas for storing oil and fuel. ,&
Keep the oil and fuel in the specified place and do not al-
low unauthorized persons to enter.
• When performing grinding or welding work on the machine, move any flammable materials to a safe place
before starting.
Fire caused by accumulation or attachment of flammable material
• Remove any dry leaves, chips, pieces of paper, coal dust, or any other flammable materials accumulated or
attached to or around the engine exhaust manifold, muffler, or battery, or on the undercovers.
• To prevent fires from being caught, remove any flammable materials such as dry leaves, chips, pieces of
paper, coal dust, or any other flammable materials accumulated around the cooling system (radiator, oil
cooler) or on the undercover.
Fire coming from electric wiring
Short circuits in the electrical system can cause fire. Always observe the following.
• Keep all the electric wiring connections clean and securely tightened.
• Check the wiring every day for looseness or damage. Reconnect any loose connectors or refasten wiring
clamps. Repair or replace any damaged wiring.
Fire caused by piping
Check that all the clamps for the hoses and tubes, guards, and cushions are securely fixed in position.
If they are loose, they may vibrate during operation and rub against other parts.There is danger that this may
lead to damage to the hoses and cause high-pressure oil to spurt out, leading to fire and serious personal injury
or death.
Fire around the machine due to highly heated exhaust gas
Some models and specifications may be equipped with KDPF (Komatsu Diesel Particulate Filter).
KDPF is a system for purifying exhaust gas by removing soot in exhaust gas. In the process of purification (re-
generation), the temperature of discharged exhaust gas may be higher than that of conventional models. Do not
bring any flammable materials close to exhaust pipe outlet.

00-38 HB365LC-3
00 INDEX AND FOREWORD PRECAUTIONS TO PREVENT FIRE

• When there are thatched houses, dry leaves or pieces of paper near the work site, set the system to disa-
ble the regeneration before starting work to prevent fire hazards due to highly heated exhaust gas caused
by KDPF regeneration.
See the Operation and Maintenance Manual for the setting procedure.
Explosion caused by lighting equipment
• When checking fuel, oil, battery electrolyte, or coolant, always use lighting equipment with anti-explosion
specifications.
• When taking the electrical power for the lighting equipment from the machine, follow the instructions in the
Operation and Maintenance Manual.

HB365LC-3 00-39
ACTIONS IF FIRE OCCURS 00 INDEX AND FOREWORD

ACTIONS IF FIRE OCCURS (ALL-K-11U0-17A-01-B)

• Turn the starting switch to OFF position to stop the engine.

• Use the handrails and steps to get off the machine.
• Do not jump off the machine. You may fall and suffer serious injury.
• The fumes generated by a fire contain harmful materials which have a bad influence on your body when
they are inhaled.
Do not breathe the fumes.
• After a fire, there may be harmful compounds left. If they touch your skin they may have a bad influence on
your body.
Be sure to wear rubber gloves when handling the materials left after the fire.
The material of the gloves, which is recommended is polychloroprene (Neoprene) or polyvinyl chloride (in
the lower temperature environment).
When wearing cotton work gloves, wear rubber gloves under them.

00-40 HB365LC-3
00 INDEX AND FOREWORD PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS

PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS (PC400_10-K-11U0-99A-00-B)

To prevent pollution, pay full attention to the way to dispose of waste materials.
• Always drain the oil from your machine in containers. Nev-
er drain the oil and coolant directly onto the ground or
dump into the sewage system, rivers, seas, or lakes.
• Obey appropriate laws and regulations when disposing of
harmful objects such as oil, fuel, coolant, solvent, filters,
batteries, and DEF.

Avoid exposure to burning rubber or plastics which produce a toxic gas that is harmful to people.
• When disposing of parts made of rubber or plastics (hoses, cables, and harnesses), always comply with the
local regulations for disposing industrial waste products.

HB365LC-3 00-41
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 00 INDEX AND FOREWORD

ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS (PC400_11-K-0000-01C-00-B)

This machine conforms to either regulation of Tier4 Final (North America) or Stage IV (Europe).
This machine is equipped with the following two exhaust gas treatment systems:
• Komatsu Diesel Particulate Filter (hereafter KDPF): A device which captures soot in the exhaust gas to pu-
rify exhaust gas. This process performs the combustion of soot referred to as "regeneration".
• Urea SCR system: A device which decomposes the toxic nitrogen oxides (NOx) mixed in the exhaust gas
into harmless nitrogen and water. Spraying aqueous urea solution into the exhaust gas produces a reaction
between the nitrogen oxides and ammonia generated from the urea solution and decomposes the nitrogen
oxides into nitrogen and water.
Either AdBlue® or DEF may be used as the aqueous urea solution for the SCR system.
AdBlue® is a registered trade-mark of VDA (Verband der Automobilindustrie e.V.: Automobile Association of
Germany).
DEF is the abbreviation for Diesel Exhaust Fluid.
Commercial DEF that is API approved and meets all the requirements defined in ISO 22241-1.
This solution will be represented as DEF throughout this manual.
About DEF
DEF is necessary for the urea SCR system. DEF is a colorless transparent 32.5% aqueous urea solution. Urea
as main constituent is a material which is used for cosmetics, medical and pharmaceutical products, and fertiliz-
er, etc.
If you add any additional additive agents or water to DEF and use it, the devices will not function properly, and
conformance to the exhaust gas regulations will be lost. In addition, it will cause failure of the machine.
• In Europe, use AdBlue®.
• In North America, use DEF (Diesel Exhaust Fluid) which is certified by API (American Petroleum Institute).
The certified DEF has the API DEF Certification Mark shown as follows. Look for the API DEF Certification
Mark when purchasing DEF.
API Diesel Exhaust Fluid Certification Mark is the trade
mark of API (American Petroleum Institute).

00-42 HB365LC-3
00 INDEX AND FOREWORD PRECAUTIONS FOR DEF

PRECAUTIONS FOR DEF (PC400_11-K-AFD0-012-00-B)

GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING (PC400_11-K-AFD0-10A-00-B)

DEF is a colourless transparent 32.5% aqueous urea solution. Urea as main constituent is a material which is
used for cosmetics, medical and pharmaceutical products, and fertilizer, etc. The following situations require im-
mediate action:
• If it gets on your skin, it may cause inflammation. Immediately take the contaminated clothes or shoes off
and wash it off with water. In addition, use a soap to wash it off thoroughly. If your skin becomes irritated or
begins to hurt, immediately consult a doctor for treatment.
• Do not induce vomiting if swallowed. If swallowed, thoroughly rinse mouth with water and consult a doctor
for treatment.
• Avoid contact with the eyes. If there is contact, flush with clean water for several minutes and consult a doc-
tor for treatment.
• Wear protective eyeglasses when exposed to DEF to protect from solution splashing in your eyes. Wear
rubber gloves when you perform work handling DEF to avoid skin contact.

PRECAUTIONS FOR ADDING (PC400_11-K-AFD0-21E-00-B)

Do not put fluid other than DEF into DEF tank. If diesel fuel or gasoline is added into the tank, it can cause a
fire. Some fluids or agents added can create and emit a toxic gas.
When opening the cap of DEF tank of the machine, the ammonia vapour may escape. Keep your face away
from the filler port during opening or refilling.

PRECAUTIONS FOR STORING (PC400_11-K-AFD0-876-02-B)

If the temperature of AdBlue/DEF becomes high, harmful ammonia gas may be generated. Completely seal up
its container for storage. When opening the container, perform it where there is good ventilation. For storage,
see “STORE AdBlue/DEF”.
Store AdBlue/DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do not
exchange the container of AdBlue/DEF with another one. If AdBlue/DEF is stored in an iron or aluminum con-
tainer, toxic gas may develop and a chemical reaction may corrode the container.

PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE (PC400_11-K-AFD0-17B-01-B)

AdBlue/DEF is non-flammable; however, in the case of a fire it may generate an ammonia gas. Act on the base
of “Actions if fire occurs”.
If AdBlue/DEF is spilled, immediately wipe and wash the area with water. If spilled AdBlue/DEF is left unattend-
ed and the area is not wiped and cleaned, toxic gas or corrosive substance may be produced by chemical reac-
tions.

THE OTHER PRECAUTIONS (PC400_11-K-AFD0-99A-01-B)

When disposing of AdBlue/DEF, treat it as an industrial waste. For the waste treating method, refer to “Precau-
tions for disposing of waste materials”. It should be treated in the same way.
Never use an iron or aluminum container when disposing AdBlue/DEF fluid, because toxic gas may develop and
a chemical reaction may corrode the container. Use a container made of resin (PP, PE) or stainless steel when
handling the fluid waste of AdBlue/DEF.
Do not touch any fluid discharged from urea SCR. This fluid becomes acid by the influence of sulphur in the fuel
or built-in oxidation catalyzer. If it gets on your skin, thoroughly wash it off with water.
Never relocate or modify the exhaust gas after-treatment device. The harmful gas may be exhausted and it can
cause serious damage to the environment as well as violation of laws.

HB365LC-3 00-43
STORE AdBlue/DEF 00 INDEX AND FOREWORD

STORE AdBlue/DEF (PC400_11-K-AFD0-876-03-B)

• If the temperature of AdBlue/DEF becomes high, harmful ammonia gas may be generated. Completely seal
up its container for storage. Only open containers in a well-ventilated area.
• Store AdBlue/DEF avoiding direct sunlight. Always use the original container at the time of purchase. Do
not exchange the container of AdBlue/DEF with another one. If AdBlue/DEF is stored in an iron or alumi-
num container, toxic gas may develop and a chemical reaction may corrode the container.
• AdBlue/DEF freezes at –11 °C. The recommended temperature for storage is -5 °C or above.
The relation between the upper limit of storage temperature and the storage period of AdBlue/DEF is
shown in the table.
Temperature of storage area Storage period
Max.10 °C Up to 36 months
Max.25 °C Up to 18 months
Max.30 °C Up to 12 months
Max.35 °C Up to 6 months

*: Do not store AdBlue/DEF in the temperature of 35 °C or above.

Handling AdBlue/DEF in cold weather
• AdBlue/DEF freezes at –11 °C.
AdBlue/DEF may freeze and expand to break the devices and parts in the tank. The parts inside the tank
may be affected. Add AdBlue/DEF to the specified amount for cold weather (below the level of when AdBl-
ue/DEF may freeze).
• In cold weather, keep AdBlue/DEF or the machine installed with AdBlue/DEF in the indoors where the tem-
perature is at –11 °C or higher to prevent AdBlue/DEF in the tank from freezing.
If AdBlue/DEF or the machine installed with AdBlue/DEF cannot be stored in the indoors where the temper-
ature is at –11 °C or higher (if they are left outdoors in cold weather), AdBlue/DEF in the tank may freeze.
Drain AdBlue/DEF to prevent it from freezing.

00-44 HB365LC-3
00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT (ALL-P-C000-2A4-00-B)

Because of the higher pressure and more precise hydraulic components, the most common cause of a failure is
dust (foreign material) in the hydraulic circuit. The special care must be taken when adding hydraulic oil, or
when disassembling, or assembling the hydraulic components.
Select an appropriate workplace
• In rain or high winds, or in dusty environment, avoid adding hydraulic oil, replacing filters, or repairing the
machine.
Disassembly and maintenance work in the field
k Any component may jump out or oil may spurt out by the remaining pressure in the hydraulic circuit
and it may result in serious personal injury or death when removing and disassembling of the hy-
draulic equipment is performed.
k Release the remaining pressure from the hydraulic circuit always before performing the work.

• In the field, there is a risk of dust entering the component

during disassembling or maintenance work, and perform-
ance check is hardly performed. Replacement of the as-
sembly is recommended.
• Perform disassembling and maintenance work in the dust
proof area.

Sealing of openings (prevention of flowing out of oil)

Plug the openings of the piping and the device which have been removed to prevent foreign material from enter-
ing and oil from flowing out.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter or leaked oil may pollute
the environment.
Do not discard the oil inconsiderately. Ask the customer for disposal or bring it back to dispose it ap-
propriately.
REMARK
Cover the places tightly with caps, tapes, or plastic bags if it is
hard to provide the plugs.

HB365LC-3 00-45
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 00 INDEX AND FOREWORD

Preventing intrusion of foreign materials during refilling

• During refilling with the hydraulic oil, do not let water enter
the electrical components.
• Clean the oil filler port and its around, refilling pump, oil
jug, or etc.
• Refilling by using an oil cleaning device is better method
since it can filtrate the contaminants accumulated in the oil
during storage.

Replacing hydraulic oil while its temperature is high

• The higher the oil temperature is, the softer the oil is, and the smoother the oil runs. Also, the sludges are
easily discharged from the circuit. Perform the replacement while oil temperature is high.
• Old hydraulic oil needs to be drained as much as possible when replacing.
NOTICE
Old hydraulic oil contaminates the new one if it is mixed since it contains contaminants and sludg-
es, and the service life of the hydraulic oil is shortened.
REMARK
Drain the old hydraulic oil not only from the hydraulic tank but also from the filter and drain plug in the cir-
cuit.
Avoid reusing the hydraulic oil and lubricating oil
Avoid reusing the hydraulic oil and lubricating oil which has been drained from the machine.
If reused, any foreign material may enter the hydraulic equipment, and it may cause a failure.
Flushing operation
• Flushing is required to completely dislodge the contami-
nants and sludges, and existing oil containing those inside
the hydraulic circuit after disassembling and assembling,
and when replacing the oil with the new one.
• Normally, flushing is performed twice. Primary flushing is
performed by using the flushing oil (1) and the secondary
flushing is performed by using the specified hydraulic oil.

Cleaning operation
Perform oil cleaning to remove the contaminants and sludges in the hydraulic circuit after repair of the hydraulic
device (pump, or control valve) or during operation of the machine.

00-46 HB365LC-3
00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT

REMARK
The oil cleaning equipment can remove the ultra fine (approxi-
mately 3 μm) particles that the filter built in the hydraulic equip-
ment cannot remove. So, it is very effective device.

HB365LC-3 00-47
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS

(ALL-A-1160-927-00-B)

When performing "testing and adjusting" of the machine, "removal and installation" and "disassembly and as-
sembly" of the components, observe the following precautions.
Precautions for removal and disassembling work
• If the cooling water contains coolant, dispose of it correctly as chemicals. Do not drain it to the sewage
rashly.
• After disconnecting the hoses or tubes, plug them to prevent dust from entering.
• When draining oil, prepare a container with sufficient capacity.
• Check the matchmarks which indicate the installing position, and put matchmarks on the places where they
seem necessary before removal of the components to prevent any mistake when assembling.
• To prevent any excessive force from being applied to the wiring, always hold the connectors when discon-
necting the connectors. Do not pull the wires.
• Attach the tags to wires and hoses so that installation is done to the correct installing positions.
• Check the thickness and number of shims when storing shims.
• When hoisting the components, prepare the slings with sufficient strength.
• When using forcing screws to remove any component, tighten the forcing screws uniformly and alternately.
• Before removing any component, clean the surrounding area and cover the component to prevent any for-
eign material from entering after removal.
• To disconnect the face seal type hose from the cylinder
tube, loosen the joint by gripping the two wrenches togeth-
er, one is the wrench (1) on the hose side, and another is
the wrench (2) on the cylinder tube reaction force point as
shown in the following figure. Use the grip strength on-
ly.Check after disconnecting the hose that the joint portion
of the cylinder and the cylinder tube is tightened to the
specified torque. Re-tighten it if the tightening torque is in-
sufficient.
NOTICE
Cylinder tube is rotated due to the load applied to the
reaction force point of the cylinder tube, and it is a
cause of weakening of the tightening torque. It may
lead to oil leakage.
• After disconnecting the piping or removing a pipe joint, install the following plugs.
NOTICE
When disassembling the machine, check the part number by referring to the Parts Book and use the
appropriate parts according to the usage conditions.
REMARK
The part numbers of O-ring shown in the table indicate the temporary part number when disassembling and
transporting the machine.

00-48 HB365LC-3
 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
00 INDEX AND FOREWORD INGS

Introduction of parts for the disassembly of the face seal type hoses and tubes

Hose side Pipe joint side

Nominal No. O-ring (3)
Plug (1) Nut (2)
02 07376-70210 02789-00210 02896-11008
03 07376-70315 02789-00315 02896-11009
04 07376-70422 02789-00422 02896-11012
05 07376-70522 02789-00522 02896-11015
06 07376-70628 02789-00628 02896-11018

Introduction of parts for the disconnection of the taper seal type hoses and
tubes

Hose side Pipe joint side

Nominal No.
Plug (1) Nut (2)
02 07376-50210 07222-00210
03 07376-50315 07222-00312
04 07376-50422 07222-00414
05 07376-50522 07222-00515
06 07376-50628 07222-00616
10 07376-51034 07222-01018
12 07376-51234 07222-01219
14 07376-51443 07222-01422

HB365LC-3 00-49
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD

Introduction of parts for the disconnection of the split flange type hoses and
tubes

Nomi Bolt pitch (mm) Hose side Tube side

nal Split flange Sleeve head O-ring (4) Bolt (5) Washer (6)
No. a b Flange (1)
(2) (3)
04 38.1 17.5 07379-00400 07371-30400 07378-10400 07000-12021 01010-80825 01643-50823
05 42.9 19.8 07379-00500 07371-30500 07378-10500 07000-13022 01010-80830 01643-50823
06 47.6 22.2 07379-00640 07371-30640 07378-10600 07000-13025 07372-51035 01643-51032
10 52.4 26.2 07379-01044 07371-31049 07378-11000 07000-13032 07372-51035 01643-51032
58.7 30.2 07379-01250 07371-31255 07378-11200 07000-13038 07372-51035 01643-51032
12
66.7 31.8 07379-01260 07371-51260 07378-11210 07000-13038 01010-81245 01643-51232
69.9 35.8 07379-01460 07371-31465 07378-11400 07000-13048 07372-51240 01643-51232
14
79.4 36.5 07379-01470 07371-51470 07378-11410 07000-13048 01010-81455 01643-31445
77.8 42.8 07379-02071 07371-32076 07378-12000 07000-12060 07372-51240 01643-51232
20
96.8 44.5 07379-02080 07371-52080 07378-12010 07000-12060 01010-81865 01643-31845
24 88.9 50.8 07379-02484 07371-12484 07378-12400 07000-12070 07372-51240 01643-51232
30 106.4 62 07379-03010 07371-13010 07378-13000 07000-12085 07372-51650 01643-51645
34 120.6 69.8 07379-03411 07371-13411 07378-13400 07000-12100 07372-51650 01643-51645
40 130.2 77.8 07379-04012 07371-14012 07378-14000 07000-12110 07372-51650 01643-51645
50 152.4 92 07379-05011 07371-15011 07378-15000 07000-12135 07372-51655 01643-51645

Introduction of parts for the removal of O-ring boss type joint

00-50 HB365LC-3
 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
00 INDEX AND FOREWORD INGS

Nominal No. Plug (1) O-ring (2)

08 07040-10807 07002-10823
10 07040-11007 07002-11023
12 07040-11209 07002-11223
14 07040-11409 07002-11423
16 07040-11612 07002-11623
18 07040-11812 07002-11823
20 07040-12012 07002-12034
24 07040-12412 07002-12434
30 07041-13012 07002-13034
33 07040-13316 07002-13334
36 07041-13612 07002-13634
42 07040-14220 07002-14234
52 07040-15223 07002-15234

Introduction of parts for the removal of taper pipe thread type joint

Nominal Plug (1)

Nominal No.
thread size Square head type (A) Hexagonal socket head (B)
01 R1/8 07042-00108 07043-00108

02 R1/4 07042-00211 07043-00211

03 R3/8 07042-00312 07043-00312

04 R1/2 07042-00415 07043-00415

06 R3/4 07042-00617 07043-00617

10 R1 07042-01019 07043-01019
12 R11/4 07042-01222 07043-01222

14 R11/2 07042-01422 07043-01422

20 R2 07042-02026 07043-02026

Precautions for installation and assembling work

• Tighten the bolts and nuts (sleeve nuts) to the specified torque (KES) unless otherwise specified.
• Install the hoses without twist and interference. If there is any in-between clamp, securely fasten it.

HB365LC-3 00-51
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD

• Replace all of the gaskets, O-rings, cotter pins, and lock plates with new ones.
• Bend the cotter pins and lock plates securely.
• When applying adhesive, clean and degrease the surface to apply, and apply 2 to 3 drops of adhesive to
the threaded portion.
• When applying liquid gasket, clean and degrease the surface, and apply it uniformly after making sure that
the surface is free from dust or damage.
• Clean all of the parts. If there is any damage, dents, burrs, or rust found on them, repair it.
• Apply engine oil to the rotating parts and sliding surface.
• Apply molybdenum disulfide lubricant (LM-P) to the surfaces of the press-fitting parts.
• After installing the snap ring, check that the snap ring is settled in the ring groove completely.
• When connecting wiring harness connectors, clean the connectors to remove oil, dust, or water, then con-
nect them securely.
• Use the eye bolts without fatigue and deformation and screw them in securely. Match the directions of the
eyes and the hook.
• When installing split flanges, tighten the bolts uniformly and alternately to prevent uneven tightening.
• As a rule, apply liquid gasket (LG-5) or liquid sealant (LS-2) to the threaded portion of each taper male
screws which receive pressure.
REMARK
If the threaded portion is difficult to degrease, you may use a seal tape.
When winding a seal tape onto a right-handed taper male screw, start winding the screw clockwise from the
third thread in the advancing direction of the threads seeing from the screw end.
NOTICE
If the seal tape is wound counterclockwise, it may become loose when screwed in, and it may come
off. If the sealed tip is pushed outside, it may cause oil leakage.
• To connect the face seal type hose to the cylinder tube,
tighten the joint by gripping the two wrenches together,
one is the wrench (1) on the hose side, and another is the
wrench (2) on the cylinder tube reaction force point at the
same time as shown in the following figure. Use the grip
strength only.Check after connecting the hose that the joint
portion of the cylinder and the cylinder tube is tightened to
the specified torque. Re-tighten it if the tightening torque is
insufficient.
NOTICE
Cylinder tube is rotated due to the load applied to the
reaction force point of the cylinder tube, and it is a
cause of weakening of the tightening torque. It may
lead to oil leakage.
NOTICE
When assembling the hydraulic equipment such as cylinders, pumps and pipings which are removed,
be sure to bleed air from the hydraulic circuit before operating it for the first time according to the fol-
lowing procedure.
1. Start the engine, and run it at low idle.
2. Perform the operation to extend and retract each cylinder of the work equipment and stop it at approximate-
ly 100 mm before the stroke end for 4 or 5 times.
3. Perform the operation to extend and retract each cylinder of the work equipment and stop it at the stroke
end for 3 or 4times.

00-52 HB365LC-3
 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
00 INDEX AND FOREWORD INGS

NOTICE
After repair is finished, when operating the machine which has been stored for a long period, bleed air
from the hydraulic circuit according to the same procedure.
Precautions at the time of completion of work
Refilling of coolant or water or oil, greasing, and adding of AdBlue/DEF
• For machines with urea SCR system, fill AdBlue/DEF to the specified level before starting the engine.
• Supply the specified amount of grease to the work equipment parts.
• When the coolant is drained, be sure that the drain valve is securely tightened, then refill the coolant reser-
voir with the coolant Komatsu recommends to the specified level. Start the engine to circulate the coolant in
the piping, and add the coolant to the specified level again.
• When the hydraulic components are removed and installed, refill the tank with the oil Komatsu recommends
to the specified level. Start the engine to circulate the oil in the piping, and add the oil to the specified level
again.
• If the hydraulic piping or hydraulic equipment is removed, be sure to bleed air from the system after rebuild-
ing the parts, by referring to TESTING AND ADJUSTING.
Testing installed condition of cylinder heads and manifolds
• Check the cylinder head and intake and exhaust manifold mountings for looseness.
• If there is any looseness, retighten the part.
REMARK
For the tightening torques, see "DISASSEMBLY AND ASSEMBLY".
Test engine piping for damage and looseness
Intake and exhaust system
Check that there is no damage on the pipings, or no looseness on mounting bolts, nuts and clamps, or no leak
of air or exhaust gas from connecting portion.
If there is any looseness, damage, or gas leak, retighten or repair the part.
Cooling system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no water
leak from connecting portion.
If there is any looseness, damage, or water leak, retighten or repair the part.
Fuel system
Check that there is no damage on the pipings, no looseness on mounting bolts, nuts and clamps, and no fuel
leak from connecting portion.
If there is any looseness, damage, or fuel leak, retighten or repair the part.
Check the exhaust equipment and its installation portion for looseness and damage.
REMARK
When an equipment is described as an exhaust equipment, it is one of the followings. (The applications or com-
ponents of equipment are different depending on its models or specifications.)
• KDPF
• AdBlue/DEF mixing tube
• SCR assembly
• KDOC muffler
• Muffler
• Exhaust pipe
• Parts which connects the above, or etc.
Visually check that there is no crack or no damage on the exhaust equipment and its installation portion. If there
is any damage, replace the part.

HB365LC-3 00-53
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIP-
INGS 00 INDEX AND FOREWORD

Check that there is no looseness on the exhaust equipment and mounting bolts, nuts, and clamps on the instal-
lation portion.
If there is any looseness, retighten the part.
Check of function of muffler in exhaust system
REMARK
When an equipment is described as an muffler in exhaust system, it is one of the followings. (The applications
or components of equipment are different depending on its models or specifications.)
• KDPF
• AdBlue/DEF mixing tube
• SCR assembly
• KDOC muffler
• Muffler
• Exhaust pipe
• Parts which connects the above, or etc.
Check that there is no unusual noise by comparing to it of the time when the machine was new.
If there is any unusual noise, repair KDPF or muffler, referring to "TROUBLESHOOTING" and "DISASSEMBLY
AND ASSEMBLY".

00-54 HB365LC-3
00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT

PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT (ALL-P-E000-2A4-00-B)

To maintain the performance of the machine over a long period, and to prevent failures or troubles before they
occur, correct "operation", "maintenance and inspection" "troubleshooting", and "repairs" must be performed.
This section deals particularly with correct repair procedures for mechatronics components and is aimed at im-
proving the quality of repairs. For this purpose, it describes the working procedures in "Handling of electrical
equipment".
Handling wiring harnesses and connectors
• Wiring harnesses consist of wires connecting one compo-
nent to another component, connectors used for connect-
ing and disconnecting one wire from another wire, and pro-
tectors or tubes used for protecting the wires.
• Compared with other electrical components fitted in boxes
or cases, wiring harnesses are likely to be directly affected
by rain water, heat, or vibration. Furthermore, during in-
spection and repair operations, they are frequently re-
moved and installed again, so they are likely to suffer de-
formation or damage. For this reason, it is necessary to be
extremely careful when handling and maintenance of the
wiring harnesses.
• If AdBlue/DEF is spilled over wiring harness and connectors, it may cause corrosion and defective contact.
Be careful not to spill it over electrical equipment, wiring harness and connectors since AdBlue/DEF is
strongly corrosive to metal.
Main causes of failure in wiring harness
Defective contact of connectors (defective contact between male and female connectors)
Problems with defective contact are likely to occur because the
male connector is not properly inserted into the female connec-
tor,or because one or both of connectors are deformed or the
position is not correctly aligned, or because there is corrosion
or oxidization of the contact surfaces. The corroded or oxidized
contact surfaces may become shiny again (and contact may
become normal) by connecting and disconnecting the connec-
tors approximately 10 times.

Defective crimping or soldering of connectors

The pins of the male and female connectors are attached to
wires by crimping or soldering. If excessive force is applied to
the wire, the jointed portion (1) may become loose, and it may
result in a defective connection or breakage.

HB365LC-3 00-55
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 00 INDEX AND FOREWORD

Disconnection in wiring
If the wiring harness is pulled to disconnect the connector, or
the components are lifted with a crane while the wiring harness
is still connected, or a heavy object hits the wiring harness, it
may separate the crimping of the connector, or damage the sol-
dering, or break the wiring harness.

Water entering the connector by high-pressure jetting

The connector is designed to make it difficult for water to enter
(drip-proof structure), but if high-pressure water is sprayed di-
rectly on the connector, water may enter the connector, de-
pending on the direction of the water jet.
Do not spray water directly on the connector.
If the connector is waterproof, intruded water is hardly drained.
Once water enters into the connector, water goes through pins
to cause short-circuit. Drying the drenched connector or take
appropriate actions before providing electricity.
Entry of water, dirt, or dust when disconnecting a con-
nector
If any water, mud or dust is stuck to the outside surface of a connector, it can enter inside the connector when
the connector is disconnected. Before disconnecting the connector, wipe off any stuck water or dirt by using a
dry cloth or blow it with compressed air.
Oil, mud, or dust stuck to connector
If any oil or grease is stuck to the connector and an oil film is
formed on the mating surface of the male and female pins, the
oil prevents electricity from passing through resulting in defec-
tive contact. If any oil, grease, dirt or dust is stuck to the con-
nector, wipe it off with a dry cloth or blow it with compressed air,
and wash it with electrical contact restorer.
NOTICE
• When wiping the jointed portion of the connector, do
not apply excessive force or deform the pins.
• If there is oil or water in the compressed air, it causes
the contacts to become dirtier. Use clean air which any
oil and water has been removed from.

00-56 HB365LC-3
00 INDEX AND FOREWORD PRECAUTIONS FOR MAINTENANCE OF HYBRID SYSTEM

PRECAUTIONS FOR MAINTENANCE OF HYBRID SYSTEM (HB335_3-K-PQG9-012-05-B)

Provide the following items for handling the hybrid components and high voltage wirings.
• Insulated gloves (rubber gloves)
• Safety shoes (insulated type)
• Protective eyeglasses
• ABC fire extinguisher
• Packing tape (for insulation)
• Waste cloths

HB365LC-3 00-57
PRECAUTIONS AGAINST HIGH VOLTAGE AND HIGH TEMPERA-
TURE 00 INDEX AND FOREWORD

PRECAUTIONS AGAINST HIGH VOLTAGE AND HIGH TEMPERATURE

(HB335_3-K-PQJE-012-00-B)

k This machine uses high voltage system. Temperature in

some portions become very high. Serious personal in-
jury such as electric shock or burn injury or death may
occur if the machine is used in wrong way. Hybrid com-
ponents and high voltage wiring in orange color have
precaution labels. They describe the precautions for
handling. Observe the instructions described on the la-
bels for the proper handling.
k Never disassemble the hybrid components and high
voltage wiring (with conduit wiring in orange color).

00-58 HB365LC-3
00 INDEX AND FOREWORD PRECAUTIONS FOR NORMAL CHECK AND MAINTENANCE

PRECAUTIONS FOR NORMAL CHECK AND MAINTENANCE (HB335_3-K-PQG9-012-01-B)

Never disassemble the hybrid components (motor-generator, electric swing motor, capacitor, and inverter) and
high voltage wiring (conduit wiring).
Removal procedure for hybrid components and high voltage wiring or check
procedure for connecting terminal
Follow the procedure described below for hybrid components to be checked, removed, or restored.
1. Park the machine indoor so that the removed parts of the hybrid components and terminals of the high volt-
age wiring are not exposed to the rain and dust.
2. Discharge the capacitor by referring to “Diagnostic Tests menu (Capacitor Discharge)” in 30 "TESTING
AND ADJUSTING".
3. Turn the starting switch to OFF position for starting the check and maintenance.
4. Wear a pair of insulated gloves (rubber gloves), protective eyeglasses, safety shoes (insulated type).
5. See the inspection window in the contactor box on the capacitor. Check the LED display indicating the
charging state of the capacitor that it shows "not yet charged state". Disconnect the one-touch connector of
the capacitor.
If it does not show "not yet charged state", leave it as it is until the LED display goes out (it can be left for 14
days maximum as a guide). Stick the indication of “Discharging capacitor” written on the packing tape, etc.
to the capacitor body.
6. Check that each hybrid component is surely grounded to the machine.
Check that the case of the hybrid component has continuity to the machine frame. If it is not grounded to
the machine body, fix the ground cable securely when performing the item 1. at restoration.
7. Remove the terminal mounting bolts of each high voltage wiring, and disconnect the connectors.
8. Measure the voltage between each terminal and case of the hybrid components.
1) The hybrid component can be removed when the voltage between each terminal and case is 50 V or
less (safe voltage). Do not touch the terminal portion and the case at the same time.
2) If the voltage described above is not 50 V or less, check again that it is 50 V or less after waiting a
while. (The voltage is zero when the inverter is normal.)
9. Cure the connector inserting portion on each hybrid component by insulating with packing tape, etc.
10. Cure the connector terminal portion by insulating. Wind the terminal with vinyl, etc., and cover it with pack-
ing tape, etc.
11. Remove the hybrid component.
Restoration procedure for hybrid components and high voltage wiring
1. Install the hybrid component.
2. Wipe the mounting face of each hybrid component, and insert the connector all the way.
3.
3 Mounting bolt:
Fix the connector terminal securely with the KOMATSU specified mounting bolt.

11.8 to 14.7 Nm {1.2 to 1.5 kgm}

4. Connect the one-touch connectors of the capacitor.

HB365LC-3 00-59
PRECAUTIONS FOR THE MACHINE NOT TO BE TIPPED OVER AND
FOR HYBRID COMPONENTS NOT TO BE DAMAGED 00 INDEX AND FOREWORD

PRECAUTIONS FOR THE MACHINE NOT TO BE TIPPED OVER AND FOR

HYBRID COMPONENTS NOT TO BE DAMAGED (HB335_3-K-PQG9-012-02-B)

k If you carelessly touch the hybrid components or high voltage wiring (conduit wiring in orange col-
or), it may lead a serious injury or death when the machine is tipped over, or the hybrid components
or high voltage wiring are damaged by the accident such as a tipping over.
Observe the following and take extreme care for performing the work safe.
• Stop the engine always when performing maintenance so that the hybrid component does not suffer from
the high voltage stress.
• Extinguish the fire with “ABC fire extinguisher” (which is effective to burning of oil and electrical fires) if the
fire breaks out.
If you use water to extinguish the fire, use a large amount of water from the fire hydrant otherwise an at-
tempt to extinguish the fire with a small amount of water is dangerous.
• Wear a pair of insulated gloves (rubber gloves), protective eyeglasses, safety shoes (insulated type).
• Raise this machine by using another machine, and move the machine to the safe place.
• Do not touch the bare cables. It can cause serious injury or death by electric shock if it is a high voltage
wiring. Wear a pair of insulated gloves if you are touching it out of necessary or there is a risk of touching it
in the work. Check that the voltage at the body ground cable is 50 V or less (safe voltage) by measuring it
with a tester. Wind the portion with the packing tape to insulate it.
• Disconnect the one-touch connector of the capacitor.
• Discharge the electric charge from the capacitor by using the discharger for the capacitor.
• See the inspection window in the contactor box on the capacitor. Check the LED display indicating the
charging state of the capacitor that it shows "not yet charged state".
If it does not show "not yet charged state", leave it as it is until the LED display goes out (it can be left for 14
days maximum as a guide). Stick the indication of “Discharging capacitor” written on the packing tape, etc.
to the capacitor body.
• Perform the work such as check, maintenance, and removal of the hybrid component by referring to the
items 6. and after that are described in the “PRECAUTIONS FOR NORMAL CHECK AND MAINTE-
NANCE”.
Take extreme care not to directly touch the cell if the capacitor case is damaged.

00-60 HB365LC-3
00 INDEX AND FOREWORD PRECAUTIONS FOR THE MACHINE NOT TO BE SUBMERGED

PRECAUTIONS FOR THE MACHINE NOT TO BE SUBMERGED

(HB335_3-K-PQG9-012-03-B)

k If the hybrid component is submerged, it may cause a malfunction or failure, and safety operation
cannot be performed. Serious personal injury or death by electric shock may occur if a person touch
the machine carelessly.
Observe the following and take extreme care for performing the work safe.
• Wear a pair of insulated gloves (rubber gloves), protective eyeglasses, safety shoes (insulated type).
• Stop the engine always when performing maintenance so that the hybrid component does not suffer from
the high voltage stress.
• Raise the submerged machine by using another machine.
• Disconnect the one-touch connector of the capacitor.
• Discharge the electric charge from the capacitor by using the discharger for the capacitor.
• See the inspection window on the capacitor. Check the LED display indicating the charging state of the ca-
pacitor that it shows "not yet charged state".
If it does not show "not yet charged state", leave it as it is until the LED display goes out (it can be left for 14
days maximum as a guide). Stick the indication of “Discharging is in progress” written on the packing tape,
etc. to the capacitor body.
• Perform the work such as check, maintenance, and removal of the hybrid component by referring to the
items 6. and after that are described in the “PRECAUTIONS FOR NORMAL CHECK AND MAINTE-
NANCE”.

HB365LC-3 00-61
PRECAUTIONS FOR THE COLD SEASON 00 INDEX AND FOREWORD

PRECAUTIONS FOR THE COLD SEASON (HB335_3-K-PQG9-012-04-B)

• The swing operation is performed the same in the cold season as the other seasons. The work equipment
operation and travel operation are performed slower in cold season than other seasons, and unexpected
movement may occur. Perform the sufficient warming up operation, otherwise the machine may hit an ob-
stacle.
• Operate the work equipment and travel the machine with extreme care if sufficient warming up operation
cannot be performed out of necessity. Keep in mind that the work equipment operation and travel operation
are performed slower in cold season than other seasons, and unexpected movement may occur.

00-62 HB365LC-3
00 INDEX AND FOREWORD PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT

PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT (ALL-K-AD00-2A4-00-B)

The machines equipped with common rail fuel injection system (CRI) consists of more precise parts than the
parts used in the conventional fuel injection pump and nozzle. If foreign material enters this system, it may
cause a failure. Use special care to prevent entry of the foreign material when servicing the fuel system.
Select an appropriate workplace
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in
dusty environment.
Sealing the opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to
prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign
material may enter or leaked oil may pollute the environ-
ment.
Do not discard the oil inconsiderately. Ask the customer
for disposal or bring it back to dispose it appropriately.

How to clean parts when dirt is stuck

If any dirt or dust sticks the parts of the fuel system, clean it off thoroughly with clean fuel.
Precautions for replacing fuel filter cartridge
Be sure to use the Komatsu genuine fuel filter cartridge.
NOTICE
The machine equipped with common rail fuel injection system (CRI) consists of more precise parts than
the parts used in the conventional fuel injection pump and nozzle. In order to prevent foreign material
from entering this system, the filter employs a specially high performance of filter element. If a filter oth-
er than a Komatsu genuine filter is used, fuel system contamination and damage may occur. Therefore
Komatsu recommends using only Komatsu fuel filters and install them following the procedures in the
shop manual.

HB365LC-3 00-63
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 00 INDEX AND FOREWORD

PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT (ALL-K-A900-2A4-01-B)

The machines equipped with Variable Geometry Turbocharger (VGT) consists of more precise parts (variable
system)than the parts used in the conventional turbocharger. If foreign material enters this system, it may cause
a failure. Use special care to prevent entry of the foreign material when servicing the intake system.
Select an appropriate workplace
Avoid the work of adding hydraulic oil, replacing filters, or repairing the machine in rainy or windy weather, or in
dusty environment.
Sealing the opening
Plug the removed pipes and the openings of the removed components with the caps, tapes, plastic bags, etc. to
prevent foreign material from entering.
NOTICE
Do not expose the openings or stuff it, otherwise foreign material may enter it.

00-64 HB365LC-3
00 INDEX AND FOREWORD PRACTICAL USE OF KOMTRAX

PRACTICAL USE OF KOMTRAX (ALL-K-Q210-13V-00-B)

Various information which KOMTRAX system transmits by using the radio communication is useful for KOM-
TRAX operator to provide various services for the customers.
When KOMTRAX system is installed to the machine and it is enabled, machine information can be checked by
KOMTRAX system, and it is used for testing and troubleshooting to be performed efficiently.
Large-sized models are equipped with KOMTRAX Plus which can use more detailed information.
REMARK
(KOMTRAX may not be installed to the machine in some countries or areas.)
Merit of using KOMTRAX
• The location where the machine is working at can be checked on the map in a personal computer.
• Operation information such as service meter, operating hours, fuel consumption, and occurred caution as
well as failure code can be checked.
• The operator can check the hours used and replacement interval of consumable parts of the machine such
as fuel filter, hydraulic oil filter, hydraulic oil and engine oil.
• Information of how machine is operated (idling time, traveling time, digging time, relieving time, etc.) can be
checked, and it is used to presume the machine operating condition.
• Various reports such as “Fuel saving operation support”, “Operation summary”, etc. is generated, and it is
utilized as an advice tool for the user and operator.
• KOMTRAX Plus can record the data of abnormality record, trend data, snap shot data, etc. to grasp the
soundness of machine, in addition to KOMTRAX function described above. These data can be used on per-
sonal computer screens.
How to make a full use of KOMTRAX
Making use of KOMTRAX enables the following activities.
• Quick response to a request for immediate repair
1. To check the displayed caution and failure code, etc. through KOMTRAX upon receiving a repair re-
quest from a user.
2. To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the
displayed failure code.
3. To find the location of the failed machine by using the map of KOMTRAX, to visit the customer there.
• Proactive maintenance
1. To check the service summary screen of KOMTRAX, to find the machine which has high priority failure
code indicated by a red or yellow flag.
2. To check the condition of the machine with the customer and to make a plan to visit.
3. To immediately arrange necessary tools, replacement parts, etc, immediately in accordance with the
displayed failure code.
• Practice of periodic maintenance and periodic inspection service
1. To check the service summary screen of KOMTRAX, and to find the machine of which the usage limits
for the consumable parts indicated by red flags are over.
2. To submit an estimate sheet for the consumable parts to be replaced and the labor cost for the replace-
ment work to the customer.
3. To propose the periodic inspection (Pm clinic, etc.) according to the service meter reading.
How to operate KOMTRAX
For the operating method of each screen of KOMTRAX, ask KOMTRAX key person in your Komatsu distributor.

HB365LC-3 00-65
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD

DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER (ALL-P-C930-927-00-B)

REMARK
• Loosen the oil filler cap of the hydraulic tank slowly to release the remaining pressure in the hydraulic tank.
• Provide an oil container to receive oil since some hydraulic oil flows out when the hose is disconnected even
after the remaining pressure is released from the hydraulic tank.

METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE

COUPLER (ALL-P-C930-925-00-B)

Disconnection
1. Hold adapter (1), and push hose joint (2) into mating
adapter (3).
REMARK
• Push it in approximately 3.5 mm.
• Do not hold rubber cap portion (4).

2. While having adapter (3) inserted into hose side joint (2),
insert rubber cap (4) to adapter (3) side until it clicks.

3. Hold hose adapter (1) or hose (5), and pull it out.

REMARK
Provide an oil container to receive a quantity of hydraulic
oil which may flow out.

Connection
1. Hold hose adapter (1) or hose (5), and insert it in mating
adapter (3), aligning the axis.
REMARK
Do not hold rubber cap portion (4).

00-66 HB365LC-3
00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

2. After inserting the hose in the mating adapter perfectly, pull

it back to check the connecting condition.
REMARK
When the hose fitting is pulled back, the rubber cap moves
approximately 3.5 mm toward the hose, but it is not a prob-
lem.

METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE

COUPLER (ALL-P-C930-925-10-B)

Disconnection
1. Hold the tightening adapter part and push body (2) straight
until sliding prevention ring (1) contacts contact surface (a)
of the hexagonal part at the male end.

2. While keeping the condition of step 1, turn lever (3) to the

right (clockwise).

3. While keeping the conditions of steps 1 and 2, pull out

whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil
which may flow out.

HB365LC-3 00-67
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 00 INDEX AND FOREWORD

Connection
Hold the tightening adapter part, and push body (2) straight un-
til sliding prevention ring (1) contacts contact surface (a) of the
hexagonal part at the male end.

METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE

COUPLER (ALL-P-C930-925-20-B)

Disconnection
1. Hold the tightening adapter part and push body (2) straight
until sliding prevention ring (1) contacts contact surface (a)
of the hexagonal part at the male end.

2. While keeping the condition of step 1, push cover (3)

straight until it contacts contact surface (a) of the hexago-
nal portion on the male side.

3. While keeping the conditions of steps 1 and 2, pull out

whole body (2) to disconnect it.
REMARK
Provide an container to receive a quantity of hydraulic oil
which may flow out.

00-68 HB365LC-3
00 INDEX AND FOREWORD DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER

Connection
Hold the tightening adapter part, and push body (2) straight un-
til sliding prevention ring (1) contacts contact surface (a) of the
hexagonal part at the male end.

HB365LC-3 00-69
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
NECTORS 00 INDEX AND FOREWORD

PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNEC-

TORS (ALL-A-1160-001-00-B)

Disconnecting connectors
1. Hold the connectors when disconnecting.
When disconnecting the connectors, always hold the con-
necting portion. If the connector is fixed with screw, loosen
the screw of the connector completely, hold the both of
male and female connectors, and pull them out in parallel.
NOTICE
Do not pull the connectors with one hand.
REMARK
If it is a lock stopper type connector, pull it out as pushing
the stopper (1) with your thumb.
2. When removing a connector from a clip
• Both of the connector and clip have stoppers (2),
which are engaged with each other when the connec-
tor is connected.
• When removing a connector from a clip, pull the con-
nector in parallel with the clip as removing stoppers.
NOTICE
If the connector is pried up and down or to the
right or left, it may break the housing.

3. Action to be taken after removing connectors

After removing the connector, cover it with plastic bags to
prevent entry of dust, dirt, oil, or water in the contact por-
tion.
NOTICE
Be sure to cover the connector with plastic bags when
leaving the machine disassembled for a long time, oth-
erwise defective contact may occur.

Connecting connectors
1. Check the connector visually.
• Check that there is no dust, dirt, oil, or water stuck to the connector pins (joint portion).

00-70 HB365LC-3
 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
00 INDEX AND FOREWORD NECTORS

• Check that there is no deformation, defective contact, corrosion, or damage on the connector pins.
• Check that there is no damage or crack on the external surfaces of the connectors.
NOTICE
• If there is any dust, dirt, oil, or water stuck to the connector, wipe it off with a dry cloth. If there is
any water intrusion into the connector, warm the inside of the connector and harness with a dry-
er. Do not overheat the connector, otherwise short circuit may occur.
• If there is any damage or breakage, replace the connector.
2. Connecting the connector securely
Position connector (1) correctly, and fit it in securely.
REMARK
If the connector is lock stopper type, insert it until it clicks.
3. Correct the protrusion of the boot and misalignment of the
wiring harness.

• If the connector is with the boot, correct any extrusion of the boot. In addition, if the wiring harness is
misaligned or the clamp is out of position, adjust it to its correct position.
REMARK
If the protrusion of the boot and misalignment of the
wiring harness cannot be fixed, remove the clamp to
adjust them.

• If the connector clamp is removed, be sure to return it

to its original position. Check that there is no loose-
ness.

Drying wiring harness

REMARK
If the wiring harness is dirty with oil and dust, wipe it off with a dry cloth. Avoid water washing or steam washing.
If water washing is unavoidable, do not use high-pressure water or steam directly on the wiring harness. If water
gets directly on the connector, do as follows.

HB365LC-3 00-71
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
NECTORS 00 INDEX AND FOREWORD

1. Disconnect the connector and wipe off the water with a dry
cloth.
NOTICE
If the connector is to be blown with dry compressed
air, there is the risk that oil in the air may cause defec-
tive contact, remove oil and water in the air before
starting air blow.

2. Dry the inside of the connector with a dryer.

If water enters inside the connector, use a dryer to dry the
connector.
NOTICE
Hot air from a dryer can be used, but limit the time of
using a dryer to prevent the connector or related parts
from becoming too hot, as this will cause deformation
or damage to the connector.

3. Perform a continuity test on the connector.

After drying, leave the wiring harness disconnected, con-
nect T-adapter(1), and perform a continuity test to check
for any short circuits between pins caused by water or etc.
REMARK
After the connector is completely dried, blow the contact
restorer, and reassemble them.

Handling controller
k When performing arc welding on the machine body, disconnect all of the wiring harness connectors
connected to the controller. Fit an arc welding ground close to the welding point.

00-72 HB365LC-3
 PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CON-
00 INDEX AND FOREWORD NECTORS

NOTICE
• Controller has been assembled with electronic circuits
for control including microcomputers. These electronic
circuits inside of the controller must be handled with
care since they control the machine.
• Do not leave things on the controller.
• Cover the connector portion of the controller with a
tape and a plastic bag. Do not touch the connecting
portion of connector.
• Do not leave the controller in a place where it is ex-
posed to rain.
• Do not place the controller on oil, water, soil or any pla-
ces where the temperature is likely to be high even for
a short period of time (Place it on a suitable dry stand).

Precautions for troubleshooting electrical circuits

• Be sure to turn the starting switch to OFF position before disconnecting or connecting the connectors.
• Before performing troubleshooting, check all the related connectors for loose connection.
REMARK
Check the related connectors for their performance by disconnecting and connecting them several times.
• Be sure to connect all the disconnected connectors before proceeding to the next step.
NOTICE
If the starting switch is turned to ON position while the connectors are disconnected, an unrelated
failure beside the actual failed part may be displayed.
• When performing the troubleshooting for the circuit (measurement of voltage, resistance,continuity, current,
etc.), shake the related wiring harnesses and connectors several times and check that the multimeter read-
ing does not change.
NOTICE
If the value changes on the multimeter, there may be a defective contact in the circuit.

HB365LC-3 00-73
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH
CONNECTOR 00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNEC-

TOR (ALL-A-1160-925-00-B)

Method for disconnecting Deutsch connector

While pressing locks (a) and (b) from each side respectively,
pull out female connector (2).

Method for connecting Deutsch connector

1. Push in female connector (2) horizontally, and insert it
straight until it clicks. (Arrow: x)
2. In order to check whether locks (a) and (b) are completely
inserted, insert female connector (2) by rocking it vertically
(in the arrow z direction). (Arrow: x, y, z)
REMARK
Lock (a) in the figure is pulled down (not set completely),
and lock (b) is set completely.

00-74 HB365LC-3
 METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK
00 INDEX AND FOREWORD TYPE CONNECTOR

METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE

CONNECTOR (ALL-A-1160-925-10-B)

Method for disconnecting slide lock type connector (FRAMATOME-3, FRAMA-

TOME-2)
1. Slide lock (L1) to the right.
2. While pressing lock (L2), pull out connector (1) toward you.
REMARK
If portion A does not float when lock (L2) is pressed, and if
connector (1) does not come out when it is pulled toward
you, push up portion A with a small flat-head screwdriver
while pressing lock (L2), and then pull out connector (1) to-
ward you.

Method for connecting slide lock type connector (FRAMATOME-3, FRAMA-

TOME-2)
Insert it straight until it clicks.

Method for disconnecting slide lock type connector (FRAMATOME-24)

1. Slide down lock (red) (L1).

HB365LC-3 00-75
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK
TYPE CONNECTOR 00 INDEX AND FOREWORD

2. While pressing lock (L2), pull out connector (1).

REMARK
Lock (L2) is located behind connector (1) in the figure.

Method for connecting slide lock type connector (FRAMATOME-24)

Insert it straight until it clicks.

00-76 HB365LC-3
 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
00 INDEX AND FOREWORD WITH LOCK TO PULL

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH

LOCK TO PULL (ALL-A-1160-925-20-B)

Method for disconnecting connector with lock to pull

Disconnect the connector (2) by pulling lock (B) (on the wiring
harness side) of connector (2) outward.

Method for connecting connector with lock to pull

Insert the connector securely until it "clicks".

HB365LC-3 00-77
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
WITH LOCK TO PUSH 00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH

LOCK TO PUSH (ALL-A-1160-925-30-B)

Method for disconnecting connector with lock to push (BOSCH-3)

While pressing lock (C), pull out connector (3) in the direction of the arrow.
• 114 series

• 107 series

REMARK
If the lock is located on the underside, use flat-head screwdriver [1] since you cannot insert your fingers.
While pushing up lock (C) of the connector with flat-head
screwdriver [1], pull out connector (3) in the direction of the ar-
row.

Method for connecting connector with lock to push (BOSCH-3)

Insert it straight until it clicks.

00-78 HB365LC-3
 METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
00 INDEX AND FOREWORD WITH LOCK TO PUSH

Method for disconnecting connector with lock to push (AMP-3)

While pressing lock (E), pull out connector (5) in the direction of
the arrow.

Method for connecting connector with lock to push (AMP-3)

Insert it straight until it clicks.

Method for disconnecting connector with lock to push (SUMITOMO-3)

While pressing lock (E), pull out connector (5) in the direction of
the arrow.
REMARK
Pull up the connector straight.

Method for connecting connector with lock to push (SUMITOMO-3)

Insert it straight until it clicks.

Method for disconnecting connector with lock to push (SUMITOMO-4)

While pressing lock (D), pull out connector (4) in the direction
of the arrow.

Method for connecting connector with lock to push (SUMITOMO-4)

Insert it straight until it clicks.

HB365LC-3 00-79
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR
WITH HOUSING TO ROTATE 00 INDEX AND FOREWORD

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH

HOUSING TO ROTATE (ALL-A-1160-925-40-B)

Method for disconnecting connector with housing to rotate

Turn housing (H1) to the left, and pull it out.
REMARK
Housing (H1) is left on the wiring harness side.

Method for connecting connector with housing to rotate

1. Insert the connector to the end while aligning its groove to the other.
2. Turn housing (H1) clockwise until it clicks.

00-80 HB365LC-3
00 INDEX AND FOREWORD HOW TO READ THE CODES (SYMBOLS) FOR ELECTRIC CABLE

HOW TO READ THE CODES (SYMBOLS) FOR ELECTRIC CABLE

(HB335_3-P-E500-030-00-B)

The following is the description for the particular electric cable code for the hybrid machines.
In the electrical circuit diagram, the material, thickness, and color of each electric cable are indicated by sym-
bols. The electric cable code is helpful in understanding the electrical circuit diagram.
Example) AEX 0.85 L: Indicates heat-resistant, low-voltage electric cable for automobile, in blue color, having
nominal No. of 0.85.
Indicates a type of electric cable by symbol.
Type, symbol, and material of electric cable are shown in (Table 2).
AEX
(Since the use of AV, AVS, AVSS, and CAVS wires depends on size (nominal No.), the symbols are
not indicated on the diagram.)
Indicates a size of electric cable by nominal No.
0.85
Size (nominal number) corresponds to the (Table 4), (Table 5), and (Table 6).
Indicates color of electric cable by color code.
L
Color code corresponds to (Table 7).

Type, symbol, and material

AV, AVS, and AVSS are different in only thickness and outside diameter of the coating. AEX is similar to AV in
thickness and outside diameter of the coating but different from AV, AVS, and AVSS in material of the coating.
CAVS has a circular compressed conductor. It differs from AV, AVS, and AVSS in the appearance. Coating ma-
terial of AESSX is the same as AEX, but conductor structure, coating thickness, and outside diameter of the
coating are different.
(Table 1)

HB365LC-3 00-81
HOW TO READ THE CODES (SYMBOLS) FOR ELECTRIC CABLE 00 INDEX AND FOREWORD

Temperature
Sym- Conductor ma-
Type Insulator material range (°C) in Example of use
bol terial
use
Low-voltage
electric cable For large current wiring
for automobile AV
(nominal No. 5 and above)
(General)
Low-voltage
electric cable
General wiring
for automobile AVS
-30 to +60 (Nominal number 0.5f to 3)
(Thin coating
1)
Low-voltage
electric cable Soft polyvinyl chloride For mid- to small-size excava-
for automobile CAVS tors
(Thin coating (nominal No. 0.5 to 1.25)
2)
Extremely thin Annealed cop-
coated low per wire for
voltage elec- electric appli- For industrial vehicle (lift-truck)
tric cable for AVSS ance -40 to +80
automobile (Nominal No.0.5f to 2f)
(Thin coating
2)
Low-voltage
electric cable General wiring for extremely
for automobile cold weather specification
AEX
(Heat resist- Wiring at high-temperature
ant 2. gener- place
al) Heat-resistant cross-
-50 to +110
Low-voltage linked polyethylene
electric cable
Very cold area, heat resistant
for automobile AESS
specification
(Heat resist- X
Wiring for thin coating
ant, extremely
thin coated)

(Table 2)
Temperature
Sym- Conductor ma-
Type Insulator material range (°C) in Example of use
bol terial
use
Annealed copper wire
Conductor
for electric appliance

Metal coated Insulator Soft polyvinyl chloride

shield electric AVSS Wiring for general signals
Draining Tinned annealed braided -30 to +60
cable for au- CS (Nominal No. 0.5, 2 core)
Wire copper wire
tomobile
Shield Aluminum foil
Sheath Soft polyvinyl chloride

00-82 HB365LC-3
00 INDEX AND FOREWORD HOW TO READ THE CODES (SYMBOLS) FOR ELECTRIC CABLE

Temperature
Sym- Conductor ma-
Type Insulator material range (°C) in Example of use
bol terial
use
Annealed copper wire
Conductor
for electric appliance

Heat-resistant Thin coated electrostatic Wiring for signals at a place

Insulator
low-voltage PEXB capacity cross link where the ambient temperature
-50 to +120 is high
electric cable S Braided tinned annealed
for automobile Shield (Nominal No. 0.5, 3 core)
copper wire
Heat-resistant cross-
Sheath
linked polyethylene
Annealed copper wire
Conductor
for electric appliance
Braided shield Insulator Soft polyvinyl chloride Wiring for general signals
CAVS
electric cable -30 to +60
BS Braided tinned annealed (Nominal No. 0.5, 3 core)
for automobile Shield
copper wire
Sheath Soft polyvinyl chloride

Dimensions

(Table 3)
Nominal No. 0.5f (0.5) 0.75f (0.85) 1.25f (1.25) 2f 2 3f 3 5
Number of
element 20 7 30 11 50 16 37 26 58 41 65
wire
Diameter of
element 0.18 0.32 0.18 0.32 0.18 0.32 0.26 0.32 0.26 0.32 0.32
Conductor wire
Cross-sec-
tional area 0.51 0.56 0.76 0.88 1.27 1.29 1.96 2.09 3.08 3.30 5.23
( mm2
d (approxi-
1.0 1.2 1.5 1.9 1.9 2.3 2.4 3.0
mately)
AVS Standard 2.0 2.2 2.5 2.9 2.9 3.5 3.6 -
Coating D

AV Standard - - - - - - - 4.6
AEX Standard 2.0 2.2 2.7 3.0 3.1 - 3.8 4.6
AVSS Standard - - - 2.7 2.7 - - -

HB365LC-3 00-83
HOW TO READ THE CODES (SYMBOLS) FOR ELECTRIC CABLE 00 INDEX AND FOREWORD

Nominal No. 8 15 20 30 40 50 60 85 100

Number of
element 50 84 41 70 85 108 127 169 217
wire
Diameter of
element 0.45 0.45 0.80 0.80 0.80 0.80 0.80 0.80 0.80
Conductor wire
Cross-sec-
tional area 7.95 13.36 20.61 35.19 42.73 54.29 63.84 84.96 109.1
( mm2
d (approxi-
3.7 4.8 6.0 8.0 8.6 9.8 10.4 12.0 13.6
mately)
AVS Standard - - - - - - - - -
Coating D

AV Standard 5.5 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AEX Standard 5.3 7.0 8.2 10.8 11.4 13.0 13.6 16.0 17.6
AVSS Standard - - - - - - - - -

(Table 4)
Nominal No. 0.5f 0.5 0.75f 0.85 1.25f 1.25
Number of
element - 7 - 11 - 16
wire
Diameter of
Round compres- Round compres- Round compres-
element - - -
sion sion sion
Conductor wire
Cross-sec-
tional area - 0.56 - 0.88 - 1.29
( mm2)
d (approxi-
- 0.9 - 1.1 - 1.4
mately)
Coating D

CAVS Standard - 1.6 - 1.8 - 2.1

AVSSCS
(Table 5)
Nominal No. 0.5f
Number of cores 2
Structure of the conductor (piece/ mm) 19/0.19
Conductor with lead core Cross-sectional area ( mm2) 0.54
Outside diameter( mm) 1.6
Structure of the conductor (piece/ mm) 20/0.18
Drain wire
Cross-sectional area ( mm2) 0.51
Aluminum foil thickness ( mm) 0.03
Sheath thickness ( mm) 0.5
finished dimension( of outside diameter mm) 4.3

00-84 HB365LC-3
00 INDEX AND FOREWORD HOW TO READ THE CODES (SYMBOLS) FOR ELECTRIC CABLE

PEXBS
(Table 6)
Nominal No. 0.5f
Number of cores 3
Structure of the conductor (piece/ mm) 20/0.18
Conductor with lead core Cross-sectional area ( mm2) 0.51
Outside diameter( mm) 2.0
Diameter of element wire ( mm) 0.12
Number of single wires, number of braid-
Braided shield 5/16
ed wires (piece)
Density ( %) Min. 824 (70)
Sheath thickness ( mm) 0.5
finished dimension( of outside diameter mm) 5.9

REMARK
“f” of nominal No. denotes "flexible".
Color codes table
(Table 7)
Color cord Color of electric cable Color cord Color of electric cable
B Black LgW Light green and White
Br Brown LgY Light green and Yellow
BrB Brown and Black LR Blue and Red
BrR Brown and Red LW Blue and White
BrW Brown and White LY Blue and Yellow
BrY Brown and Yellow O Orange
Ch Charcoal P Pink
Dg Dark green R Red
G Green RB Red and Black
GB Green and Black RG Red and Green
GL Green and Blue RL Red and Blue
Gr Gray RW Red and White
GR Green and Red RY Red and Yellow
GW Green and White Sb Sky Blue
GY Green and Yellow Y Yellow
L Blue YB Yellow and Black
LB Blue and Black YG Yellow and Green
Lg Light green YL Yellow and Blue
LgB Light green and Black YR Yellow and Red
LgR Light green and Red YW Yellow and White

HB365LC-3 00-85
HOW TO READ THE CODES (SYMBOLS) FOR ELECTRIC CABLE 00 INDEX AND FOREWORD

REMARK
In a color code consisting of 2 colors, the first color is the color of the background of the electric cable and the
second color is the color of the marking.
Example) GW indicates that the background is "Green" and marking is "White".
Types of circuits and color codes
Type of electric cable AVS, AV, CAVS AEX
Charge R WG - - - - R -
Ground B - - - - - B -
Start R - - - - - R -
Light RW RB RY RG RL - O -
Instrument Y YR YB YG YL YW Y Gr
Signal G GW GR GY GB GL G Br
L LW LR LY LB - L -
Type of circuit Br BrW BrR BrY BrB - - -
Lg LgR LgY LgB LgW - - -
O - - - - - - -
Others Gr - - - - - - -
P - - - - - - -
Sb - - - - - - -
Dg - - - - - - -
Ch - - - - - - -

00-86 HB365LC-3
00 INDEX AND FOREWORD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

EXPLANATION OF TERMS FOR MAINTENANCE STANDARD (ALL-A-0330-006-00-B)

The maintenance standard section shows the judgment criteria whether the equipment or parts should be re-
placed or can be reused when the machine is disassembled for the maintenance. The following terms are the
descriptions of the judgment criteria.
Standard dimension and tolerance
• The finished dimension of a part is slightly different from one to another actually.
• A standard dimension of a finished part is set, and an allowable difference from that dimension is set for the
part.
• The dimension set as the standard is called the standard dimension and the allowable range of difference
from this standard dimension is called "tolerance".
• An indication example of a standard dimension and tolerance is shown in the following table.
(The standard dimension is entered on the left side and the tolerance is entered with a positive or negative
symbol on the right side)
Example:
Standard dimension Tolerance
-0.022
120
-0.126

• The tolerance may be indicated in the text and a table as "standard dimension (upper limit of tolerance/
lower limit of tolerance)."
Example) 120 (-0.022/ -0.126)
• Usually, the dimension of a hole and the dimension of the shaft to be inserted into that hole are indicated by
the same standard dimension and different tolerances of the hole and shaft. The tightness of fit is deter-
mined by the tolerance.
• A dimension indication example of a shaft and hole is shown in the following table.
(The standard dimension is entered on the left side and the tolerance of the shaft is entered with a positive
or negative symbol at the center and that of the hole on the right side)
Tolerance
Standard dimension
Shaft Hole
-0.030 +0.046
60
-0.076 0

HB365LC-3 00-87
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 00 INDEX AND FOREWORD

Standard clearance and standard value

• The clearance made when new parts are assembled is
called the standard clearance, which is indicated by the
range from the minimum clearance to the maximum clear-
ance.
• When some parts are repaired, the clearance is generally
adjusted to the standard clearance.
• The values indicating performance and function of new
products or equivalent are called "standard value", which is
indicated by a range or a target value.
• When some parts are repaired, the value of performance/
function is set to the standard value.

Standard interference
• When the diameter of a hole of a part shown in the given standard dimension and tolerance table is smaller
than that of the shaft to be inserted, the difference between those diameters is called "interference".
• Subtract the maximum dimension of the hole from the minimum dimension of the shaft and call it (A). Sub-
tract the minimum dimension of the hole from the maximum dimension of the shaft and call it (B). The range
between (A) and (B) is "standard interference".
• After repairing or replacing some parts, measure the dimension of their hole and shaft and check that the
interference is in the standard range.
Repair limit and allowable value or allowable dimension
• The dimension of parts changes due to the wear or deformation while they are used. When the dimension
changes exceeding certain value, parts cannot be used any longer. This value is called "repair limit".
• If a part is worn to the repair limit, it must be replaced or repaired.
• The performance and function of products lower while they are used. A value with which the product can be
used without causing a problem is called "allowable value" or "allowable dimension".
• A product whose dimension is out of the allowable value, must be repaired. However, since the allowable
values are generally estimated through various tests or experiences in most cases, the judgment must be
made in consideration of the operating condition and customer's requirement.
Allowable clearance
• Parts can be used until the clearance between them is increased to a certain limit. The limit at which those
parts cannot be used is called "allowable clearance".
• If the clearance between the parts exceeds the allowable clearance, they must be replaced or repaired.
Allowable interference
• The allowable maximum interference between the hole of a part and the shaft of another part to be assem-
bled is called "allowable interference".
• The allowable interference shows the repair limit of the part of smaller tolerance.

00-88 HB365LC-3
00 INDEX AND FOREWORD EXPLANATION OF TERMS FOR MAINTENANCE STANDARD

• The parts whose interferences are out of the allowable interference must be replaced or repaired.

HB365LC-3 00-89
STANDARD TIGHTENING TORQUE TABLE 00 INDEX AND FOREWORD

STANDARD TIGHTENING TORQUE TABLE (ALL-P-M140-03B-00-B)

Table of tightening torque for bolts and nuts

REMARK
Tighten the metric nuts and bolts to the torque shown in the table below unless otherwise specified.

Thread diameter Width across flats

Tightening torque ( Nm { kgm} )
( mm) ( mm)
10
6 11.8 to 14.7 {1.2 to 1.5}
(*2) 10
13
8 27 to 34 {2.8 to 3.5}
(*2) 12
17
10 59 to 74 {6 to 7.5}
(*1, *2) 14
19
12 98 to 123 {10 to 12.5}
(*1, *2) 17
14 22 153 to 190 {15.5 to 19.5}
24
16 235 to 285 {23.5 to 29.5}
(*1) 22
18 27 320 to 400 {33 to 41}
20 30 455 to 565 {46.5 to 58}
22 32 610 to 765 {62.5 to 78}
24 36 785 to 980 {80 to 100}
27 41 1150 to 1440 {118 to 147}
30 46 1520 to 1910 {155 to 195}
33 50 1960 to 2450 {200 to 250}
36 55 2450 to 3040 {250 to 310}
39 60 2890 to 3630 {295 to 370}

*1: Split flange bolt

*2: Flanged bolt
REMARK
Tighten the flanged bolt marked with “7” on the head as shown in the following to the tightening torque shown in
the table below.

00-90 HB365LC-3
00 INDEX AND FOREWORD STANDARD TIGHTENING TORQUE TABLE

Thread diameter Width across flats

Tightening torque ( Nm { kgm} )
( mm) ( mm)
6 10 5.9 to 9.8 {0.6 to 1.0}
8 12 13.7 to 23.5 {1.4 to 2.4}
10 14 34.3 to 46.1 {3.5 to 4.7}
12 17 74.5 to 90.2 {7.6 to 9.2}

REMARK
Tighten the unified coarse threaded bolts and nuts to the torque shown in the table below unless otherwise
specified.

Type of bolt A B

Nominal size - Tightening torque ( Nm { kgm} ) Tightening torque ( Nm { kgm} )

threads per inch Range Target Range Target
1/ 9.8 to 14.7 {1 to 1.5} 12.7 {1.3} 2.9 to 3.9 {0.3 to 0.4} 3.43 {0.35}
4-20UNC

5/ -18UNC 24.5 to 34.3 {2.5 to 3.5} 29.4 {3} 6.9 to 8.8 {0.7 to 0.9} 7.8 {0.8}
16

3/ 44.1 to 58.8 {4.5 to 6} 52.0 {5.3} 9.8 to 14.7 {1 to 1.5} 11.8 {1.2}
8-16UNC

7/ 73.5 to 98.1 {7.5 to 10} 86.3 {8.8} 19.6 to 24.5 {2 to 2.5} 21.6 {2.2}
16-14UNC

1/ 108 to 147 {11 to 15} 127 {13} 29.4 to 39.2 {3 to 4} 34.3 {3.5}
2-13UNC

9/ 157 to 216 {16 to 22} 186 {19} 44.1 to 58.8 {4.5 to 6} 51.0 {5.2}
16-12UNC

5/ -11UNC 226 to 294 {23 to 30} 265 {27} 63.7 to 83.4 {6.5 to 8.5} 68.6 {7}
8

3/ -10UNC 392 to 530 {40 to 54} 461 {47} 108 to 147 {11 to 15} 127 {13}
4

7/ 637 to 853 {65 to 87} 745 {76} 177 to 235 {18 to 24} 206 {21}
8-9UNC

HB365LC-3 00-91
STANDARD TIGHTENING TORQUE TABLE 00 INDEX AND FOREWORD

Type of bolt A B

Nominal size - Tightening torque ( Nm { kgm} ) Tightening torque ( Nm { kgm} )

threads per inch Range Target Range Target
1-8UNC 883 to 1196 {90 to 122} 1040 {106} 245 to 333 {25 to 34} 284 {29}

11/8-7UNC 1187 to 1608 {121 to 164} 1393 {142} 333 to 451 {34 to 46} 392 {40}

11/4-7UNC 1598 to 2157 {163 to 220} 1873 {191} 451 to 608 {46 to 62} 530 {54}

11/2-6UNC 2354 to 3177 {240 to 324} 2765 {282} 657 to 892 {67 to 91} 775 {79}

REMARK
Tighten the unified fine threaded bolts and nuts to the torque shown in the table below unless otherwise speci-
fied.

Type of bolt A B

Nominal size - Tightening torque ( Nm { kgm} ) Tightening torque ( Nm { kgm} )

threads per inch Range Target Range Target
1/ 14.7 to 19.6 {1.5 to 2} 17.7 {1.8} 3.9 to 4.9 {0.4 to 0.5} 4.41 {0.45}
4-28UNF

5/ 34.3 to 39.2 {3.5 to 4} 34.3 {3.5} 7.8 to 9.8 {0.8 to 1} 8.8 {0.9}
16-24UNF

3/ 53.9 to 68.6 {5.5 to 7} 61.8 {6.3} 14.7 to 19.6 {1.5 to 2} 16.7 {1.7}
8-24UNF

7/ 83.4 to 108 {8.5 to 11} 96.1 {9.8} 24.5 to 29.4 {2.5 to 3} 26.5 {2.7}
16-20UNF

1/ 127 to 167 {13 to 17} 147 {15} 34.3 to 49.0 {3.5 to 5} 41.2 {4.2}
2-20UNF

9/ -18UNF 186 to 245 {19 to 25} 216 {22} 49.0 to 68.6 {5 to 7} 58.8 {6}
16

5/ 255 to 343 {26 to 35} 294 {30} 73.5 to 98.1 {7.5 to 10} 83.4 {8.5}
8-18UNF

3/ 441 to 598 {45 to 61} 520 {53} 127 to 167 {13 to 17} 147 {15}
4-16UNF

7/ 716 to 961 {73 to 98} 843 {86} 196 to 265 {20 to 27} 226 {23}
8-14UNF

1-14UNF 1020 to 1373 {104 to 140} 1196 {122} 284 to 382 {29 to 39} 333 {34}

11/8-12UNF 1353 to 1844 {138 to 188} 1598 {163} 382 to 520 {39 to 53} 451 {46}

11/4-12UNF 1804 to 2432 {184 to 248} 2118 {216} 510 to 686 {52 to 70} 598 {61}

11/2-12UNF 2707 to 3658 {276 to 373} 3177 {324} 765 to 1030 {78 to 105} 892 {91}

00-92 HB365LC-3
00 INDEX AND FOREWORD STANDARD TIGHTENING TORQUE TABLE

Table of tightening torque for O-ring boss piping joints

REMARK
Tighten the pipe joint for O-ring boss to the torque shown in the table below unless otherwise specified.

Thread di- Tightening torque ( Nm { kgm} )

Width across
Nominal No. ameter
flats ( mm) Range Target
( mm)
02 14 35 to 63 {3.5 to 6.5} 44 {4.5}
- 18 59 to 98 {6.0 to 10.0} 78 {8.0}
Varies de-
03, 04 20 pending on 84 to 132 {8.5 to 13.5} 103 {10.5}
05, 06 24 type of con- 128 to 186 {13.0 to 19.0} 157 {16.0}
nector.
10, 12 33 363 to 480 {37.0 to 49.0} 422 {43.0}
14 42 746 to 1010 {76.0 to 103} 883 {90.0}

Table of tightening torque for O-ring boss plugs

REMARK
Tighten the plug for O-ring boss to the torque shown in the table below unless otherwise specified.

Thread diam- Width across Tightening torque ( Nm { kgm} )

Nominal No.
eter ( mm) flats ( mm) Range Target
08 8 14 5.88 to 8.82 {0.6 to 0.9} 7.35 {0.75}
10 10 17 9.8 to 12.74 {1.0 to 1.3} 11.27 {1.15}
12 12 19 14.7 to 19.6 {1.5 to 2.0} 17.64 {1.8}
14 14 22 19.6 to 24.5 {2.0 to 2.5} 22.54 {2.3}
16 16 24 24.5 to 34.3 {2.5 to 3.5} 29.4 {3.0}

HB365LC-3 00-93
STANDARD TIGHTENING TORQUE TABLE 00 INDEX AND FOREWORD

Thread diam- Width across Tightening torque ( Nm { kgm} )

Nominal No.
eter ( mm) flats ( mm) Range Target
18 18 27 34.3 to 44.1 {3.5 to 4.5} 39.2 {4.0}
20 20 30 44.1 to 53.9 {4.5 to 5.5} 49.0 {5.0}
24 24 32 58.8 to 78.4 {6.0 to 8.0} 68.6 {7.0}
30 30 32 93.1 to 122.5 {9.5 to 12.5} 107.8 {11.0}
33 33 - 107.8 to 147.0 {11.0 to 15.0} 127.4 {13.0}
36 36 36 127.4 to 176.4 {13.0 to 18.0} 151.9 {15.5}
42 42 - 181.3 to 240.1 {18.5 to 24.5} 210.7 {21.5}
52 52 - 274.4 to 367.5 {28.0 to 37.5} 323.4 {33.0}

Table of tightening torque for hose (taper seal type and face seal type)
REMARK
• Tighten the hose fittings (taper seal type and face seal type) to the torque shown in the following table un-
less otherwise specified.
• The table is applied to the threaded portion coated with engine oil (wet threaded portion).

Width Tightening torque ( Nm { kgm} ) Taper seal Face seal

Nominal
across Nominal size - Thread root
No. of Thread size
flats Range Target threads per diameter( mm)
hose ( mm)
( mm) inch (reference)
34 to 54 {3.5 to 5.5} 44 {4.5} - 9/ 14.3
16-18UN
02 19
34 to 63 {3.5 to 6.5} 44 {4.5} 14 - -
22 54 to 93 {5.5 to 9.5} 74 {7.5} - 11/ 17.5
16-16UN
03
24 59 to 98 {6.0 to 10.0} 78 {8.0} 18 - -
04 27 84 to 132 {8.5 to 13.5} 103 {10.5} 22 13/ -16UN 20.6
16

05 32 128 to 186 {13.0 to 19.0} 157 {16.0} 24 1 -14UNS 25.4

06 36 177 to 245 {18.0 to 25.0} 216 {22.0} 30 13/16-12UN 30.2
(10) 41 177 to 245 {18.0 to 25.0} 216 {22.0} 33 - -
(12) 46 197 to 294 {20.0 to 30.0} 245 {25.0} 36 - -
(14) 55 246 to 343 {25.0 to 35.0} 294 {30.0} 42 - -

00-94 HB365LC-3
00 INDEX AND FOREWORD STANDARD TIGHTENING TORQUE TABLE

Table of tightening torque for face seal joints

REMARK
• The tightening torque table below applies to the seal joint (sleeve nut type) made with steel pipe for plated
low pressure piping which is used for engine.
• The table is applied to the threaded portion coated with engine oil (wet threaded portion).
• Reference: The face seal joint of the dimension in ( ) is also used depending on the specification.

Outside di- Tightening torque ( Nm { kgm} ) Face seal

Width
ameter of Thread root diam-
across flats Nominal size -
adequate Range Target eter( mm) (refer-
( mm) threads per inch
pipe ( mm) ence)
8 19 14 to 16 {1.4 to 1.6} 15 {1.5} 9/ 14.3
16-18UN

10 22 24 to 27 {2.4 to 2.7} 25.5 {2.6} 11/ -16UN 17.5

16

12 24 (27) 43 to 47 {4.4 to 4.8} 45 {4.6} 13/ -16UN 20.6

16

15 (16) 30 (32) 60 to 68 {6.1 to 6.8} 64 {6.5} 1 -14UNS 25.4

22 (20) 36 90 to 95 {9.2 to 9.7} 92.5 {9.4} 13/16-12UN 30.2

Tightening torque table for bolts and nuts on 102, 107 and 114 series engines
REMARK
Tighten the metric threads bolts and nuts used on the 102, 107 and 114 series engines to the torques shown in
the following table unless otherwise specified.
Thread diameter ( mm) Tightening torque ( Nm { kgm} )
6 10±2 {1.02±0.20}
8 24±4 {2.45±0.41}
10 43±6 {4.38±0.61}
12 77±12 {7.85±1.22}
14 -

Tightening torque table for 102, 107, and 114 series engines (joint bolts)
REMARK
Tighten the metric joint bolts used on the 102, 107, and 114 series engines to the torque shown in the following
table unless otherwise specified.

HB365LC-3 00-95
STANDARD TIGHTENING TORQUE TABLE 00 INDEX AND FOREWORD

Thread diameter ( mm) Tightening torque ( Nm { kgm} )

6 8±2 {0.81±0.20}
8 10±2 {1.02±0.20}
10 12±2 {1.22±0.20}
12 24±4 {2.45±0.41}
14 36±5 {3.67±0.51}

Tightening torque table for tapered screws on 102, 107, and 114 series engines
(National taper pipe thread (NPT))
REMARK
Tighten the National taper pipe threaded (NPT) screws used on the 102, 107, and 114 series engines to the
torques shown in the following table unless otherwise specified.
Material of female screw In cast iron or steel In aluminum
Nominal thread size Tightening torque ( Nm { kgm} ) Tightening torque ( Nm { kgm} )
1/ 15±2 {1.53±0.20} 5±1 {0.51±0.10}
16

1/ 20±2 {2.04±0.20} 15±2 {1.53±0.20}

8

1/ 25±3 {2.55±0.31} 20±2 {2.04±0.20}

4

3/ 35±4 {3.57±0.41} 25±3 {2.55±0.31}

8

1/ 55±6 {5.61±0.61} 35±4 {3.57±0.41}

2

3/ 75±8 {7.65±0.82} 45±5 {4.59±0.51}

4

00-96 HB365LC-3
00 INDEX AND FOREWORD CONVERSION TABLE

CONVERSION TABLE (ALL-A-2150-931-00-B)

Method of using the conversion table

The conversion table is provided to enable simple conversion of the numerical numbers between the different
units. For further details of the method of using the conversion table, see the examples given below.
Examples of using the conversion table to convert a unit from mm to in.
When converting 55 mm to in
1. Locate the number 50 in the leftmost column, take this as (A), and then draw a horizontal line from (A).
2. Locate the number 5 in the top row, take this as (B), then draw a vertical line down from (B).
3. Take the crossover point of the two lines as (C). This point (C) gives the value when converting the unit
from mm to in. Accordingly, 55 mm = 2.165 in.
When converting 550 mm to in
1. The number 550 does not appear in the table. Divide it by 10 (move the decimal point one place to the left)
to get 55 mm.
2. Convert 55 mm to 2.165 in according to the preceding procedure.
3. The original value (550 mm) has been divided by 10, so multiply 2.165 in by 10 (move the decimal point
one place to the right) to restore the target value. This gives 550 mm = 21.65 in
mm to in
(B)
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
(C)
50 1.969 2.008 2.017 2.087 2.126 2.165 2.205 2.244 2.283 2.323
(A)
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.780 3.819 3.858 3.898

mm to in
1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
0 0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354
10 0.394 0.433 0.472 0.512 0.551 0.591 0.630 0.669 0.709 0.748
20 0.787 0.827 0.866 0.906 0.945 0.984 1.024 1.063 1.102 1.142
30 1.181 1.220 1.260 1.299 1.339 1.378 1.417 1.457 1.496 1.536
40 1.575 1.614 1.654 1.693 1.732 1.772 1.811 1.850 1.890 1.929
50 1.969 2.008 2.047 2.087 2.126 2.165 2.205 2.244 2.283 2.323

HB365LC-3 00-97
CONVERSION TABLE 00 INDEX AND FOREWORD

1 mm = 0.03937 in
0 1 2 3 4 5 6 7 8 9
60 2.362 2.402 2.441 2.480 2.520 2.559 2.598 2.638 2.677 2.717
70 2.756 2.795 2.835 2.847 2.913 2.953 2.992 3.032 3.071 3.110
80 3.150 3.189 3.228 3.268 3.307 3.346 3.386 3.425 3.465 3.504
90 3.543 3.583 3.622 3.661 3.701 3.740 3.780 3.819 3.858 3.898

kg to lb
1 kg = 2.2046 lb
0 1 2 3 4 5 6 7 8 9
0 0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84
10 22.05 24.25 26.46 28.66 30.86 33.07 35.27 37.48 39.68 41.89
20 44.09 46.30 48.50 50.71 51.91 55.12 57.32 59.53 61.73 63.93
30 66.14 68.34 70.55 72.75 74.96 77.16 79.37 81.57 83.78 85.98
40 88.18 90.39 92.59 94.80 97.00 99.21 101.41 103.62 105.82 108.03
50 110.23 112.44 114.64 116.85 119.05 121.25 123.46 125.66 127.87 130.07
60 132.28 134.48 136.69 138.89 141.10 143.30 145.51 147.71 149.91 152.12
70 154.32 156.53 158.73 160.94 163.14 165.35 167.55 169.76 171.96 174.17
80 176.37 178.57 180.78 182.98 185.19 187.39 189.60 191.80 194.01 196.21
90 198.42 200.62 202.83 205.03 207.24 209.44 211.64 213.85 216.05 218.26

ℓ to U.S.Gal
1 ℓ = 0.2642 U.S.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378
10 2.642 2.906 3.170 3.434 3.698 3.963 4.227 4.491 4.755 5.019
20 5.283 5.548 5.812 6.076 6.340 6.604 6.869 7.133 7.397 7.661
30 7.925 8.189 8.454 8.718 8.982 9.246 9.510 9.774 10.039 10.303
40 10.567 10.831 11.095 11.359 11.624 11.888 12.152 12.416 12.680 12.944
50 13.209 13.473 13.737 14.001 14.265 14.529 14.795 15.058 15.322 15.586
60 15.850 16.115 16.379 16.643 16.907 17.171 17.435 17.700 17.964 18.228
70 18.492 18.756 19.020 19.285 19.549 19.813 20.077 20.341 20.605 20.870
80 21.134 21.398 21.662 21.926 22.190 22.455 22.719 22.983 23.247 23.511
90 23.775 24.040 24.304 24.568 24.832 25.096 25.361 25.625 25.889 26.153

ℓ to U.K.Gal
1 ℓ = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980
10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379

00-98 HB365LC-3
00 INDEX AND FOREWORD CONVERSION TABLE

1 ℓ = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
30 6.599 6.819 7.039 7.259 7.479 7.699 7.919 8.139 8.359 8.579
40 8.799 9.019 9.239 9.459 9.679 9.899 10.119 10.339 10.559 10.778
50 10.998 11.281 11.438 11.658 11.878 12.098 12.318 12.528 12.758 12.978
60 13.198 13.418 13.638 13.858 14.078 14.298 14.518 14.738 14.958 15.178
70 15.398 15.618 15.838 16.058 16.278 16.498 16.718 16.938 17.158 17.378
80 17.598 17.818 18.037 18.257 18.477 18.697 18.917 19.137 19.357 19.577
90 19.797 20.017 20.237 20.457 20.677 20.897 21.117 21.337 21.557 21.777

kgm to lbft
1 kgm = 7.233 lbft
0 1 2 3 4 5 6 7 8 9
0 0 7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1
10 72.3 79.6 86.8 94.0 101.3 108.5 115.7 123.0 130.2 137.4
20 144.7 151.9 159.1 166.4 173.6 180.8 188.1 195.3 202.5 209.8
30 217.0 224.2 231.5 238.7 245.9 253.2 260.4 267.6 274.9 282.1
40 289.3 296.6 303.8 311.0 318.3 325.5 332.7 340.0 347.2 354.4
50 361.7 368.9 376.1 383.4 390.6 397.8 405.1 412.3 419.5 426.8
60 434.0 441.2 448.5 455.7 462.9 470.2 477.4 484.6 491.8 499.1
70 506.3 513.5 520.8 528.0 535.2 542.5 549.7 556.9 564.2 571.4
80 578.6 585.9 593.1 600.3 607.6 614.8 622.0 629.3 636.5 643.7
90 651.0 658.2 665.4 672.7 679.9 687.1 694.4 701.6 708.8 716.1
100 723.3 730.5 737.8 745.0 752.2 759.5 766.7 773.9 781.2 788.4
110 795.6 802.9 810.1 817.3 824.6 831.8 839.0 846.3 853.5 860.7
120 868.0 875.2 882.4 889.7 896.9 904.1 911.4 918.6 925.8 933.1
130 940.3 947.5 954.8 962.0 969.2 976.5 983.7 990.9 998.2 1005.4
140 1012.6 1019.9 1027.1 1034.3 1041.5 1048.8 1056.0 1063.2 1070.5 1077.7
150 1084.9 1092.2 1099.4 1106.6 1113.9 1121.1 1128.3 1135.6 1142.8 1150.0
160 1157.3 1164.5 1171.7 1179.0 1186.2 1193.4 1200.7 1207.9 1215.1 1222.4
170 1129.6 1236.8 1244.1 1251.3 1258.5 1265.8 1273.0 1280.1 1287.5 1294.7
180 1301.9 1309.2 1316.4 1323.6 1330.9 1338.1 1345.3 1352.6 1359.8 1367.0
190 1374.3 1381.5 1388.7 1396.0 1403.2 1410.4 1417.7 1424.9 1432.1 1439.4

kg/cm2 to lb/in2
1 kg/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
0 0 14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0
10 142.2 156.5 170.7 184.9 199.1 213.4 227.6 241.8 256.0 270.2
20 284.5 298.7 312.9 327.1 341.4 355.6 369.8 384.0 398.3 412.5
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7

HB365LC-3 00-99
CONVERSION TABLE 00 INDEX AND FOREWORD

1 kg/cm2 = 14.2233 lb/in2

0 1 2 3 4 5 6 7 8 9
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542

Temperature
Conversion of Fahrenheit to Celsius
• A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice versa
is to see the number in the center column of the following table. The figures in the center of the following
table show the temperatures in both Fahrenheit and Celsius.
• When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Celsius temperature in the column at the left.
• When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius
values, and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8 °F
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
-27.8 -18 -0.4 -8.3 17 62.6 11.1 52 125.6 30.6 87 188.6

00-100 HB365LC-3
00 INDEX AND FOREWORD CONVERSION TABLE

1 °C = 33.8 °F
°C °F °C °F °C °F °C °F
-27.2 -17 1.4 -7.8 18 64.4 11.7 53 127.4 31.1 88 190.4
-26.7 -16 3.2 -7.2 19 66.2 12.2 54 129.2 31.7 89 192.2
-26.1 -15 5.0 -6.7 20 68.0 12.8 55 131.0 32.2 90 194.0
-25.6 -14 6.8 -6.1 21 69.8 13.3 56 132.8 32.8 91 195.8
-25.0 -13 8.6 -5.6 22 71.6 13.9 57 134.6 33.3 92 197.6
-24.4 -12 10.4 -5.0 23 73.4 14.4 58 136.4 33.9 93 199.4
-23.9 -11 12.2 -4.4 24 75.2 15.0 59 138.2 34.4 94 201.2
-23.3 -10 14.0 -3.9 25 77.0 15.6 60 140.0 35.0 95 203.0
-22.8 -9 15.8 -3.3 26 78.8 16.1 61 141.8 35.6 96 204.8
-22.2 -8 17.6 -2.8 27 80.6 16.7 62 143.6 36.1 97 206.6
-21.7 -7 19.4 -2.2 28 82.4 17.2 63 145.4 36.7 98 208.4
-21.1 -6 21.2 -1.7 29 84.2 17.8 64 147.2 37.2 99 210.2
-20.6 -5 23.0 -1.1 30 86.0 18.3 65 149.0 37.8 100 212.0
-20.0 -4 24.8 -0.6 31 87.8 18.9 66 150.8 40.6 105 221.0
-19.4 -3 26.6 0 32 89.6 19.4 67 152.6 43.3 110 230.0
-18.9 -2 28.4 0.6 33 91.4 20.0 68 154.4 46.1 115 239.0
-18.3 -1 30.2 1.1 34 93.2 20.6 69 156.2 48.9 120 248.0
-17.8 0 32.0 1.7 35 95.0 21.1 70 158.0 51.7 125 257.0
-17.2 1 33.8 2.2 36 96.8 21.7 71 159.8 54.4 130 266.0
-16.7 2 35.6 2.8 37 98.6 22.2 72 161.6 57.2 135 275.0
-16.1 3 37.4 3.3 38 100.4 22.8 73 163.4 60.0 140 284.0
-15.6 4 39.2 3.9 39 102.2 23.3 74 165.2 62.7 145 293.0
-15.0 5 41.0 4.4 40 104.0 23.9 75 167.0 65.6 150 302.0
-14.4 6 42.8 5.0 41 105.8 24.4 76 168.8 68.3 155 311.0
-13.9 7 44.6 5.6 42 107.6 25.0 77 170.6 71.1 160 320.0
-13.3 8 46.4 6.1 43 109.4 25.6 78 172.4 73.9 165 329.0
-12.8 9 48.2 6.7 44 111.2 26.1 79 174.2 76.7 170 338.0
-12.2 10 50.0 7.2 45 113.0 26.7 80 176.0 79.4 175 347.0

HB365LC-3 00-101
 01 SPECIFICATIONS

HB365LC-3 01-1
CONTENTS 01 SPECIFICATIONS

CONTENTS (ALL-A-0310-002-00-B)
ABBREVIATION LIST .................................................................................................................................... 01-3
SPECIFICATIONS ......................................................................................................................................... 01-9
SPECIFICATION DRAWING................................................................................................................... 01-9
SPECIFICATION DRAWING: HB365LC-3, HB365NLC-3 ................................................................ 01-9
WORKING RANGE DRAWINGS .......................................................................................................... 01-10
WORKING RANGE: HB365LC-3, HB365NLC-3 ............................................................................ 01-10
SPECIFICATIONS .................................................................................................................................01-11
SPECIFICATIONS: HB365LC-3, HB365NLC-3 ...............................................................................01-11
WEIGHT TABLE ................................................................................................................................... 01-15
WEIGHT TABLE: HB365LC-3, HB365NLC-3 ................................................................................. 01-15
TABLE OF FUEL, COOLANT, AND LUBRICANTS ............................................................................... 01-17

01-2 HB365LC-3
01 SPECIFICATIONS ABBREVIATION LIST

ABBREVIATION LIST (ALL-A-0360-005-00-B)

• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).

HB365LC-3 01-3
ABBREVIATION LIST 01 SPECIFICATIONS

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
This is an electronic control device that send the
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.

01-4 HB365LC-3
01 SPECIFICATIONS ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.

HB365LC-3 01-5
ABBREVIATION LIST 01 SPECIFICATIONS

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a service that allows transmission and re-
Multimedia Messaging
MMS Communication ception of short messages consisting of charac-
Service
ters or voice or images between cell phones.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NC Normally Closed circuits. Circuit is normally closed if it is not actu-
system
ated, and it opens when it is actuated.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NO Normally Open circuits. Circuit is normally open if it is not actuat-
system
ed, and it closes when it is actuated.
This is a hydraulic system that can operate multi-
Open-center Load
OLSS Hydraulic system ple actuators at the same time regardless of the
Sensing System
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
Steering This is a function that electrically controls the en-
Palm command control gine and transmission in an optimal way with the
PCCS
system (D Series) controller instantly analyzing data from levers,
pedals, and dials.
This is a valve that adjusts the fuel intake amount
PCV Pre-stroke Control Valve Engine at the pump inlet in order to control fuel dis-
charged volume of supply pump.
Proportional Pressure This is a system that operates actuators in pro-
PPC Hydraulic system
Control portion to the oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Work equipment This is a function that performs hydraulic control
Power Tilt and power
PTP of the tilt and pitch of the dozer blade of the bull-
Pitch dozer (D Series) dozer.
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
Roll-Over Protective crushed when the machine rolls over. (Roll-over
ROPS Cab and canopy
Structure protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
Selective Catalytic Re- less nitrogen and water by oxidation-reduction re-
SCR Urea SCR system
duction action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
Le Systeme Internation- Abbreviation for "International System of Units" It
SI al d' Unites (Internation- Unit is the universal unit system and "a single unit for
al unit system) a single quantity" is the basic principle applied.
This is an actuator that consists of a solenoid and
SOL Solenoid Electrical system an iron core that is operated by the magnetic
force when the solenoid is energized.

01-6 HB365LC-3
01 SPECIFICATIONS ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.

*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection

HB365LC-3 01-7
ABBREVIATION LIST 01 SPECIFICATIONS

Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

01-8 HB365LC-3
01 SPECIFICATIONS SPECIFICATION DRAWING

SPECIFICATIONS (PC400_10-A-2111-001-00-B)

SPECIFICATION DRAWING (PC400_10-A-2110-001-00-B)

SPECIFICATION DRAWING: HB365LC-3, HB365NLC-3 (HB365_3-A-2110-931-01-B)

Item Unit HB365LC-3 HB365NLC-3

Machine weight kg 36400 36300
Bucket capacity m3 1.4
Engine model － KOMATSU SAA6D140E-6 diesel engine
202 / 1950 (ISO 14396)
Engine power kW / rpm
201 / 1950 (ISO 9249)
A Overall length mm 11145
B Overall height mm 3285
C Overall width mm 3190 2990
D Shoe width mm 600
E Cab height mm 3160
F Tail swing radius mm 3445
G Overall length of track mm 4955
H Distance between tumbler centres mm 4030
I Height of handrail mm 3255
Min. ground clearance mm 498
Travel speed (Lo/Mi/Hi) km/h 3.2 / 4.5 / 5.5
Continuous Swing speed rpm 9.5

REMARK
The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower
measured on the basic engine unit while net denotes the value measured of an engine under the condition near-
ly the same as that when it is installed on a machine.

HB365LC-3 01-9
WORKING RANGE DRAWINGS 01 SPECIFICATIONS

WORKING RANGE DRAWINGS (PC400_10-A-2110-001-10-B)

WORKING RANGE: HB365LC-3, HB365NLC-3 (HB365_3-A-2110-931-00-B)

Item Unit HB365LC-3, HB365NLC-3

A Maximum digging reach mm 11100
B Maximum digging depth mm 7380
C Maximum digging height mm 10100
D Maximum vertical wall digging depth mm 6400
E Maximum dumping height mm 7050
F Minimum dumping height mm 2640
G Maximum digging reach at ground level mm 10920

01-10 HB365LC-3
01 SPECIFICATIONS SPECIFICATIONS

SPECIFICATIONS (PC400_10-A-2111-001-00-B)

SPECIFICATIONS: HB365LC-3, HB365NLC-3 (HB365_3-A-2111-931-00-B)

Item Unit HB365LC-3 HB365NLC-3

Bucket capacity m3 1.4
Machine weight kg 36400 36300
Performance
Working ranges
Maximum digging depth mm 7380
Maximum vertical wall digging depth mm 6400
Maximum digging reach mm 11100
Maximum digging reach at ground level mm 10920
Maximum digging height mm 10100
Maximum dumping height mm 7050
Maximum digging force
211.8{21600}
(When one-touch power maximizing function is op- kN { kg}
(226.5{23100})
erated)
Continuous swing speed min-1 { rpm} 9.5{9.5}
Swing operation max. slope angle deg. 21
Travel speed (Lo/Mi/Hi) km/h 3.2/4.5/5.5
Gradeability deg. 35
kPa
Ground pressure (standard shoe) 66{0.67}
{ kg/cm2}
Dimensions
Overall length mm 11145
Overall width mm 3190 2990
Overall height (for transport) (*1) mm 3285
Ground clearance of upper structure bottom (*2) mm 1190
Minimum ground clearance mm 498
Tail swing radius mm 3445
Minimum swing radius of work equipment mm 4310
Maximum height at minimum swing radius of work
mm 8520
equipment
Overall width of track mm 3190 2990
Overall length of the track mm 4955
Distance between crawler centres mm 2590 2390
Distance between tumbler centres mm 4030
Machine cab height mm 3160
Width of standard shoe mm 600
*1: Including grouser height (36 mm)
*2: Excluding grouser height (36 mm)
Engine

HB365LC-3 01-11
SPECIFICATIONS 01 SPECIFICATIONS

Item Unit HB365LC-3 HB365NLC-3

Model - SAA6D114E-6
4-cycle, water-cooled, in-line, vertical, and di-
Type - rect injection type with variable geometry turbo-
charger and air-cooled aftercooler
No. of cylinders - bore x stroke mm 6-114 x 144.5
Total piston displacement ℓ { cc} 8.85{8850}
Performance
Rated horsepower
• Gross (SAE J1995) 202{271}/1950{1950}
kW
• ISO 14396 { HP} / min-1 202{271}/1950{1950}
{ rpm}
• Net (ISO 9249/SAE J1349) 201{269}/1950{1950}
Nm
Maximum torque { kgm} / min-1 1171{119.4}/1450{1450}
{ rpm}
Max. speed with no load
• When mounted on machine (*3) 2050{2050}
min-1 { rpm}
• As a bare engine 2050{2050}
Min. speed with no load min-1 { rpm} 700{700}
g/kWh
Min. fuel consumption ratio 216{159}
{ g/HPh}
Starting motor - 24 V, 7.5 kW
Alternator - 24 V, 90 A
Battery (*4) - 12 V, 120 Ah x 2 pieces
Radiator type - CF90-4
Undercarriage
*3: When swing lock is ON
*4: The battery capacity (Ah) is indicated in the 5-hour rate.
REMARK
The engine rated horsepower is indicated in the net value and gross value. Gross denotes the rated horsepower
measured on the basic engine unit while net denotes the value measured of an engine under the condition nearly
the same as that when it is installed on a machine.
Carrier roller - 2 piece on one side
Track roller - 8 piece on one side
Assembly type triple grouser shoe, 48 pieces
Track shoe -
on one side

Hydraulic system
Main pump
Variable displacement piston type (HPV140
Type x quantity -
+ 140) x 2 piece
Discharged volume ℓ/min 267.5 x 2
MPa
Set pressure 38.2{390}
{ kg/cm2}
Hybrid lubrication gear pump

01-12 HB365LC-3
01 SPECIFICATIONS SPECIFICATIONS

Item Unit HB365LC-3 HB365NLC-3

Type x quantity
• Motor-generator FB(0)8.0
-
• Swing motor FB(00)1.0
Discharged volume
• Motor-generator 8.09
cm3/rev
• Swing motor 1.00
Set pressure
• Motor-generator MPa 0.3{3.0}
• Swing motor { kg/cm2} 0.2{2.0}
Control valve
Type x quantity - 6-spool + 1-spool type x 1 piece
Operating method - Hydraulically operated
Variable displacement piston type
Travel motor - (HMV180ADT-2) x 2 pieces
(with brake valve and shaft brake)
Boom cylinder (*5)
Type - Double-acting piston
Inside diameter of cylinder bore mm 140
Diameter of piston rod mm 100
Stroke mm 1480
Max. distance between pins mm 3525
Min. distance between pins mm 2045
Arm cylinder (*6)
Type - Double-acting piston
Inside diameter of cylinder bore mm 160
Diameter of piston rod mm 110
Stroke mm 1825
Max. distance between pins mm 4255
Min. distance between pins mm 2430
Bucket cylinder
Type - Double-acting piston
Inside diameter of cylinder bore mm 140
Diameter of piston rod mm 100
Stroke mm 1285
Max. distance between pins mm 3155
Min. distance between pins mm 1870
Hydraulic tank - Box-shaped airtight type
Hydraulic oil filter - Tank return side
Hydraulic oil cooler - Air-cooled type (CF40-1)

HB365LC-3 01-13
SPECIFICATIONS 01 SPECIFICATIONS

Item Unit HB365LC-3 HB365NLC-3

Electrical system
Motor-generator
Type x quantity - 3 phase motor x 1 piece
Working voltage - 650 V(DC)
Driving type - Direct to machinery
Electric swing motor
Type x quantity - 3 phase motor x 1 piece
Working voltage - 650 V(AC)
Electric control unit
Inverter - 1 pieces
Capacitor - 1 pieces
*5: With cushion on head side.
*6: With cushions on head side and bottom side.

01-14 HB365LC-3
01 SPECIFICATIONS WEIGHT TABLE

WEIGHT TABLE (PC400_10-A-2120-001-00-B)

WEIGHT TABLE: HB365LC-3, HB365NLC-3 (HB365_3-A-2120-931-00-B)

k This weight table is provided for your reference for the time when handling the components or when
transporting.
k This weight table shows the dry weight.
Unit: kg
Item HB365LC-3 HB365NLC-3
Engine assembly 1478
• Engine 935
• Motor-generator 327
• Main pump 216
Cooling assembly (excluding hydraulic oil and coolant) 321
Inverter 61
Capacitor 109
Hydraulic tank and filter assembly 197
Fuel tank assembly 237
Revolving frame 3416
Operator cab (including head guard and front half guard) 520
Operator's seat 35
Counterweight 5330
Swing machinery 439
Control valve 255
Electric swing motor 115
Travel motor 162 x 2
Centre swivel joint 30.2
Track frame assembly (excluding track shoes) 8161 8034
• Track frame 4370 4243
• Swing circle 525
• Idler 164 x 2
• Idler cushion 270 x 2
• Carrier roller 28 x 4
• Track roller (double flange) 57.5 x 16
• Track roller (single flange) 52.2 x 16
• Final drive (including travel motor and sprocket) 605 x 2
Track shoe assembly
Triple shoe (600 mm) 3700
Triple shoe (700 mm) 4300
Triple shoe (800 mm) 4680
Boom assembly 2449
Arm assembly 1216

HB365LC-3 01-15
WEIGHT TABLE 01 SPECIFICATIONS

Unit: kg
Item HB365LC-3 HB365NLC-3
Bucket assembly 1448
Boom cylinder assembly 262 x 2
Arm cylinder assembly 390
Bucket cylinder assembly 235
Bucket link (large) assembly 316
Bucket link (small) assembly -
Boom foot pin 76
Boom cylinder bottom pin 15 x 2
Boom cylinder head pin 57
Arm cylinder bottom pin 21
Arm cylinder head pin 17
Boom and arm connecting pin 42
Bucket cylinder bottom pin 13
Bucket pin 30 x 2
Bucket link pin 27 x 2

01-16 HB365LC-3
01 SPECIFICATIONS TABLE OF FUEL, COOLANT, AND LUBRICANTS

TABLE OF FUEL, COOLANT, AND LUBRICANTS (HB335_3-K-0000-05A-10-B)

For details of notes (Note 1, Note 2...) in the table, see Operation and Maintenance Manual.

Unit: ℓ
Objective portion Specified amount Refill capacity
Engine oil system 39.5 38.5
Motor-generator case 9.1 8.5
Electric swing motor case 3.6 3.0
Swing machinery case 18.1 15.6
Final drive case (right and left sides) 9 9
Hydraulic oil system 365 188
Fuel tank 605 -
Engine cooling system 42.0 42.0

HB365LC-3 01-17
TABLE OF FUEL, COOLANT, AND LUBRICANTS 01 SPECIFICATIONS

Unit: ℓ
Objective portion Specified amount Refill capacity
Bleeding the air from hybrid system coolant 15.5 11.7
AdBlue/DEF tank 60.5 -

01-18 HB365LC-3
 10 STRUCTURE AND FUNCTION

HB365LC-3 10-1
CONTENTS 10 STRUCTURE AND FUNCTION

CONTENTS (ALL-A-0310-002-00-B)
ABBREVIATION LIST .................................................................................................................................... 10-6
UREA SCR SYSTEM................................................................................................................................... 10-12
LAYOUT DRAWING OF UREA SCR SYSTEM ..................................................................................... 10-12
UREA SCR SYSTEM DIAGRAM .......................................................................................................... 10-16
FUNCTION OF UREA SCR SYSTEM................................................................................................... 10-17
FUNCTION OF AdBlue/DEF SYSTEM........................................................................................... 10-17
INDUCEMENT STRATEGY ........................................................................................................... 10-19
COMPONENT PARTS OF UREA SCR SYSTEM.................................................................................. 10-37
AdBlue/DEF MIXING TUBE ........................................................................................................... 10-37
SCR ASSEMBLY ........................................................................................................................... 10-37
AdBlue/DEF TANK ......................................................................................................................... 10-40
AdBlue/DEF PUMP ........................................................................................................................ 10-42
AdBlue/DEF INJECTOR................................................................................................................. 10-43
AdBlue/DEF HOSE ........................................................................................................................ 10-44
AdBlue/DEF TANK HEATING VALVE............................................................................................. 10-45
BOOT-UP SYSTEM ..................................................................................................................................... 10-46
LAYOUT DRAWING OF BOOT-UP SYSTEM........................................................................................ 10-46
SYSTEM OPERATING LAMP SYSTEM ............................................................................................... 10-48
SYSTEM OPERATING LAMP SYSTEM DIAGRAM ....................................................................... 10-48
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM ............................................................... 10-48
BATTERY DISCONNECT SWITCH ...................................................................................................... 10-50
FUNCTION OF BATTERY DISCONNECT SWITCH ...................................................................... 10-50
ENGINE SYSTEM ....................................................................................................................................... 10-51
LAYOUT DRAWING OF ENGINE SYSTEM .......................................................................................... 10-51
FUNCTION OF ENGINE SYSTEM ................................................................................................ 10-52
ENGINE CONTROL SYSTEM .............................................................................................................. 10-53
ENGINE CONTROL SYSTEM DIAGRAM...................................................................................... 10-53
FUNCTION OF ENGINE CONTROL SYSTEM .............................................................................. 10-54
AUTO-DECELERATION SYSTEM ........................................................................................................ 10-56
AUTO-DECELERATION SYSTEM DIAGRAM ............................................................................... 10-56
FUNCTION OF AUTO-DECELERATION SYSTEM........................................................................ 10-56
OPERATION OF AUTO-DECELERATION SYSTEM...................................................................... 10-57
ENGINE AUTOMATIC WARM-UP SYSTEM ......................................................................................... 10-58
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM................................................................. 10-58
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM ......................................................... 10-59
OVERHEAT PREVENTION SYSTEM ................................................................................................... 10-60
OVERHEAT PREVENTION SYSTEM DIAGRAM........................................................................... 10-60
FUNCTION OF OVERHEAT PREVENTION SYSTEM ................................................................... 10-61
TURBOCHARGER PROTECTION SYSTEM ........................................................................................ 10-63
TURBOCHARGER PROTECTION SYSTEM DIAGRAM ............................................................... 10-63
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM........................................................ 10-64
AUTOMATIC IDLE STOP SYSTEM ...................................................................................................... 10-65
AUTOMATIC IDLE STOP SYSTEM DIAGRAM.............................................................................. 10-65
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM ...................................................................... 10-65
COMPONENT PARTS OF ENGINE SYSTEM ...................................................................................... 10-69
VGT ............................................................................................................................................... 10-69
EGR SYSTEM ............................................................................................................................... 10-72
EGR VALVE ................................................................................................................................... 10-74
EGR COOLER ............................................................................................................................... 10-76
KCCV SYSTEM ............................................................................................................................. 10-77
KCCV VENTILATOR ...................................................................................................................... 10-79
KDPF ............................................................................................................................................. 10-80
COOLING SYSTEM..................................................................................................................................... 10-85
LAYOUT DRAWING OF COOLING SYSTEM ....................................................................................... 10-85
SPECIFICATIONS OF COOLING SYSTEM................................................................................... 10-86
HYBRID SYSTEM........................................................................................................................................ 10-87

10-2 HB365LC-3
10 STRUCTURE AND FUNCTION CONTENTS

LAYOUT DRAWING OF HYBRID SYSTEM .......................................................................................... 10-87

SYSTEM DIAGRAM OF HYBRID SYSTEM .......................................................................................... 10-88
STRUCTURE OF HYBRID SYSTEM .................................................................................................... 10-89
HYBRID PROTECTION SYSTEM......................................................................................................... 10-90
SYSTEM DIAGRAM OF HYBRID PROTECTION SYSTEM........................................................... 10-90
FUNCTION OF HYBRID PROTECTION SYSTEM ........................................................................ 10-90
COOLING SYSTEM OF HYBRID COMPONENTS ............................................................................... 10-92
SYSTEM DIAGRAM OF COOLING SYSTEM OF HYBRID COMPONENTS ................................. 10-92
INTERLOCK SYSTEM OF HYBRID COMPONENTS ........................................................................... 10-93
SYSTEM DIAGRAM OF INTERLOCK SYSTEM OF HYBRID COMPONENTS.............................. 10-93
FUNCTION OF INTERLOCK SYSTEM OF HYBRID COMPONENTS ........................................... 10-93
WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID COMPONENTS ... 10-94
SYSTEM DIAGRAM OF WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HY-
BRID COMPONENTS ................................................................................................................ 10-94
FUNCTION OF WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HYBRID
COMPONENTS.......................................................................................................................... 10-95
COMPONENT PARTS OF HYBRID SYSTEM ...................................................................................... 10-96
MOTOR-GENERATOR .................................................................................................................. 10-96
ELECTRIC CONTROL UNIT.......................................................................................................... 10-97
HIGH VOLTAGE WIRING (POWER CABLE) ................................................................................. 10-98
HYBRID WATER PUMP................................................................................................................. 10-99
INVERTER (HYBRID CONTROLLER) ..........................................................................................10-100
CONTROL SYSTEM...................................................................................................................................10-103
LAYOUT DRAWING OF CONTROL SYSTEM .....................................................................................10-103
MACHINE MONITOR SYSTEM ...........................................................................................................10-106
MACHINE MONITOR SYSTEM DIAGRAM...................................................................................10-106
FUNCTION OF MACHINE MONITOR SYSTEM ...........................................................................10-106
KomVision SYSTEM ............................................................................................................................10-108
KomVision SYSTEM ............................................................................................................................10-109
LAYOUT DRAWING OF KOMVISION SYSTEM ...........................................................................10-109
KomVision SYSTEM DIAGRAM....................................................................................................10-110
FUNCTION OF KomVision SYSTEM ............................................................................................ 10-111
KOMTRAX SYSTEM............................................................................................................................10-113
KOMTRAX SYSTEM DIAGRAM ...................................................................................................10-113
FUNCTION OF KOMTRAX SYSTEM ...........................................................................................10-113
PPC LEVERS ......................................................................................................................................10-114
LH PPC LEVER ............................................................................................................................10-114
RH PPC LEVER............................................................................................................................10-115
AUTOMATIC GREASE SYSTEM .........................................................................................................10-116
OUTLINE OF AUTO GREASE SYSTEM ......................................................................................10-116
COMPONENT PARTS OF CONTROL SYSTEM..................................................................................10-131
MACHINE MONITOR....................................................................................................................10-131
KomVision CONTROLLER............................................................................................................10-144
KomVision CAMERA.....................................................................................................................10-148
KomVision CAMERA.....................................................................................................................10-148
KOMTRAX TERMINAL .................................................................................................................10-149
PUMP CONTROLLER ..................................................................................................................10-151
RESISTOR FOR PC-EPC VALVE .................................................................................................10-155
CAN TERMINATING RESISTOR ..................................................................................................10-156
ENGINE CONTROLLER ...............................................................................................................10-157
FUEL CONTROL DIAL .................................................................................................................10-163
HYDRAULIC SYSTEM................................................................................................................................10-165
LAYOUT DRAWING OF HYDRAULIC SYSTEM ..................................................................................10-165
CLSS ...................................................................................................................................................10-168
STRUCTURE OF CLSS................................................................................................................10-168
OPERATION OF UNLOAD VALVE AND LS PRESSURE .............................................................10-170
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL ..............................................................10-171
PRESSURE COMPENSATION CONTROL...................................................................................10-184

HB365LC-3 10-3
CONTENTS 10 STRUCTURE AND FUNCTION

ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................................................10-187

ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM .............................................10-187
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM......................................10-188
PUMP AND VALVE CONTROL SYSTEM ............................................................................................10-193
PUMP AND VALVE CONTROL SYSTEM DIAGRAM ....................................................................10-193
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM ............................................................10-194
COMPONENT PARTS OF HYDRAULIC SYSTEM ..............................................................................10-196
HYDRAULIC TANK .......................................................................................................................10-196
MAIN PUMP..................................................................................................................................10-198
CONTROL VALVE ........................................................................................................................10-225
WORK EQUIPMENT SYSTEM ...................................................................................................................10-279
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM .....................................................................10-279
STRUCTURE OF VALVE CONTROL...................................................................................................10-285
ONE-TOUCH POWER MAXIMIZING SYSTEM ...................................................................................10-286
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM ...........................................................10-286
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM ..................................................10-287
MACHINE PUSH-UP SYSTEM ............................................................................................................10-288
MACHINE PUSH-UP SYSTEM DIAGRAM ...................................................................................10-288
FUNCTION OF MACHINE PUSH-UP SYSTEM............................................................................10-289
PPC LOCK SYSTEM ...........................................................................................................................10-290
PPC LOCK SYSTEM DIAGRAM...................................................................................................10-290
FUNCTION OF PPC LOCK SYSTEM ...........................................................................................10-290
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM .....................................................10-291
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM.............................10-291
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM .....................10-291
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM...................10-292
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT........................................................................10-293
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT ...............................................10-293
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT .......................................10-294
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM ..................................................................10-295
WORK EQUIPMENT AND SWING PPC VALVE ...........................................................................10-295
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) .........................................................10-300
2ND-LINE ATTACHMENT PPC VALVE.........................................................................................10-305
SOLENOID VALVE .......................................................................................................................10-307
ANTI-DROP VALVE FOR BOOM ..................................................................................................10-310
ANTI-DROP VALVE FOR ARM .....................................................................................................10-313
ATTACHMENT CIRCUIT SELECTOR VALVE ...............................................................................10-317
PILOT CIRCUIT ACCUMULATOR ................................................................................................10-320
SWING SYSTEM ........................................................................................................................................10-321
LAYOUT DRAWING OF SWING SYSTEM ..........................................................................................10-321
SWING CONTROL SYSTEM DIAGRAM .............................................................................................10-324
FUNCTION OF SWING CONTROL SYSTEM...............................................................................10-325
COMPONENT PARTS OF SWING SYSTEM.......................................................................................10-327
ELECTRIC SWING MOTOR .........................................................................................................10-327
SWING MACHINERY WITH SWING PARKING BRAKE ...............................................................10-328
SWING CIRCLE............................................................................................................................10-330
TRAVEL SYSTEM.......................................................................................................................................10-331
LAYOUT DRAWING OF TRAVEL SYSTEM .........................................................................................10-331
TRAVEL CONTROL SYSTEM DIAGRAM ............................................................................................10-335
FUNCTION OF TRAVEL CONTROL SYSTEM .............................................................................10-336
COMPONENT PARTS OF TRAVEL SYSTEM .....................................................................................10-337
TRAVEL MOTOR ..........................................................................................................................10-337
FINAL DRIVE................................................................................................................................10-350
TRAVEL PPC VALVE ....................................................................................................................10-351
CENTER SWIVEL JOINT..............................................................................................................10-356
UNDERCARRIAGE AND FRAME...............................................................................................................10-358
LAYOUT DRAWING OF UNDERCARRIAGE .......................................................................................10-358
SPECIFICATIONS OF UNDERCARRIAGE...................................................................................10-358

10-4 HB365LC-3
10 STRUCTURE AND FUNCTION CONTENTS

WORK EQUIPMENT...................................................................................................................................10-360
STRUCTURE OF WORK EQUIPMENT ...............................................................................................10-360
FUNCTION OF WORK EQUIPMENT ..................................................................................................10-361
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM...................................................................10-362
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM ..................................10-362
BUCKET CLEARANCE ADJUSTMENT SHIM .....................................................................................10-363
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM .....................................................10-363
CAB AND ITS ATTACHMENTS ..................................................................................................................10-364
ROPS CAB ..........................................................................................................................................10-364
STRUCTURE OF ROPS CAB.......................................................................................................10-364
FUNCTION OF ROPS CAB ..........................................................................................................10-364
CAB MOUNT .......................................................................................................................................10-365
STRUCTURE OF CAB MOUNT....................................................................................................10-365
FUNCTION OF CAB MOUNT .......................................................................................................10-365
CAB TIPPING STOPPER ....................................................................................................................10-366
STRUCTURE OF CAB TIPPING STOPPER.................................................................................10-366
FUNCTION OF CAB TIPPING STOPPER ....................................................................................10-366

HB365LC-3 10-5
ABBREVIATION LIST 10 STRUCTURE AND FUNCTION

ABBREVIATION LIST (ALL-A-0360-005-00-B)

• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).

10-6 HB365LC-3
10 STRUCTURE AND FUNCTION ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
This is an electronic control device that send the
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.

HB365LC-3 10-7
ABBREVIATION LIST 10 STRUCTURE AND FUNCTION

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.

10-8 HB365LC-3
10 STRUCTURE AND FUNCTION ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a service that allows transmission and re-
Multimedia Messaging
MMS Communication ception of short messages consisting of charac-
Service
ters or voice or images between cell phones.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NC Normally Closed circuits. Circuit is normally closed if it is not actu-
system
ated, and it opens when it is actuated.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NO Normally Open circuits. Circuit is normally open if it is not actuat-
system
ed, and it closes when it is actuated.
This is a hydraulic system that can operate multi-
Open-center Load
OLSS Hydraulic system ple actuators at the same time regardless of the
Sensing System
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
Steering This is a function that electrically controls the en-
Palm command control gine and transmission in an optimal way with the
PCCS
system (D Series) controller instantly analyzing data from levers,
pedals, and dials.
This is a valve that adjusts the fuel intake amount
PCV Pre-stroke Control Valve Engine at the pump inlet in order to control fuel dis-
charged volume of supply pump.
Proportional Pressure This is a system that operates actuators in pro-
PPC Hydraulic system
Control portion to the oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Work equipment This is a function that performs hydraulic control
Power Tilt and power
PTP of the tilt and pitch of the dozer blade of the bull-
Pitch dozer (D Series) dozer.
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
Roll-Over Protective crushed when the machine rolls over. (Roll-over
ROPS Cab and canopy
Structure protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
Selective Catalytic Re- less nitrogen and water by oxidation-reduction re-
SCR Urea SCR system
duction action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
Le Systeme Internation- Abbreviation for "International System of Units" It
SI al d' Unites (Internation- Unit is the universal unit system and "a single unit for
al unit system) a single quantity" is the basic principle applied.
This is an actuator that consists of a solenoid and
SOL Solenoid Electrical system an iron core that is operated by the magnetic
force when the solenoid is energized.

HB365LC-3 10-9
ABBREVIATION LIST 10 STRUCTURE AND FUNCTION

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.

*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection

10-10 HB365LC-3
10 STRUCTURE AND FUNCTION ABBREVIATION LIST

Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

HB365LC-3 10-11
LAYOUT DRAWING OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

UREA SCR SYSTEM (PC400_11-K-AF00-001-00-B)

SCR
Abbreviation for Selective Catalytic Reduction

LAYOUT DRAWING OF UREA SCR SYSTEM (HB335_3-K-AF00-04D-00-B)

SCR: Abbreviation for Selective Catalytic Reduction

1: AdBlue/DEF tank 2: AdBlue/DEF filler port

10-12 HB365LC-3
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF UREA SCR SYSTEM

3: AdBlue/DEF Pump 9: KDPF

4: AdBlue/DEF suction hose 10: AdBlue/DEF tank coolant outlet hose
5: AdBlue/DEF return hose 11: AdBlue/DEF tank coolant inlet hose
6: AdBlue/DEF pressure hose (low-temperature side) 12: AdBlue/DEF tank heating valve
7: AdBlue/DEF pressure hose (high-temperature side) 13: AdBlue/DEF injector
8: AdBlue/DEF mixing tube

14: SCR assembly 16: AdBlue/DEF tank sensor

15: AdBlue/DEF injector coolant hose

HB365LC-3 10-13
LAYOUT DRAWING OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

Detailed drawing of SCR assembly

1: Turbocharger outlet NOx sensor 4: SCR outlet temperature sensor

2: Ammonia sensor 5: SCR outlet NOx sensor
3: SCR temperature sensor
Detail of temperature sensor

10-14 HB365LC-3
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF UREA SCR SYSTEM

1: Engine room temperature sensor 2: Ambient temperature sensor

HB365LC-3 10-15
UREA SCR SYSTEM DIAGRAM 10 STRUCTURE AND FUNCTION

UREA SCR SYSTEM DIAGRAM (PC220_11-K-AF00-052-00-B)

A: Coolant inlet B: Coolant outlet

1: Mass air flow and temperature sensor
2: Engine
3: Engine controller
4: KDPF assembly
5: KDOC unit
6: KCSF unit
7: KDPF differential pressure sensor
8: KDPF outlet pressure sensor
9: Turbocharger outlet NOx sensor
10: Turbocharger outlet NOx sensor controller
11: KDOC inlet temperature sensor
12: KDOC outlet temperature sensor
13: KDPF outlet temperature sensor
14: KDPF temperature sensor controller
15: AdBlue/DEF mixing tube
16: AdBlue/DEF injector
17: SCR assembly
18: Upstream SCR catalyst
19: Downstream SCR catalyst and ammonia oxidation
catalyst (integrated type)
20: Ammonia sensor
21: Ammonia sensor controller
22: SCR temperature sensor
23: SCR outlet temperature sensor
24: SCR temperature sensor controller
25: SCR outlet NOx sensor
26: SCR outlet NOx sensor controller
27: Smart sensor
28: Ambient temperature sensor
29: Engine room temperature sensor
30: AdBlue/DEF system
31: AdBlue/DEF tank heating valve
32: AdBlue/DEF tank
33: AdBlue/DEF tank sensor
34: AdBlue/DEF suction line
35: AdBlue/DEF return line
36: AdBlue/DEF pressure line
37: AdBlue/DEF pump
38: AdBlue/DEF line heater relay
39: Machine monitor

10-16 HB365LC-3
10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

FUNCTION OF UREA SCR SYSTEM (PC400_11-K-AF00-042-00-B)

1: Engine 5: AdBlue/DEF injector

2: Engine controller 6: KDPF
3: AdBlue/DEF pump 7: SCR catalyst
4: AdBlue/DEF tank 8: Ammonia oxidation catalyst
• Urea SCR system is a device which converts toxic nitrogen oxides (NOx) in the exhaust gas into harmless
nitrogen and water.
• By spraying AdBlue/DEF into the exhaust gas, it decomposes and hydrolyzes to form ammonia (NH3) and
the ammonia selectively reacts with nitrogen oxides for the conversion to nitrogen and water.

FUNCTION OF AdBlue/DEF SYSTEM (PC400_11-K-AFC0-042-00-B)

1: AdBlue/DEF tank 5
2: AdBlue/DEF suction hose
6
3: AdBlue/DEF Pump
4
3A: Selector valve
3B: Pump
3C: AdBlue/DEF filter
3D: Pressure sensor 2
4: AdBlue/DEF return hose
1
5: AdBlue/DEF pressure hose
6: AdBlue/DEF injector 3A 3D
P
• AdBlue/DEF system consists of AdBlue/DEF tank (1),
3C
AdBlue/DEF hoses (2), (4), (5), AdBlue/DEF pump (3), and
AdBlue/DEF injector (6). It injects AdBlue/DEF into mixing
tube. 3B 3
• This system automatically starts operation after starting
the engine.
A4P15761
• This system has a heating function to thaw AdBlue/DEF
and to prevent AdBlue/DEF from freezing since
AdBlue/DEF freezes at -11 °C.
AdBlue/DEF injection function
• AdBlue/DEF injection function is a function that injects AdBlue/DEF which is pressurized with AdBlue/DEF
pump into mixing tube.

HB365LC-3 10-17
FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

• Engine controller controls the injection volume by using AdBlue/DEF injector.

• Engine controller determines the injection volume by the information from the turbocharger outlet NOx sen-
sor, SCR temperature sensor, and the intake gas flow sensor while correcting it by ammonia sensor and
SCR outlet NOx sensor.
• AdBlue/DEF injection is controlled according to the system temperature as well since the urea SCR system
does not operate efficiently at low temperature. The temperature sensor is used for this monitoring.
• The engine controller commands to stop injection, and injector does not inject when a failure code is dis-
played due to an abnormality which is detected by any sensor which determines the injection volume.
• The urea in AdBlue/DEF are deposited in the mixing tube, and it may stick to block the passage if an abnor-
mality occurs.
AdBlue/DEF purge function
• This is a function that purges remaining AdBlue/DEF in 5
AdBlue/DEF system automatically after engine is stopped.
6
• It purges AdBlue/DEF from inside of injector or pump in or-
der to prevent blocking or sticking by deposited urea in 4
AdBlue/DEF, or defective operation of equipment by frozen
AdBlue/DEF in cold weather.
For this reason, the system operates for few minutes even
after engine is stopped, but this is not an abnormality.
2
NOTICE
Do not turn off the battery disconnect switch while purging 1
AdBlue/DEF.
3A 3D
P
3C

3B 3

A4P15762

AdBlue/DEF function of thawing and preventing from freezing

• Thawing control system has the thawing mode and freeze prevention mode.
• Thawing mode is the function to thaw the frozen AdBlue/DEF.
• After starting engine, if the engine controller judges that AdBlue/DEF must be thawed, this function au-
tomatically heats the system.
• At this time, pressure control of AdBlue/DEF pump and injection of AdBlue/DEF are not performed until
the thawing is completed.
• Freeze prevention mode is the function to keep AdBlue/DEF warm to prevent it from freezing.
• This function automatically heats the system to prevent it from freezing while operating the machine, if
engine controller judges that AdBlue/DEF could be frozen.
• This function stops the pressure control of AdBlue/DEF pump and injection of AdBlue/DEF if it judges
that AdBlue/DEF is frozen while operating the machine.
• Thawing and freeze prevention are controlled by sensor, and the control sensors vary by devices which
AdBlue/DEF system consists of. The following table shows the relationship between the object devices of
thawing control, heating system, and control sensors for each mode.

10-18 HB365LC-3
10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

Object devices of thawing control, heating system, and control sensors for each mode
Heating system Thawing mode Freeze prevention mode
AdBlue/DEF suction hose and re-
turn hoses Ambient temperature Ambient temperature
Heater around hose
AdBlue/DEF pressure hose (low- sensor sensor
temperature side)
AdBlue/DEF pressure hose (high- Engine room temperature Engine room temperature
Heater around hose
temperature side) sensor sensor
Heater which is built in AdBlue/DEF pump tem- Ambient temperature
AdBlue/DEF pump
the pump perature sensor sensor
AdBlue/DEF tank temper- AdBlue/DEF tank temper-
AdBlue/DEF tank Circulation of coolant
ature sensor ature sensor

INDUCEMENT STRATEGY (PC400_11-K-AF00-042-10-B)

• The purpose of inducement is to prompt the operator to perform maintenance or repair on the emissions
control system.
• Inducement strategy is a control action to ensure prompt correction of various failures in the engine emis-
sions control system. It requires actions to limit engine performance and defines required indication such as
warning lamps and messages, as well as alarms while the control actions are imposed.
The warning steps of Inducement are different between for North America and for European Union.
• The categories of abnormalities that have triggered Inducement are displayed on the “SCR Information”
screen of the machine monitor.

INDUCEMENT STRATEGY WHEN THE AdBlue/DEF LEVEL IN THE TANK BE-

COMES LOW (FOR NORTH AMERICA) (HB335_3-K-AF00-042-11-B)
• When the AdBlue/DEF level in the tank becomes low, AdBlue/DEF level caution lamp on the machine moni-
tor lights up, the Audible alert sounds, the action level is displayed and Inducement strategy including en-
gine power deration is activated.
• The Inducement strategy progresses in 5 levels from Warning, Escalated Warning, Mild Inducement, Se-
vere Inducement and Final Inducement.
• Up to the start of Severe Inducement the start of each warning step is triggered by the amount of
AdBlue/DEF in the AdBlue/DEF tank. Final Inducement starts at 1 hour after the start of Severe Inducement
if the machine continues its operation without adding AdBlue/DEF into the tank, and reduces the engine
speed to low idle and keeps it at low idle.
• The Inducement strategy status can be checked on “SCR Information” screen of the user menu.
• The table shows warning indications and engine power derations by each Inducement strategy status.
Machine monitor
AdBlue/DEF
level (*1) AdBlue/DEF Engine dera-
Status Message of level caution
(AdBlue/DEF Tone of audi- Activated fail- tion (*3)
SCR Informa- lamp
level gauge) ble alert ure code (*2)
tion
(Action level)
Red
10% CA3497
1: DEF low
1 Warning (The bottom level warning No sound (AdBlue/DEF No deration
two grada- appears. level low error
tions light on) 1)

HB365LC-3 10-19
FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

Machine monitor
AdBlue/DEF
level (*1) AdBlue/DEF Engine dera-
Status Message of level caution
(AdBlue/DEF Tone of audi- Activated fail- tion (*3)
SCR Informa- lamp
level gauge) ble alert ure code (*2)
tion
(Action level)
5%
2: Without Red
(Within the CA3498
Escalated treatment, en- Triplet (*4)
2 Warning gradation of gine power (AdBlue/DEF No deration
Short intermit-
the second will be derat- level low error
(Warning 2) tently (*5)
from the bot- ed. 2)
tom )
Red

Red
2.5%
Mild Induce- CA1673
ment (The grada- 3: Engine
Long intermit- (AdBlue/DEF Torque: over
3 tion of the end power is un-
(Inducement tently level low error 25%
of the bottom der deration.
1) 3)
lights on)
Red

(*7)
Red

Red CA1673 Torque: over

Severe In- 0% 4: Engine 50%
ducement CA3547
(All grada- power is un-
4 Continuously (AdBlue/DEF and
(Inducement tions lights der heavy de-
2) off) ration. level low error RPM: over
4) 40%
Red

(*7)

10-20 HB365LC-3
10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

Machine monitor
AdBlue/DEF
level (*1) AdBlue/DEF Engine dera-
Status Message of level caution
(AdBlue/DEF Tone of audi- Activated fail- tion (*3)
SCR Informa- lamp
level gauge) ble alert ure code (*2)
tion
(Action level)
Red

Not remaining Red CA1673

Final Induce- in the tank CA3547
ment (*6) 5: Engine is Engine speed
5 running at low Continuously AS00ZK is fixed to low
(Inducement (All grada- idle. (AdBlue/DEF idle
3) tions lights level low error
off) 5)
Red

(*7)

*1: It is shown the value of Monitoring ID 19111: “AdBlue/DEF Level Corrected”.

*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING POINTS FOR
UREA SCR SYSTEM”.
*3: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*4: Construction equipment with crawler
*5: Construction equipment with wheel
*6: After progressed “Severe Inducement” the status advances to “Final Inducement” with in 1 hour.
*7: Construction equipment with hybrid system

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE UREA SCR

SYSTEM DEVICES (FOR NORTH AMERICA) (HB335_3-K-AF00-042-12-B)
• When any abnormality is found in the AdBlue/DEF quality or in the Urea SCR system tampering or fault,
AdBlue/DEF system caution lamp on the machine monitor lights up, the Audible alert sounds. If time has
elapsed after any abnormality is generated, not only the warning by AdBlue/DEF caution lamp on the ma-
chine monitor and Audible alert, but also an action level is displayed, Inducement strategy is activated and
then the engine output is reduced.
• The Inducement strategy status and the categories of abnormalities can be checked on the “SCR Informa-
tion” screen of the machine monitor.
• The table shows warning indications and engine power derations by each Inducement strategy status.

HB365LC-3 10-21
FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Yellow

1: Please
inspect and CA3571
1 Warning 1 hour maintain No sound No indication No deration
SCR sys- Yellow CB3571
tem.

Yellow

2: Without Triplet (*6) AS00R2

Escalated treatment,
2 Warning 2 hours engine Short inter- CA3571 (Warning 2 No deration
power will Yellow mittently CB3571 (SCR Device
(Warning 2)
be derated. (*7) Abnormality))

Red

Red
AS00R3
Mild In- 3: Engine
ducement power is Long inter- CA3571 (Inducement Torque: over
3 3 hours 1(SCR De-
(Induce- under dera- mittently CB3571 25%
tion. vice Abnor-
ment 1)
mality))
Red

(*8)

10-22 HB365LC-3
10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

Red Torque: over

4: Engine AS00R4
Severe In- 50%
ducement power is CA3571 (Inducement
Continu-
4 4 hours under 2 (SCR De- and
(Induce- ously CB3571
heavy dera- vice Abnor- RPM: over
ment 2) tion. mality)) 40%
Red

(*8)
Red

Red
AS00R5
Final In- Engine
ducement 5: Engine is CA3571 (Inducement
Until repair- Continu- speed is
5 running at 3 (SCR De-
(Induce- ing ously CB3571 fixed to low
low idle. vice Abnor-
ment 3) idle
mality))
Red

(*8)

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing”stage. Final Inducement is not cleared till abnormality is repaired.
*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. The failure code shown here is an example of failure code which is displayed on the machine
monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING
POINTS FOR UREA SCR SYSTEM”.
*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devi-
ces branching off to 2 lines.
*4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode.
*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*6: Construction equipment with crawler
*7: Construction equipment with wheel

HB365LC-3 10-23
FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

*8: Construction equipment with hybrid system

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE KDPF SYS-

TEM BY THE UREA SCR SYSTEM (FOR NORTH AMERICA) (HB335_3-K-AF00-042-15-B)
• The Inducement strategy is different if Inducement is triggered by abnormalities in KDPF. Although the total
steps are the same and 5, warning indications are different and engine power deration (Over 25% torque
reduction) starts from that of “Warning”.
• The table shows warning indications and engine power derations by each Inducement strategy status.
Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

Red
1: Please
inspect and CA4151
Long inter- Torque: over
1 Warning 1 hour maintain No indication
mittently CB4151 25%
SCR sys-
tem.
Red

(*8)
Red

Yellow

2: Without Triplet (*6) AS00R2

Escalated treatment,
2 Warning 2 hours engine Short inter- CA4151 (Warning 2 Torque: over
Red
power will mittently CB4151 (SCR Device 25%
(Warning 2)
be derated. (*7) Abnormality))

Red

(*8)

10-24 HB365LC-3
10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

Red

AS00R3
Mild In- 3: Engine
ducement power is Long inter- CA4151 (Inducement Torque: over
3 3 hours Red 1 (SCR De-
(Induce- under dera- mittently CB4151 25%
tion. vice Abnor-
ment 1)
mality))

Red

(*8)
Red

Red

4: Engine AS00R4 Torque: over

Severe In- 50%
ducement power is CA4151 (Inducement
Continu-
4 4 hours under Red 2 (SCR De- and
(Induce- ously CB4151
heavy de- vice Abnor- RPM: over
ment 2) ration. mality)) 40%

Red

(*8)

HB365LC-3 10-25
FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

Red

AS00R5
Final In- Engine
ducement 5: Engine CA4151 (Inducement
Until repair- Continu- speed is
5 is running Red 3 (SCR De-
(Induce- ing ously CB4151 fixed to low
at low idle. vice Abnor-
ment 3) idle
mality))

Red

(*8)

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing” stage. Final Inducement is not cleared till abnormality is repaired.
*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. The failure code shown here is an example of failure code which is displayed on the machine
monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING
POINTS FOR UREA SCR SYSTEM”.
*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devi-
ces branching off to 2 lines.
*4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode.
*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*6: Construction equipment with crawler
*7: Construction equipment with wheel
*8: Construction equipment with hybrid system

FUNCTION OF TEMPORARY RESTORATION FROM INDUCEMENT (FOR NORTH

AMERICA) (PC400_11-K-AF00-042-13-B)
• Temporary Restoration from Inducement is one of the Inducement strategies allowed to be included in Urea
SCR systems. In case the Urea SCR system advances to “Severe Inducement”, engine power is derated
heavily. This may cause difficulties of moving the machine to a safe place for adding AdBlue/DEF or trou-
bleshooting and correcting abnormalities of the Urea SCR system. For temporary remedies from these diffi-
culties the operator can restore engine power for a short time to the deration of “Mild Inducement” through
the machine monitor. Note that “Temporary Restoration from Inducement” does not regain full engine pow-
er.

10-26 HB365LC-3
10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

• “Temporary Restoration from Inducement” can be activated only when the Urea SCR system is in “Severe
Inducement”. The maximum duration is limited to 30 minutes in each restoration operation, and 3 opera-
tions are allowed, but “Temporary Restoration from Inducement” is turned off whenever the system advan-
ces to “Final Inducement” even if either 30 minutes or 3 operations are not used up. All the abnormalities of
the Urea SCR system need to be corrected to regain another restoration capability.
• If all the abnormalities of the Urea SCR system are not corrected when the system is in “Severe Induce-
ment”, the system advances to “Final Inducement” in 1 hour after “Severe Inducement” started and engine
speed will be fixed to low idle to disable practical machine operation.
• To activate Temporary Restoration, follow the procedures described below.
REMARK
For the operating procedure on this function, refer to "TEMPORARY RESTORATION FROM INDUCE-
MENT" on the OPERATION section in the Operation and Maintenance Manual.

INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE WITHIN 40

HOURS (FOR NORTH AMERICA) (PC400_11-K-AF00-042-14-B)
• The Urea SCR system continuously monitors its operation conditions and stores information on inappropri-
ate operations including malfunctions.
• The stored information is utilized to monitor recurrences of abnormalities, “Abnormality Counter”. “Abnor-
mality Counter” is required by the authorities. The abnormality counting spans 40 hours and it monitors the
abnormalities that trigger Inducement other than the amount of AdBlue/DEF in the tank.
• If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were cor-
rected, regardless of the level of the previous Inducement and whether the new abnormality/abnormalities
is the same as the previous ones or not, it is judged as a recurrence.
• If a recurrence occurs, the Inducement strategy will be activated and starts from “Severe Inducement”.
• The duration of “Severe Inducement” in the recurrence is limited to 30 minutes. If the abnormalities are not
corrected while Inducement is in “Severe Inducement (30 minutes)”, Inducement will advance to “Final In-
ducement” and engine speed will be fixed to low idle to disable practical machine operation.

INDUCEMENT STRATEGY WHEN THE AdBlue/DEF LEVEL IN THE TANK BE-

COMES LOW (FOR EUROPEAN UNION) (HB335_3-K-AF00-042-21-B)
• When the AdBlue/DEF level in the tank becomes low, AdBlue/DEF level caution lamp on the machine moni-
tor lights up, the Audible alert sounds, the action level is displayed and Inducement strategy including en-
gine power deration is activated.
• The Inducement strategy progresses in 4 levels from Warning, Continuous Warning, Low-Level Induce-
ment, and Severe Inducement.
• Up to the start of Severe Inducement the start of each warning step is triggered by the amount of
AdBlue/DEF in the AdBlue/DEF tank.
• The Inducement strategy status can be checked on “SCR Information” screen of the user menu.
• The table shows warning indications and engine power derations by each Inducement strategy status.
Machine monitor
AdBlue/DEF
level (*1) AdBlue/DEF Engine dera-
Status Message of level caution
(AdBlue/DEF Tone of audi- Activated fail- tion (*3)
SCR Informa- lamp
level gauge) ble alert ure code (*2)
tion
(Action level)
Red
10% CA3497
1: DEF low
1 Warning (The bottom level warning No sound (AdBlue/DEF No deration
two grada- appears. level low error
tions light on) 1)

HB365LC-3 10-27
FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

Machine monitor
AdBlue/DEF
level (*1) AdBlue/DEF Engine dera-
Status Message of level caution
(AdBlue/DEF Tone of audi- Activated fail- tion (*3)
SCR Informa- lamp
level gauge) ble alert ure code (*2)
tion
(Action level)
5%
2: Without Red
(Within the CA3498
Continuous treatment, en- Triplet (*4)
2 Warning gradation of gine power (AdBlue/DEF No deration
Short intermit-
the second will be derat- level low error
(Warning 2) tently (*5)
from the bot- ed. 2)
tom )
Red

Red
2.5%
Low-Level In- CA1673
ducement (The grada- 3: Engine
Long intermit- (AdBlue/DEF Torque: over
3 tion of the end power is un-
(Inducement tently level low error 25%
of the bottom der deration.
1) 3)
lights on)
Red

(*6)
Red

Red CA1673 Torque: over

Severe In- 0% 4: Engine 50%
ducement CA3547
(All grada- power is un-
4 Continuously (AdBlue/DEF and
(Inducement tions lights der heavy de-
2) off) ration. level low error RPM: over
4) 40%
Red

(*6)

*1: It is shown the value of Monitoring ID 19111: “AdBlue/DEF Level Corrected”.

*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING POINTS FOR
UREA SCR SYSTEM”.
*3: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*4: Construction equipment with crawler
*5: Construction equipment with wheel

10-28 HB365LC-3
10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

*6: Construction equipment with hybrid system

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE AdBlue/DEF

QUALITY OR IN THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION)
(HB335_3-K-AF00-042-22-B)
• When any abnormality is found in the AdBlue/DEF quality or in the Urea SCR system tampering or fault,
AdBlue/DEF caution lamp on the machine monitor lights up, the Audible alert sounds. If time has elapsed
after any abnormality is generated, not only the warning by AdBlue/DEF caution lamp on the machine moni-
tor and Audible alert, but also an action level is displayed, Inducement strategy is activated and then the
engine output is reduced.
• The Inducement strategy status and the categories of abnormalities can be checked on the “SCR Informa-
tion” screen of the machine monitor.
• The table shows warning indications and engine power derations by each Inducement strategy status.
Machine monitor
AdBlue/DE
Elapsed F system Failure code Engine de-
Status Message of caution Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- lamp for abnormali-
dible alert ment strategy
mation ty (*2),(*3)
(Action lev- status (*4)
el)

1: Please Yellow
inspect and CA3571
1 Warning 5 hours maintain No sound No indication No deration
SCR sys- CB3571
tem.

Yellow

2: Without Triplet (*6) AS00R2

Continuous treatment,
2 Warning 10 hours engine Short inter- CA3571 (Warning 2 No deration
power will Yellow mittently CB3571 (SCR Device
(Warning 2)
be derated. (*7) Abnormality))

Red

Red
AS00R3
Low-Level 3: Engine
Inducement power is Long inter- CA3571 (Inducement Torque: over
3 20 hours 1 (SCR De-
(Induce- under dera- mittently CB3571 25%
tion. vice Abnor-
ment 1)
mality))
Red

(*8)

HB365LC-3 10-29
FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

Machine monitor
AdBlue/DE
Elapsed F system Failure code Engine de-
Status Message of caution Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- lamp for abnormali-
dible alert ment strategy
mation ty (*2),(*3)
(Action lev- status (*4)
el)
Red

Red Torque: over

4: Engine AS00R4
Severe In- 50%
ducement power is CA3571 (Inducement
Until repair- Continu-
4 under 2 (SCR De- and
(Induce- ing ously CB3571
heavy dera- vice Abnor- RPM: over
ment 2) tion. mality)) 40%
Red

(*8)

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing” stage. Final Inducement is not cleared till abnormality is repaired.
*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. The failure code shown here is an example of failure code which is displayed on the machine
monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING
POINTS FOR UREA SCR SYSTEM”.
*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devi-
ces branching off to 2 lines.
*4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode.
*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*6: Construction equipment with crawler
*7: Construction equipment with wheel
*8: Construction equipment with hybrid system

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE KDPF SYS-

TEM BY THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION)
(HB335_3-K-AF00-042-25-B)
• The Inducement strategy is different if Inducement is triggered by abnormalities in KDPF. Although the total
steps are the same and 4, warning indications are different and engine power deration (Over 25% torque
reduction) starts from that of “Warning ”.
• The table shows warning indications and engine power derations by each Inducement strategy status.

10-30 HB365LC-3
10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

Red
1: Please
inspect and CA4151
Long inter- Torque: over
1 Warning 5 hours maintain No indication
mittently CB4151 25%
SCR sys-
tem.
Red

(*8)
Red

Yellow

2: Without Triplet (*6) AS00R2

Continuous treatment,
2 Warning 10 hours engine Short inter- CA4151 (Warning 2 Torque: over
Red 25%
power will mittently CB4151 (SCR Device
(Warning 2)
be derated. (*7) Abnormality))

Red

(*8)

HB365LC-3 10-31
FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

Red

AS00R3
Low-Level 3: Engine
Inducement power is Long inter- CA4151 (Inducement Torque: over
3 20 hours Red 1 (SCR De-
(Induce- under dera- mittently CB4151 25%
tion. vice Abnor-
ment 1)
mality))

Red

(*8)
Red

Red

4: Engine AS00R4 Torque: over

Severe In- 50%
ducement power is CA4151 (Inducement
Until repair- Continu-
4 under Red 2 (SCR De- and
(Induce- ing ously CB4151
heavy dera- vice Abnor- RPM: over
ment 2) tion. mality)) 40%

Red

(*8)

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing”stage. Final Inducement is not cleared till abnormality is repaired.
*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. The failure code shown here is an example of failure code which is displayed on the machine

10-32 HB365LC-3
10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING
POINTS FOR UREA SCR SYSTEM”.
*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devi-
ces branching off to 2 lines.
*4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode.
*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*6: Construction equipment with crawler
*7: Construction equipment with wheel
*8: Construction equipment with hybrid system

INDUCEMENT STRATEGY WHEN ABNORMALITY IS FOUND IN THE EGR SYS-

TEM BY THE UREA SCR SYSTEM DEVICES (FOR EUROPEAN UNION)
(HB335_3-K-AF00-042-26-B)
• The Inducement strategy is different if Inducement is triggered by abnormalities in EGR. Although the total
steps are the same and 4, warning indications are different and engine power deration (Over 25% torque
reduction) starts from that of “Warning”.
• The table shows warning indications and engine power derations by each Inducement strategy status.
Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

Red
1: Please
inspect and CA2271
Long inter- Torque: over
1 Warning 5 hours maintain No indication
mittently CB2271 25%
SCR sys-
tem.
Red

(*8)

HB365LC-3 10-33
FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

Yellow

2: Without Triplet (*6) AS00R2

Continuous treatment,
2 Warning 10 hours engine Short inter- CA2271 (Warning 2 Torque: over
Red
power will mittently CB2271 (SCR Device 25%
(Warning 2)
be derated. (*7) Abnormality))

Red

(*8)
Red

Red

AS00R3
Low-Level 3: Engine
Inducement power is Long inter- CA2271 (Inducement Torque: over
3 20 hours Red 1 (SCR De-
(Induce- under dera- mittently CB2271 25%
tion. vice Abnor-
ment 1)
mality))

Red

(*8)

10-34 HB365LC-3
10 STRUCTURE AND FUNCTION FUNCTION OF UREA SCR SYSTEM

Machine monitor

Elapsed Caution Failure code Engine de-

Status Message of lamp Failure code
time (*1) Tone of au- for Induce- ration (*5)
SCR Infor- for abnormali-
mation (Action lev- dible alert ty (*2),(*3)
ment strategy
el) status (*4)

Red

Red

4: Engine AS00R4 Torque: over

Severe In- 50%
ducement power is CA2271 (Inducement
Until repair- Continu-
4 under Red 2 (SCR De- and
(Induce- ing ously CB2271
heavy dera- vice Abnor- RPM: over
ment 2) tion. mality)) 40%

Red

(*8)

*1: Elapsed time of each stage describes an accumulated time advancing to the next stage after starting “Warn-
ing”stage. Final Inducement is not cleared till abnormality is repaired.
*2: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode. The failure code shown here is an example of failure code which is displayed on the machine
monitor when an abnormality occurs. For the failure codes, see TROUBLESHOOTING, “TROUBLESHOOTING
POINTS FOR UREA SCR SYSTEM”.
*3: The failure code which starts with CB may be displayed for the machine equipped with aftertreatment devi-
ces branching off to 2 lines.
*4: These failure codes are displayed on “Current Abnormality” in the operator mode, or “Abnormality Record” in
the service mode.
*5: These percentages show a torque reduction ratio from the full torque curve, and a speed reduction ratio from
the rated speed.
*6: Construction equipment with crawler
*7: Construction equipment with wheel
*8: Construction equipment with hybrid system

FUNCTION OF TEMPORARY RESTORATION FROM INDUCEMENT (FOR EURO-

PEAN UNION) (PC400_11-K-AF00-042-23-B)
• Temporary Restoration from Inducement is one of the Inducement strategies allowed to be included in Urea
SCR systems. In case the Urea SCR system advances to “Severe Inducement”, engine power is derated
heavily. This may cause difficulties of moving the machine to a safe place for adding AdBlue/DEF or trou-
bleshooting and correcting abnormalities of the Urea SCR system. For temporary remedies from these diffi-
culties the operator can restore engine power for a short time to the deration of “Low-Level Inducement”
through the machine monitor. Note that “Temporary Restoration from Inducement” does not regain full en-
gine power.

HB365LC-3 10-35
FUNCTION OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

• “Temporary Restoration from Inducement” can be activated only when the Urea SCR system is in “Severe
Inducement”. The maximum duration is limited to 30 minutes in each restoration operation, and 3 opera-
tions are allowed. All the abnormalities of the Urea SCR system need to be corrected to regain another re-
storation capability.
• To activate Temporary Restoration, follow the procedures described below.
REMARK
For the operating procedure on this function, refer to "TEMPORARY RESTORATION FROM INDUCE-
MENT" on the OPERATION section in the Operation and Maintenance Manual.

INDUCEMENT STRATEGY FOR ABNORMALITY RECURRENCE WITHIN 40

HOURS (FOR EUROPEAN UNION) (PC400_11-K-AF00-042-24-B)
• The Urea SCR system continuously monitors its operation conditions and stores information on inappropri-
ate operations including malfunctions.
• The stored information is utilized to monitor recurrences of abnormalities, “Abnormality Counter”. “Abnor-
mality Counter” is required by the authorities. The abnormality counting spans 40 hours and it monitors the
abnormalities that trigger Inducement other than the amount of AdBlue/DEF in the tank.
• If another abnormality/abnormalities is detected within 40 hours after the previous abnormalities were cor-
rected, regardless of the level of the previous Inducement and whether the new abnormality/abnormalities
is the same as the previous ones or not, it is judged as a recurrence.
• If a recurrence occurs, the Inducement strategy will be activated.
• Inducement in the recurrence resumes counting time at the time when the previous abnormalities were cor-
rected if the previous Inducement is in “Warning”, “Continuous Warning” or “Low-Level Inducement”. The
alerts resume the previous Inducement.
• If the time the previous abnormalities were corrected is in “Severe Inducement”, Inducement in the recur-
rence starts from “Low-Level Inducement” but the remaining time to “Severe Inducement” is 1 hour or 2
hours depending on abnormalities. If the 1 hour or 2 hours are used up without correcting the new abnor-
malities, Inducement will advance to “Severe Inducement” and engine power will be derated heavily.

10-36 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM

COMPONENT PARTS OF UREA SCR SYSTEM (PC400_11-K-AF00-001-01-B)

SCR
Abbreviation for Selective Catalytic Reduction

AdBlue/DEF MIXING TUBE (PC400_11-K-AFB0-001-00-B)

STRUCTURE OF AdBlue/DEF MIXING TUBE (PC220_11-K-AFB0-041-00-B)

REMARK
The shape is subject to machine models.

A: Exhaust gas inlet (from KDPF) B: Exhaust gas outlet (to SCR)
1: Clamp 4: AdBlue/DEF mixing tube (connector)
2: AdBlue/DEF injector 5: AdBlue/DEF mixing tube (tube)
3: Gasket for AdBlue/DEF injector

FUNCTION OF AdBlue/DEF MIXING TUBE (PC400_11-K-AFB0-042-00-B)

It mixes AdBlue/DEF injected from AdBlue/DEF injector with exhaust gas, and decomposes it to ammonia which
is needed to purge NOx from SCR assembly.

SCR ASSEMBLY (PC400_11-K-AF10-001-00-B)

SCR
Abbreviation for Selective Catalytic Reduction

STRUCTURE OF SCR ASSEMBLY (PC220_11-K-AF10-041-00-B)

REMARK
The shape is subject to machine models.

HB365LC-3 10-37
COMPONENT PARTS OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

A: From AdBlue/DEF mixing tube B: To exhaust pipe

1: SCR body 3: SCR outlet NOx sensor
2: SCR temperature sensor 4: SCR outlet temperature sensor

10-38 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM

5: Temperature sensor controller 12: Catalyzer hold mat

6: Ammonia sensor 13: Water dam
7: Hanger plate 14: Downstream SCR catalyst and ammonia oxidation
8: water baffle catalyst (integrated type)

9: Water drain port 15: Upstream SCR catalyst

10: Sensor table 16: Rectifier tube

11: Sensor table band

• SCR assembly consists of rectifier tube (16) equalizing the distribution of flow speed by leading exhaust
gas, upstream SCR catalyst (15), downstream SCR catalyst, ammonia oxidation catalyst (14), and water
dam which prevents rain water from entering into downstream SCR catalyst and ammonia oxidation cata-
lyst (14) while exhausting gas.
• Ammonia oxidation catalyst (a part of 14) oxidizes ammonia to water and nitrogen with ammonia oxidation
catalyst (a part of 14) to prevent ammonia which is supplied to SCR assembly from being released out be-
cause SCR catalyst (a part of 14, 15)cannot completely consume it.
• Each 1 piece of SCR temperature sensor (2), SCR outlet temperature sensor (4), ammonia sensor (6), and
SCR outlet NOx sensor (3) are installed. These sensors are usable for various troubleshooting, such as
they are used to control the feedback of denitration efficiency or they monitor that SCR catalyst properly
functions or not.
• Rectifying tube (16) equalizes the distribution of exhaust gas flow speed.
• SCR catalyst (15, a part of 14) uses the ceramic honeycomb.
• The catalyzer holding mat (12) is made of a specific fiber and protects the ceramic catalyst against vibra-
tions by the engine and the machine body. It also protects the outer periphery of SCR assembly against a
heat transfer of the ceramics during operation.
• Water dam (13) is located at the upstream side of the outlet and prevents rainwater from entering into
downstream SCR catalyst unit and ammonia oxidation catalyst (14).
• Water baffle (8) is located at the downstream side of the outlet and prevents rainwater at outlet from splash-
ing over the detection part of NOx sensor.

HB365LC-3 10-39
COMPONENT PARTS OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

AdBlue/DEF TANK (PC400_11-K-AFF0-001-00-B)

STRUCTURE OF AdBlue/DEF TANK (PC400_11-K-AFF0-041-00-B)

A: Coolant inlet D: From AdBlue/DEF pump

B: Coolant outlet E: To breather
C: To AdBlue/DEF pump
1: Sensor flange assembly 5: AdBlue/DEF tank sensor
2: Cap 6: AdBlue/DEF tank filter
3: Sight gauge 7: Drain plug
4: AdBlue/DEF tank

10-40 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM

AdBlue/DEF TANK SENSOR (PC400_11-K-AFG1-001-00-B)

STRUCTURE OF AdBlue/DEF TANK SENSOR (PC400_11-K-AFG1-041-00-B)

REMARK
The shape is subject to machine models.

1: Connector 3: Temperature sensing part

2: Concentration Sensing part 4: Level sensing part

FUNCTION OF AdBlue/DEF TANK SENSOR (PC400_11-K-AFG1-042-00-B)

• This sensor is installed to AdBlue/DEF tank and outputs AdBlue/DEF level, AdBlue/DEF concentration, and
AdBlue/DEF temperature through CAN communication.
• AdBlue/DEF level and AdBlue/DEF concentration are measured by using ultrasonic wave.
• When the tank is frozen or empty, AdBlue/DEF level and AdBlue/DEF concentration are not measured.

HB365LC-3 10-41
COMPONENT PARTS OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

AdBlue/DEF PUMP (PC400_11-K-AFH0-001-00-B)

STRUCTURE OF AdBlue/DEF PUMP (PC400_11-K-AFH0-041-00-B)

A: Suction from AdBlue/DEF tank
B: Return to AdBlue/DEF tank
C: Pressurized sending to AdBlue/DEF injector
1: AdBlue/DEF pump
2: AdBlue/DEF inlet connector
3: AdBlue/DEF return connector
4: AdBlue/DEF outlet connector
5: Electric connector
6: AdBlue/DEF filter cap
7: AdBlue/DEF filter (built-in)

• The followings are built-in: The filter to collect the dust in

AdBlue/DEF, the valve to switch the flow direction when
purging, and the heater to thaw AdBlue/DEF when it is fro-
zen.
• It sucks AdBlue/DEF from AdBlue/DEF tank, pressurizes it
to 900 kPa {9.18 kg/cm2} , and sends it to AdBlue/DEF in- 2 3 4
jector.
• To prevent wrong connection of connectors, the return
connectors are white and can be distinguished from oth-
ers. The sizes of inlet connector and outlet connector are
different and they cannot be connected each other.
P

A4P15769

10-42 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM

AdBlue/DEF INJECTOR (PC400_11-K-AFJ0-001-00-B)

STRUCTURE OF AdBlue/DEF INJECTOR (PC400_11-K-AFJ0-041-00-B)

A: Pressurized sending from AdBlue/DEF pump
B: Coolant inlet
C: Coolant outlet
1: AdBlue/DEF injector
2: AdBlue/DEF inlet connector
3: Coolant inlet connector
4: Coolant outlet connector
5: Electric connector

FUNCTION OF AdBlue/DEF INJECTOR (PC400_11-K-AFJ0-042-00-B)

• It injects AdBlue/DEF which is pressurized by AdBlue/DEF pump into AdBlue/DEF mixing tube.
• The injection amount is controlled by the valve opening or closing time while the pressure is constant.
• It circulates the engine coolant to prevent it from being heated by the heat from the exhaust pipe.

OPERATION OF AdBlue/DEF INJECTOR (PC400_11-K-AFJ0-044-00-B)

Principle of injection of the injector is described. Following fig-
ure shows the state of injection.
1. Engine controller sends the electrical signal to control
AdBlue/DEF injector.
2. Solenoid (4) moves seal ball (2), and seal ball (2) leaves
from injection port (1) to make opening state.
Pressurized AdBlue/DEF by AdBlue/DEF pump is injected.
3. When the electrical signal is not sent, seal ball (2) closes
injection port (1) with spring force (3), so AdBlue/DEF is
not injected.

HB365LC-3 10-43
COMPONENT PARTS OF UREA SCR SYSTEM 10 STRUCTURE AND FUNCTION

AdBlue/DEF HOSE (PC400_11-K-AFH7-001-00-B)

STRUCTURE OF AdBlue/DEF HOSE (PC400_11-K-AFH7-041-00-B)

1: Connector 5: Insulation tape

2: Housing 6: Heating wire
3: Coupling 7: Nylon tube
4: Corrugated tube
• It is used as AdBlue/DEF piping between AdBlue/DEF tank and AdBlue/DEF pump or between AdBlue/DEF
pump and AdBlue/DEF injector.
• The shape of the engaging portion between AdBlue/DEF tank and AdBlue/DEF pump or AdBlue/DEF injec-
tor pin is based on 3/8 inches or 5/16 inches of SAE J2044. It can be disconnected or connected with one
touch.
• There are 2 types of hose end shape such as straight shape and 90 deg. elbow shape.
• There are 2 types of nylon tubes of its outside diameter 5 mm and 8 mm. Choose the suitable one accord-
ing to the model and the part to use.

FUNCTION OF AdBlue/DEF HOSE (PC400_11-K-AFH7-042-00-B)

• In the cold weather, the specified current flows in the heating wire immediately after the engine is started. It
heats nylon tube and thaws AdBlue/DEF which has frozen in the nylon tube while machine is stopped.
• It also keeps temperature to prevent AdBlue/DEF from freezing again while machine is operated.

10-44 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF UREA SCR SYSTEM

AdBlue/DEF TANK HEATING VALVE (PC400_11-K-AFK2-001-00-B)

STRUCTURE OF AdBlue/DEF TANK HEATING VALVE (PC220_11-K-AFK2-041-00-B)

A: Engine coolant inlet B: Engine coolant outlet

1: Solenoid 5: Plunger
2: Solenoid core 6: Diaphragm
3: Solenoid coil 7: Valve
4: Spring

FUNCTION OF AdBlue/DEF TANK HEATING VALVE (PC220_11-K-AFK2-042-00-B)

• AdBlue/DEF tank heating valve thaws AdBlue/DEF tank, and opening/closing of the valve (7) is done by
solenoid (1).
• The opening position of valve is fixed and the control is only for opening/closing. When the solenoid (1) is
de-energized, the valve is closed.
• Diaphragm (6) prevents entering of engine coolant into solenoid (1).

OPERATION OF AdBlue/DEF TANK HEATING VALVE (PC400_11-K-AFK2-044-00-B)

1. When solenoid coil (3) is energized, solenoid core (2) is magnetized and pull plunger (5) to open valve (7)
which is directly connected to plunger (5).
2. When solenoid coil (3) is de-energized, solenoid core (2) loses pulling force and plunger (5) is pushed down
by spring (4) and valve (7) is closed.

HB365LC-3 10-45
LAYOUT DRAWING OF BOOT-UP SYSTEM 10 STRUCTURE AND FUNCTION

BOOT-UP SYSTEM (PC400_11-K-AK60-001-00-B)

LAYOUT DRAWING OF BOOT-UP SYSTEM (HB335_3-K-AK60-04D-00-B)

1: Machine monitor 4: Pump controller

2: Battery 5: Fuse box
3: Engine controller 6: KOMTRAX terminal

10-46 HB365LC-3
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF BOOT-UP SYSTEM

7: Fusible link 9: System operating lamp

8: Battery disconnect switch

HB365LC-3 10-47
SYSTEM OPERATING LAMP SYSTEM 10 STRUCTURE AND FUNCTION

SYSTEM OPERATING LAMP SYSTEM (PC400_10-K-AW1Q-001-00-B)

SYSTEM OPERATING LAMP SYSTEM DIAGRAM (HB335_3-K-AW1Q-052-00-B)

1: Battery disconnect switch 6: Machine monitor

2: Battery 7: Engine controller
2: Fusible link 8: Pump controller
4: Fuse box 9: KOMTRAX terminal
5: System operating lamp 10: KomVision controller (*1)
*1: Machine with KomVision.

FUNCTION OF SYSTEM OPERATING LAMP SYSTEM (D65_18-K-AW1Q-042-00-B)

The operation state of each controller is checked by ON/OFF of the system operating lamp.
This lamp is lit while any controller is in operation. Accordingly, the operator must not shut off the battery power
circuit while this lamp is lit.
k Before shutting off the battery power supply circuit, turn the starting switch to “OFF” position, and
check that the system operating lamp goes out, then turn the battery disconnect switch to “OFF”
position.
k If the battery disconnect switch is turned to “OFF” position (battery power supply circuit is OFF)
while the system operating lamp is lit, data loss error of controller may occur. Never operate the bat-
tery disconnect switch while the system operating lamp is lit.
REMARK
• The system operating lamp goes out in max. 6 minutes after the starting switch is turned to “OFF” position.
• The system operating lamp may sometimes light up while the starting switch is in “OFF” position, because
KOMTRAX terminal may maintain its communication under this condition.
ON and OFF of system operating lamp
• Voltage of 24 V is constantly applied to one side of system operating lamp (LED (Light Emitting Diode)).
• When any controller is in operation, the controller side outputs Low (0 V), and a current flows through the
diode and the system operating lamp lights up.
• When all controllers are stopped, the controller side outputs High (24 V), and no current flows through the
diode and the system operating lamp goes off.
• KOMTRAX terminal performs communication periodically even if the starting switch is kept in “OFF” posi-
tion, thus it starts and stops repeatedly.
• The start and stop cycle (sleep cycle) of KOMTRAX terminal varies depending on the factors including the
communication state and machine stop time. So the lamp can be lit as long as approximately 1 hour.
• The system operating lamp may look slightly luminous in the dark after it is turned off. It is due to the minute
leakage of current and not an abnormal phenomenon.

10-48 HB365LC-3
10 STRUCTURE AND FUNCTION SYSTEM OPERATING LAMP SYSTEM

REMARK
• When you want to cut off the battery circuit for maintenance but the system operating lamp is kept lit, turn
the starting switch to “ON” position once, and then turn it to “OFF” position, and the lamp goes out in max. 6
minutes.
After the system operating lamp goes out, turn the battery disconnect switch immediately to “OFF” position.
• After the engine is stopped, AdBlue/DEF in AdBlue/DEF injector or AdBlue/DEF pump is automatically
sucked into AdBlue/DEF tank to prevent malfunction caused by freezing of AdBlue/DEF or deposition of
urea. Accordingly, the system operating lamp keeps lit for a while after the starting switch is turned to “OFF”
position, and this is normal.

HB365LC-3 10-49
BATTERY DISCONNECT SWITCH 10 STRUCTURE AND FUNCTION

BATTERY DISCONNECT SWITCH (ALL-K-AW1P-001-00-B)

FUNCTION OF BATTERY DISCONNECT SWITCH (PC400_11-K-AW1P-042-00-B)

(O): OFF position
(I): ON position
• Usually, battery disconnect switch (1) is used instead of
disconnecting the cable from the negative terminal of the
battery in the following cases.
• When storing the machine for a long period (1 month
or longer)
• When servicing or repairing the electrical system
• When performing electric welding
• When handling the battery
• When replacing the fuse, etc.
• When battery disconnect switch (1) is turned to OFF position (the contact is opened), all the continuous
power supplies for the components, including the starting switch B terminal and controllers, are all cut out,
and the condition is the same as the condition when the battery is not connected. Accordingly, all of the
electrical system of the machine does not operate.
NOTICE
• Do not turn battery disconnect switch (1) to OFF position while the system operating lamp is lit.
If battery disconnect switch (1) is turned to OFF position while the system operating lamp is lit, the
data in the controller may be lost and the controller may be damaged seriously.
• Do not turn battery disconnect switch (1) to OFF position while the engine is running or immediately
after the engine is stopped.
If battery disconnect switch (1) is turned to OFF position while the alternator is generating power, the
generated current has nowhere to go, leading to overvoltage in the electrical system of the machine,
which may cause serious damage to the electrical system, including the electric devices and control-
lers.
REMARK
• The system operating lamp lights up while the controller is in operation or AdBlue/DEF pump is in operation.
It lights up when KOMTRAX is performing communication, even if the starting switch is set to OFF position.
• If battery disconnect switch (1) has been at OFF position for a long period, the machine monitor and the
clock of the radio may be initialized. In this case, re-setting is required.

10-50 HB365LC-3
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF ENGINE SYSTEM

ENGINE SYSTEM (PC400_10-K-A000-001-01-B)

LAYOUT DRAWING OF ENGINE SYSTEM (HB335_3-K-A000-04D-00-B)

1: EGR cooler 4: KCCV ventilator

2:VGT 5: Air cleaner
3: SCR assembly 6: Fan clutch

HB365LC-3 10-51
LAYOUT DRAWING OF ENGINE SYSTEM 10 STRUCTURE AND FUNCTION

7: Vibration damper 12: Engine oil filter

8: Auto-tensioner 13: Generator
9: Alternator 14: Rear engine mount
10: Starting motor 15: Front engine mount
11: KDPF 16: Engine controller

FUNCTION OF ENGINE SYSTEM (HB335_3-K-A000-042-00-B)

• VGT (2) is a turbocharger that changes the cross-sectional area of the exhaust passage.
• EGR cooler (1) is a device that cools down the exhaust gas with the coolant.
• KDPF (3) is a device that purify the exhaust gas with KDOC (catalyst) and KCSF (soot collecting filter) built-
in.
• KCCV ventilator (4) is a mechanism that returns the blowby gas to the intake side after removing the oil
from it in order to burn it again. It mainly consists of filters.

10-52 HB365LC-3
10 STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM

ENGINE CONTROL SYSTEM (PC400_10-K-AP00-001-00-B)

ENGINE CONTROL SYSTEM DIAGRAM (PC220_11-K-AP00-052-00-B)

1: Battery disconnect switch 11: Starting motor cut-off relay (for PPC lock)
2: Battery 12: Starting motor cut-off relay (for personal code)
3: Battery relay 13: Fuel control dial
4: Fusible link 14: Safety relay
5: Fuse box 15: Starting motor
6: Starting switch 16: Fuel supply pump
7: Engine shutdown secondary switch 17: Various sensors
8: Engine controller 18: Machine monitor
9: Lock lever 19: KOMTRAX terminal
10: PPC lock switch 20: Pump controller

HB365LC-3 10-53
ENGINE CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

FUNCTION OF ENGINE CONTROL SYSTEM (PC220_11-K-AP00-042-00-B)

Mechanism and function of engine starting system

• When starting switch (6) is turned to ON position, engine controller (8) sends a command current to fuel
supply pump (16).
Accordingly, a fail-safe mechanism is provided, that is, the engine stops when the electrical system has
trouble.
• When starting switch (6) is turned to START position while lock lever (9) is in LOCK position, the starting
current is supplied to starting motor (15) and the engine starts.
If lock lever (9) is in FREE position, starting motor cut-off relay (11) operates to cut off the starting current to
starting motor (15) and the engine does not start, that is, a neutral safety mechanism.
• Upon receipt of the engine cut-off command from the external source, KOMTRAX terminal (19) sends the
signal to machine monitor (18).
Machine monitor (18) operates starting motor cut-off relay (12) to cut off the starting current to starting mo-
tor (15), thus the engine does not start.
Mechanism and function of engine speed control system

10-54 HB365LC-3
10 STRUCTURE AND FUNCTION ENGINE CONTROL SYSTEM

Upon receipt of the throttle signals from fuel control dial (13) and pump controller (20), engine controller (8) se-
lects the lower throttle signal and sends the command current to fuel supply pump (16). Fuel supply pump (16)
adjust the fuel injection rate to control the engine speed.
Mechanism and function of engine stopping system

When starting switch (6) is turned to OFF position, the current from terminal ACC of starting switch (6) to engine
controller (8) is cut off, and the command current to fuel supply pump (16) is also cut off. Fuel supply pump (16)
stops supplying fuel, the engine speed decreases, and the engine stops.
Mechanism and function of engine stopping system with engine shutdown sec-
ondary switch

When engine shutdown secondary switch (7) is set to the engine stop position, the current from terminal ACC of
starting switch (6) to engine controller (8) is cut off forcibly. The condition becomes the same as when starting
switch (6) is turned to OFF position, and the engine stops.

HB365LC-3 10-55
AUTO-DECELERATION SYSTEM 10 STRUCTURE AND FUNCTION

AUTO-DECELERATION SYSTEM (PC400_10-K-AF60-001-00-B)

AUTO-DECELERATION SYSTEM DIAGRAM (HB335_3-K-AF60-052-00-B)

a: CAN signal d: 1st throttle signal

b: Oil pressure sensor signal e: Fuel supply pump control signal
c: Oil pressure switch signal f: Signal from various sensors
1: Pump controller 9: Main pump
2: Engine controller 10: Control valve
3: Machine monitor 10a: Self-pressure reducing valve
4: Fuel control dial 10b: Merge-divider valve
5: Fuel supply pump 10c: Travel junction valve
6: Various sensors 11: PPC lock solenoid valve
7: Oil pressure switch 12: Inverter (hybrid controller)
8: Oil pressure sensor

FUNCTION OF AUTO-DECELERATION SYSTEM (HB335_3-K-AF60-042-00-B)

• Auto-deceleration function is a function that improves the fuel economy and reduce the noise by automati-
cally decreasing the engine speed to the control speed when all the control levers are set to NEUTRAL po-
sitions while waiting for a dump truck or next work.

10-56 HB365LC-3
10 STRUCTURE AND FUNCTION AUTO-DECELERATION SYSTEM

• If any control lever is operated, the engine speed returns immediately to the speed set with the fuel control
dial.

OPERATION OF AUTO-DECELERATION SYSTEM (HB335_3-K-AF60-044-00-B)

A: All work equipment control levers are in NEUTRAL
B: Work equipment control lever is operated
C: Speed which is set with fuel control dial
D: Engine control speed (approximately 1160 rpm)
E: Engine control speed (deceleration)
F: Engine control speed (capacitor charge)
G: 4 seconds
H: 2 seconds or less
J: 1 second or less
Engine control speed
Working mode
D E F
P, ATT/P
1160 rpm 700 rpm 1000 rpm
E, ATT/E
Without decel-
B eration func- 1000 rpm
tion
L Without deceleration function

When control lever is in NEUTRAL

1. The engine speed is decreased to the waiting speed that is approximately 1160 rpm when all the control
levers are shifted to NEUTRAL position during operation or travel while the auto-decelerator is enabled.
The engine speed is further decelerated to approximately 700 rpm when the machine remains the state for
4 seconds. The engine speed (approximately700 rpm) is held until any control lever is operated.
2. If the capacitor voltage is lowered, the engine speed is increased to 1000 rpm even when the engine speed
is decelerated. The engine speed is decreased to 700 rpm after it is charged.
When control lever is operated
1. The engine speed increases immediately to the speed according to the operating amount when any control
lever is operated while the engine speed is kept at the control speed.

HB365LC-3 10-57
ENGINE AUTOMATIC WARM-UP SYSTEM 10 STRUCTURE AND FUNCTION

ENGINE AUTOMATIC WARM-UP SYSTEM (PC400_10-K-AP13-001-00-B)

ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM (PC300_11-K-AP13-052-00-B)

a: Front pump PC-EPC valve drive signal e: Hydraulic oil temperature signal
b: Rear pump PC-EPC valve drive signal f: 1st throttle signal
c: Solenoid valve GND g: Fuel supply pump control signal
d: CAN signal h: Various sensor signals
1: Battery disconnect switch 16: Front pump
2: Battery 16a: Servo
3: Battery relay 16b: LS valve
4: Fusible link 16c: PC valve
5: Fuse box 17: Rear pump
6: Resistor for PC-EPC valve 17a: Servo
7: Pump controller 17b: LS valve
8: Engine controller 17c: PC valve
9: Machine monitor 18: Control valve
10: Air conditioner unit 18a: Self-pressure reducing valve
11: Pump drive secondary switch 18b: Merge-divider valve
12: Fuel control dial 18c: Travel junction valve
13: Fuel supply pump 19: Front pump PC-EPC valve
14: Various sensors 20: Rear pump PC-EPC valve
15: Hydraulic oil temperature sensor

10-58 HB365LC-3
10 STRUCTURE AND FUNCTION ENGINE AUTOMATIC WARM-UP SYSTEM

FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM (PC300_11-K-AP13-042-00-B)

• This system increases the engine speed to warm up the engine when the coolant temperature is low after
the engine is started.
• The engine automatic warm-up function has 2 types; “Heater warm-up” and “Normal warm-up”, either can
be used according to the purpose.
The purpose of the heater warm-up is to increase the coolant temperature to improve the heat efficiency.
The purpose of the normal warm-up is to heat the engine to prevent damage on the engine caused by low
temperature.

Operating conditions 1
Machine specification: Air conditioner specification
Air conditioner: Blower “ON”
Coolant temperature: Below 50 °C
Ambient temperature: Below 5 °C
Manual stationary regeneration: OFF
Soot accumulation: Max. 4 g/ ℓ
↓ ↓
When any of operating conditions 1 is not satisfied When all of operating conditions 1 are satisfied
Heater warm-up disabled (normal warm-up) Heater warm-up enabled
Operating conditions 2
(Operates when all of the following conditions are sat- ↓
isfied)
Coolant temperature: Below 30 °C
↓
Engine speed: Max. 1250 rpm
↓ ↓
Operation Operation
Engine speed: 1250 rpm Engine speed: Min. 1300 rpm
↓ ↓
Condition to cancel Condition to cancel
(Canceled when any of the following conditions is sat- (Canceled when any of the following conditions is sat-
isfied) isfied)

Automat- Coolant temperature: Min. 30 °C

ic Warm-up operation time: Min. 10 minutes Coolant temperature: Min. 55 °C
Fuel control dial: Held at 70 % or more of Ambient temperature: Min. 10 °C
Manual
High idle (MAX) for 3 seconds and longer.
↓ ↓
Cancellation
Engine speed: Any

HB365LC-3 10-59
OVERHEAT PREVENTION SYSTEM 10 STRUCTURE AND FUNCTION

OVERHEAT PREVENTION SYSTEM (PC400_10-K-B717-001-00-B)

OVERHEAT PREVENTION SYSTEM DIAGRAM (PC300_11-K-B717-052-00-B)

a: Front pump PC-EPC valve drive signal e: Hydraulic oil temperature signal
b: Rear pump PC-EPC valve drive signal f: 1st throttle signal
c: Solenoid valve GND g: Fuel supply pump control signal
d: CAN signal h: Various sensor signals
1: Battery disconnect switch 16: Front pump
2: Battery 16a: Servo
3: Battery relay 16b: LS valve
4: Fusible link 16c. PC valve
5: Fuse box 17: Rear pump
6: Resistor for PC-EPC valve 17a: Servo
7: Pump controller 17b: LS valve
8: Engine controller 17c: PC valve
9: Machine monitor 18: Control valve
10: Air conditioner unit 18a: Self-pressure reducing valve
11. Pump secondary drive switch 18b: Merge-divider valve
12: Fuel control dial 18c: Travel junction valve
13: Fuel supply pump 19: Front pump PC-EPC valve
14: Various sensors 20: Rear pump PC-EPC valve
15: Hydraulic oil temperature sensor

10-60 HB365LC-3
10 STRUCTURE AND FUNCTION
FUNCTION OF OVERHEAT PREVENTION SYSTEM
The overheat prevention system is a system that prevents overheating by reducing the pump load and by lower-
ing the engine speed when the coolant temperature or the hydraulic oil temperature become too high during op-
eration in order to protect engine and hydraulic components.
Operating condition
Working mode: Travel (Hi
speed)
When hydraulic oil tempera-
ture is 95 °C or more
Operating condition
Working mode: P, ATT/P
mode
When coolant temperature
100 °C or more
When hydraulic oil tempera-
ture is 100 °C or more
Operating condition
Working mode: P, ATT/P
mode
When coolant temperature is
102 °C or more
When hydraulic oil tempera-
ture is 102 °C or more
Operating condition
working mode: B, E, ATT/E
mode
When coolant temperature is
102 °C or more
When hydraulic oil tempera-
ture is 102 °C or more
HB365LC-3
Operation and remedy
→ Engine speed: Kept as it is
Pump discharged volume: Throt-
tled
Operation and remedy
Engine speed: Kept as it is
Pump discharged volume: Throt-
→ tled
• Lowers the pump absorp-
tion torque to reduce en-
gine load according to the
torque control signal.
Operation and remedy
Engine speed: Kept as it is
Pump discharged volume: Throt-
→ tled
• Lowers the pump absorp-
tion torque to reduce en-
gine load according to the
torque control signal.
Operation and remedy
Engine speed: Kept as it is
→ Pump discharged volume: Throt-
tled
Alarm monitor: Lights up
OVERHEAT PREVENTION SYSTEM
(HB335_3-K-B717-042-00-B)
Condition to cancel
Hydraulic oil temperature: Less
than 93 °C
→
• When above condition is
satisfied, it is restored to
the state before operation
(automatic restoration).
Condition to cancel
Coolant temperature: Less than
100 °C
Hydraulic oil temperature: Less
→
than 100 °C
• When above condition is
satisfied, it is restored to
the state before operation
(automatic restoration).
Condition to cancel
Coolant temperature: Less than
102 °C
Hydraulic oil temperature: Less
→
than 102 °C
• When above condition is
satisfied, it is restored to
the state before operation
(automatic restoration).
Condition to cancel
Coolant temperature: Less than
102 °C
Hydraulic oil temperature: Less
→ than 102 °C
• When above condition is
satisfied, it is restored to
the state before operation
(automatic restoration).
10-61
OVERHEAT PREVENTION SYSTEM 10 STRUCTURE AND FUNCTION

Operating condition Operation and remedy Condition to cancel

Working mode: All modes
When coolant temperature is
→ →
105 °C or more
When hydraulic oil tempera-
ture is 105 °C or more
Coolant temperature: Less than
105 °C
Hydraulic oil temperature: Less
than 105 °C
Engine speed: Low idle
Fuel control dial: Return to low
Alarm monitor: Lights up
idle (MIN) position.
Alarm buzzer: Sounds
• When above conditions
are satisfied, it is restored
to the state before opera-
tion (manual restoration).

Overheat prevention function of hybrid components

• Overheat prevention function of hybrid components is a function that prevents overheating by reducing the
load applied to the hybrid system when the temperature of hybrid components becomes too high during op-
eration.
• The overheat prevention function of hybrid components operates the alarm buzzer to sound and the hybrid
temperature monitor to light up.
• The alarm buzzer sounds and the error message is displayed on the machine monitor if the hybrid compo-
nents are overheated when this function failed to prevent the hybrid components from overheating.

10-62 HB365LC-3
10 STRUCTURE AND FUNCTION TURBOCHARGER PROTECTION SYSTEM

TURBOCHARGER PROTECTION SYSTEM (PC400_10-K-AA09-001-00-B)

TURBOCHARGER PROTECTION SYSTEM DIAGRAM (PC300_11-K-AA09-052-00-B)

a: Front pump PC-EPC valve drive signal e: Hydraulic oil temperature signal
b: Rear pump PC-EPC valve drive signal f: 1st throttle signal
c: Solenoid valve GND g: Fuel supply pump control signal
d: CAN signal h: Various sensor signals
1: Battery disconnect switch 16: Front pump
2: Battery 16a: Servo
3: Battery relay 16b: LS valve
4: Fusible link 16c: PC valve
5: Fuse box 17: Rear pump
6: Resistor for PC-EPC valve 17a: Servo
7: Pump controller 17b: LS valve
8: Engine controller 17c: PC valve
9: Machine monitor 18: Control valve
10: Air conditioner unit 18a: Self-pressure reducing valve
11: Pump drive secondary switch 18b: Merge-divider valve
12: Fuel control dial 18c: Travel junction valve
13: Fuel supply pump 19: Front pump PC-EPC valve
14: Various sensors 20: Rear pump PC-EPC valve
15: Hydraulic oil temperature sensor

HB365LC-3 10-63
TURBOCHARGER PROTECTION SYSTEM 10 STRUCTURE AND FUNCTION

FUNCTION OF TURBOCHARGER PROTECTION SYSTEM (HB335_3-K-AA09-042-00-B)

The turbocharger protection system is a system that prevents seizure of the turbocharger when the engine
speed is increased suddenly after the engine is started by limiting the engine speed.

Operating condition Actuated

Engine oil pressure: Less than 50 kPa → Turbocharger protection

{0.51 kg/cm2} (See the figure below)

A: Starting of engine
B: Turbocharger protection time (approximately 0 to 20 sec-
onds)
C: Modulation time (approximately 1 second)
D: 500 rpm
E: Approximately 1000 rpm
F: Speed correcponding to the work

10-64 HB365LC-3
10 STRUCTURE AND FUNCTION AUTOMATIC IDLE STOP SYSTEM

AUTOMATIC IDLE STOP SYSTEM (PC400_11-K-AF87-001-00-B)

AUTOMATIC IDLE STOP SYSTEM DIAGRAM (HB335_3-K-AF87-052-00-B)

a: CAN signal c: Lock lever signal

b. BR signal d. Signal from various sensors
1: Battery disconnect switch 9: PPC lock switch
2: Battery 10: Pump controller
3: Battery relay 11: Machine monitor
4: Fusible link 12: Engine controller
5: Fuse box 13: KOMTRAX terminal
6: Starting switch 14: Inverter (hybrid controller)
7: Relay 15: Hydraulic oil temperature sensor
8: Lock lever 16: Coolant temperature sensor

FUNCTION OF AUTOMATIC IDLE STOP SYSTEM (HB335_3-K-AF87-042-00-B)

• Auto idle stop function is a function that stops the engine when the operating conditions are satisfied after a
set period of time while the auto idle stop function is enabled.
• The engine is stopped by the engine controller when it judges that the conditions are met while the auto idle
stop function is enabled.
• If the engine is stopped by the auto idle stop function when the engine is running with high speed, a mes-
sage is displayed to turn on the auto-deceleration function on the machine monitor, and it turns on the auto-
deceleration function.
• The operating time of the auto idle stop function can be set by the user menu or Service Menu on the ma-
chine monitor.
Operating conditions of auto idle stop system
The auto idle stop function operates when all of the following conditions are satisfied at the same time.
• Engine is running
• Lock lever is in "LOCK" position.
• Working mode is “P”, “E”, “ATT/P”, “ATT/E”, or “B”. (It does not operate when working mode is “L”)
• "Normal warm-up" mode of engine automatic warm-up function is not in operation.
• Engine coolant temperature is not overheated (below 102 °C).

HB365LC-3 10-65
AUTOMATIC IDLE STOP SYSTEM 10 STRUCTURE AND FUNCTION

• Hydraulic oil is not overheated (below 102 °C)

• Hybrid components are not overheated.
• “Auto Idle Stop Timer Setting” on the machine monitor is not set.
• Service mode on the machine monitor is not set . (*1)
• None of the following failure codes is occurring.
*1: See “Setting time”.
Relevant failure codes are as follows.
Failure code Failure (displayed on screen)
B@BCNS Eng Water Overheat
B@HANS Hyd Oil Overheat
CA144 Coolant Temperature Sensor High Error
CA145 Coolant Temperature Sensor Low Error
D8AQKR CAN 2 Defective Communication (KOMTRAX)
DA2RKR Controller Area Network 1 Defective Communication (Pump Controller)
DA2QKR Controller Area Network 2 Defective Communication (Pump Controller)
DAFQKR CAN 2 Defective Communication (Monitor)
DB2RKR CAN 1 Defective Communication (Engine Controller)
DB2QKR CAN 2 Defective Communication (Engine Controller)
DGH2KA Hydraulic Oil Temperature Sensor Open Circuit
DGH2KB Hydraulic Oil Temperature Sensor Ground Fault
GA00NS HYB Equipment Overheat
GA1HKZ Swing Motor Driver Phase-U Temperature Sensor Open and Short Circuit
GA1JKZ Swing Motor Driver Phase-V Temperature Sensor Open and Short Circuit
GA1KKZ Swing Motor Driver Phase-W Temperature Sensor Open and Short Circuit
GA1NNS Swing Motor Driver IGBT Overheat
GA1UKZ Capacitor Temperature Sensor Open and short Circuit
GA1TNS Capacitor Overheat
GA1XKZ Booster Inductor Temperature Sensor Open and Short Circuit
GA1YNS Booster Inductor Overheat
GA1ZKZ Booster IGBT Temperature Sensor Open and Short Circuit
GA1ZNS Booster IGBT Temperature Sensor Overheat
GA22NS Booster IGBT Junction Overheat
GA23KZ Motor-Generator Driver Temperature Sensor 0 Open and Short Circuit
GA24KZ Motor-Generator Driver Temperature Sensor 1 Open and Short Circuit
GA2RKR CAN 1 Defective Communication (HYB Controller)
GA2QKR CAN 2 Defective Communication (HYB Controller)
GA25NS Motor-Generator Driver IGBT 0 Overheat
GA26NS Motor-Generator Driver IGBT 1 Overheat
GA61KZ Motor-Generator Temperature Sensor Open and Short Circuit
GA61NS Motor-Generator Temperature Sensor Overheat

10-66 HB365LC-3
10 STRUCTURE AND FUNCTION AUTOMATIC IDLE STOP SYSTEM

Failure code Failure (displayed on screen)

GA70NS HYB Swing Motor Overheat
GA71KZ HYB Swing Motor Temperature Sensor Open and Short Circuit

Setting time
Set a time for the auto idle stop function according to the following items.
For setting of each menu, see TESTING AND ADJUSTING.

Auto Idle Stop Setting (Serivice menu)

Setting Contents of setting
The auto idle stop function does not operate, and the related items are not displayed on service
OFF
menu and user menu.
Set the minimum time to be selected for Auto Idle Stop Time Fixing menu and Auto Idle Stop Timer
1 min.
Setting menu to 1 min..
Set the minimum time to be selected for Auto Idle Stop Time Fixing menu and Auto Idle Stop Timer
3 min.
Setting menu to 3 min..
Set the minimum time to be selected for Auto Idle Stop Time Fixing menu and Auto Idle Stop Timer
5 min.
Setting menu to 5 min..

Auto Idle Stop Time Fixing (Service menu)

Setting Contents of setting
The "Auto Idle Stop Time" can be selected from the value of OFF and the time from the minimum
Variable to the maximum which is 60 minutes on the Auto Idle Stop Setting in the Auto Idle Stop Timer Set-
ting menu. (Default)
The auto idle stop function does not operate, and the Auto Idle Stop Timer Setting menu is not dis-
OFF
played.
Fix to x mi- The "Auto Idle Stop Time" can be set to be x minutes on the Auto Idle Stop Timer Setting menu in
nutes. the Auto Idle Stop Setting menu. (OFF is not selectable.)

Auto Idle Stop Time Fixing (User menu)

Setting Contents of setting
OFF Auto idle stop function does not operate. (Default)
y minutes It stops the engine in Y minutes (set time at left) after setting the lock lever to “LOCK” position.

NOTICE
• The screen changes to the operator screen automatically and the auto idle stop function operates 60
minutes after the lock lever is set to LOCK position if "Fix to x min." is selected in the ““Auto Idle
Stop Time Fixing”” menu even when the Service menu is being used.
• Check the set value of the auto idle stop function before performing the work with the service menu.
Abrupt engine stop is detected
• The failure code for a detected abrupt engine stop is sent when the engine is stopped by the auto idle stop
function when the auto-deceleration function is OFF and the fuel control dial is at a position larger than
MIN.
• The failure code is recorded in the mechanical system abnormality record.
• If an abrupt engine stop is detected, the auto-deceleration function is automatically turned on.
• The failure code displayed at an abrupt engine stop varies with the number of occurrence, and the mes-
sage displayed on the machine monitor varies according to the failure code.

HB365LC-3 10-67
AUTOMATIC IDLE STOP SYSTEM 10 STRUCTURE AND FUNCTION

Action level Failure code Failure (displayed on screen)

L00 A900N6 Abrupt Engine Stop by Auto Idling Stop 1
L01 A900NY Abrupt Engine Stop by Auto Idling Stop 2
L03 A900FR Abrupt Engine Stop by Auto Idling Stop 3
• When the failure code “A900FR” of action level “L03” is sent, the turbocharger assembly must be tested
and replaced if necessary otherwise it affects the durability of the engine to decrease.
• After replacing the turbocharger assembly, reset the number of occurrence by using “Reset Number of
Abrupt Engine Stop by AIS” in “Diagnostic Tests” on Service menu.
REMARK
If the number of occurrence is not reset by using “Reset Number of Abrupt Engine Stop by AIS”, failure code
“A900FR” is sent again next time and after. Be sure to perform the reset always after the turbocharger assembly
is replaced.

10-68 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ENGINE SYSTEM

COMPONENT PARTS OF ENGINE SYSTEM (PC400_11-K-A000-001-00-B)

VGT (ENG125_6-K-AA10-001-00-B)

VGT
Abbreviation for Variable Geometry Turbocharger

STRUCTURE OF VGT (D155_7-K-AA10-041-00-B)

REMARK
The shape is subject to machine models.
General view, sectional view

A: Intake air inlet B: Intake air outlet

HB365LC-3 10-69
COMPONENT PARTS OF ENGINE SYSTEM 10 STRUCTURE AND FUNCTION

C: Exhaust inlet D: Exhaust outlet

1: Blower housing 7: Nozzle ring
2: VGT speed sensor 8: Push rod
3: Hydraulic actuator 9: Shaft
4: Turbine housing 10: Blower impeller
5: Plate 11: Turbine impeller
6: Vane 12: Piston

FUNCTION OF VGT (ENG125_6-K-AA10-042-00-B)

C: Blower impeller T: Turbine impeller

1: Air cleaner 5: SCR assembly(*1)
2: VGT 6: EGR cooler
3: KDPF 7: EGR valve
4: AdBlue/DEF mixing tube(*1)
*1: This may not be installed on some machine models and specifications.
• The exhaust gas regulations are applied to the exhaust gas from the engine running at low speed, as well
as at high speed. To meet this, the EGR ratio is improved. (EGR ratio = Ratio of amount of EGR to amount
of fresh suction air)
• To attain high EGR ratio, turbine inlet pressure (P3) must be set higher than boost pressure (P2) (P3 > P2).
For this reason, the variable turbocharger (VGT) is employed, in which the exhaust gas pressure acting on
turbine impeller (T) is adjustable.
Also, since the boost pressure increases more quickly, generation of particulate caused by lack of oxygen
during low-speed operation (rotation) is reduced.
• The shaft joined to turbine impeller (T) drives blower impeller (C) and sends much air to the cylinder for
combustion.
If VGT (2) sends more air, the fuel injection rate can be increased, thus the engine output is increased.
In addition, the air cooled by aftercooler becomes dense, that is, more oxygen is supplied, thus the fuel in-
jection rate can be increased and the engine output is increased.
NOTICE
Adequate amount of clean high quality oil is required to maintain VGT performance. Be sure to use Ko-
matsu genuine high quality oil. Follow the procedures in the Operation and Maintenance Manual when
replacing oil or oil filter.
REMARK
It sounds like air is leaking from VGT or a boost pipe, but it is not abnormal.

10-70 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ENGINE SYSTEM

OPERATION OF VGT (ENG125_6-K-AA10-044-00-B)

1. The exhaust gas enters (C) of turbine housing (4) and flows out through portion (P) and (D). Portion (P) is
surrounded by plate (5) fixed to turbine housing, nozzle ring (7), and vanes (6).
The area of its passage is changed by sliding push rod (8) to the right or left.
2. Hydraulic actuator (3) moves piston (12) in the actuator up and down with the hydraulic pressure controlled
by EPC valve installed to the front cover, and slides push rod (8) to the right and left.
3. The exhaust gas flowing through vanes (6) rotates blower impeller (10) through shaft (9) joined to turbine
impeller (11). As the result, the blower impeller works as a compressor, and the intake air entering through
(A) is compressed and discharge through (B).
4. When the exhaust gas pressure at inlet (C) of turbine housing (4) is low (engine speed is in low range),
push rod (8) slides to the right and narrows portion (P).
5. The exhaust gas acting on turbine impeller (11) increases, the turbocharger speed increases, and more air
(oxygen) is taken in.
VGT speed sensor (2) detects the rotation of the turbocharger.
When nozzle ring is “closed”
1. During low speed operation (rotation), exhaust gas inlet
passage (P) is narrow (L1). (It is not fully closed, however.)
2. If the turbine inlet pressure increases while the nozzle ring
is closed, the turbine inflow speed increases, and accord-
ingly the turbocharger speed increases.

HB365LC-3 10-71
COMPONENT PARTS OF ENGINE SYSTEM 10 STRUCTURE AND FUNCTION

When nozzle ring is “open”

1. During high speed operation (rotation), exhaust gas inlet
passage (P) is wide (L2).
2. As the engine speed increases and the turbine inlet pres-
sure (exhaust gas pressure) increases exhaust gas inlet
passage (P) is widened (L2) so that the exhaust gas acts
on turbine impeller (11) efficiently.
REMARK
• Nozzle ring (7), vanes (6), and push rod (8) are all-in-one
unit, and it slides only and does not rotate.
• Hydraulic actuator (3) is equipped with VGT position sen-
sor. VGT position sensor is calibrated together with the vari-
able mechanism of VGT and the result is written in the
memory in VGT position sensor. Accordingly, if any of hy-
draulic actuator (3), VGT position sensor, and VGT unit
fails, whole VGT must be replaced.
Operation of hydraulic actuator
1. Hydraulic actuator (1) is controlled by EPC valve (2) instal-
led to the front cover and driven hydraulically.
2. The hydraulic pressure supplied by engine boost oil pump
(3) is used for this purpose.
3. The position of hydraulic actuator (1) is fed back to engine
controller by the signals from VGT position sensor (4).

EGR SYSTEM (ENG125_6-K-A9J0-001-00-B)

EGR
Abbreviation for Exhaust Gas Recirculation

LAYOUT DRAWING OF EGR SYSTEM (ENG114_6-K-A9J0-04D-00-B)

REMARK
The shape is subject to machine models.

10-72 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ENGINE SYSTEM

1: VGT 4: Intake connector

2: EGR valve 5: Exhaust manifold
3: Intake pipe 6: EGR cooler

FUNCTION OF EGR SYSTEM (ENG114_6-K-A9J0-042-00-B)

• EGR valve (hydraulically driven type) (2) controls the gas flowing from the exhaust section to the intake
section.
Since the exhaust pressure is higher than the boost pressure, the exhaust gas flows to the intake side.
• EGR cooler (6) cools down the exhaust gas.
Engine coolant is used for cooling.
• It controls EGR circuit on the basis of the information from the sensors installed to various parts so that
clean exhaust gas is always discharged to obtain EGR ratio corresponding to the operating condition. (EGR
ratio means the ratio of EGR gas contained in the intake gas.)
• It monitors EGR circuit for troubleshooting with sensor installed to each part to prevent a serious failure
from occurring.

HB365LC-3 10-73
COMPONENT PARTS OF ENGINE SYSTEM 10 STRUCTURE AND FUNCTION

CIRCUIT DIAGRAM OF EGR SYSTEM (PC220_11-K-A9J0-052-00-B)

C: Blower impeller T: Turbine impeller

1: Air Cleaner 9: EGR valve lift sensor
2: KDPF, AdBlue/DEF mixing tube, SCR assembly 10: EPC valve (for VGT)
3: Ambient pressure sensor 11: Exhaust manifold
4: Aftercooler 12: Engine boost oil pump
5: EGR cooler 13: Intake manifold
6: EGR valve 14: Charge (boost) pressure and temperature sensor
7: Hydraulic actuator (power piston) 15: Engine controller
8: EPC valve (for EGR valve) 16: Mass air flow and temperature sensor

OPERATION OF EGR SYSTEM (PC220_11-K-A9J0-044-00-B)

1. The engine controller outputs signals in order to open EGR valve (6) most properly in accordance with the
engine load, so that both of the clean exhausting gas and low fuel consumption can be achieved.
2. When EGR valve (6) opens, a part of the exhaust gas (EGR gas) flows from exhaust manifold (11) into
EGR cooler (5) through the EGR piping.
3. The exhaust gas cooled by EGR cooler (5) flows through EGR valve (6) and mixes with the intake air in the
intake connector, and then flows in intake manifold (13).

EGR VALVE (ENG125_6-K-A9K1-001-00-B)

EGR
Abbreviation for Exhaust Gas Recirculation

STRUCTURE OF EGR VALVE (ENG114_6-K-A9K1-041-00-B)

REMARK
The shape is subject to machine models.

10-74 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ENGINE SYSTEM

Sectional view

A: EGR gas inlet (from EGR cooler) D: Servo drive oil outlet
B: EGR gas outlet (to intake manifold) E: VGT control hydraulic outlet
C: Servo drive oil inlet F: VGT drive pressure outlet
1: Valve 5: Spring
2: Spring 6: EGR valve lift sensor
3: Power piston 7: EPC valve (for EGR)
4: Spool 8: EPC valve (for VGT)
Structure
• EGR valve consists of the EGR gas flow control mechanism and EPC valve.
• There are 2 EPC valves, one for the EGR valve and the other for VGT.

HB365LC-3 10-75
COMPONENT PARTS OF ENGINE SYSTEM 10 STRUCTURE AND FUNCTION

OPERATION OF EGR VALVE (ENG125_6-K-A9K1-044-00-B)

1. The oil from the engine boost oil pump flows in port (C) of
EGR valve. The control pressure from EPC valve solenoid
enters port (E).
2. Spool (4) is moved to the right by the reaction force of
spring (5), and valve (1) is closed by the reaction for spring
(2). Accordingly, the exhaust gas from EGR cooler does
not flow to the intake side.
3. To open valve (1), the control pressure from EPC valve en-
ters port (E) first. The position of spool (4) is determined by
the balance of the control pressure and spring (5).
4. Since the notch of power piston (3) opens, the oil from the
engine boost oil pump flows through port (C) and pushes
power piston (3) to the left.
5. The oil from the engine boost oil pump acts on power piston (3) and generates force (Fp).
6. When force (Fp) increases more than reaction force (Fs) of spring (2), EGR valve (1) opens and the ex-
haust gas flows to the intake side.
7. Reaction force (Fs) of spring (2) and force (Fp) of power piston are balanced since the engine controller
controls the control pressure with EPC valve solenoid.
8. Since the servo mechanism is applied, external force applied to valve (1) does not act on spool (4) which is
in contact with power piston (3).
9. EGR valve lift sensor senses the displacement of spool (4).

EGR COOLER (ENG125_6-K-A9L0-001-00-B)

EGR
Abbreviation for Exhaust Gas Recirculation

STRUCTURE OF EGR COOLER (ENG114_6-K-A9L0-041-00-B)

REMARK
The shape is subject to machine models.

10-76 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ENGINE SYSTEM

General view and sectional view

A: EGR gas inlet D: EGR gas outlet (to EGR valve)

B: Air vent E: Coolant inlet
C: Coolant outlet
1: Flat tube
Detailed drawing of flat tube
1: Flat tube
2: Inner fin

OPERATION OF EGR COOLER (ENG114_6-K-A9L0-044-00-B)

• EGR gas enters through (A) and flows through flat tubes (1) (11 pieces).
• Coolant enters through (E), flows outside of flat tubes (1) in the case, and goes out through (C).
• Flat tube (1) has inner fins (2), thus EGR gas is cooled efficiently and discharged through EGR gas outlet
(D).

KCCV SYSTEM (ENG125_6-K-A180-001-00-B)

KCCV
Abbreviation for KOMATSU Closed Crankcase Ventilation

HB365LC-3 10-77
COMPONENT PARTS OF ENGINE SYSTEM 10 STRUCTURE AND FUNCTION

LAYOUT DRAWING OF KCCV SYSTEM (ENG114_6-K-A180-04D-00-B)

REMARK
The shape is subject to machine models.

A: Blowby gas C: Removed engine oil (to engine oil pan)

B: Blowby gas from which engine oil is removed (to
VGT)
1: KCCV ventilator 3: VGT
2: CDR valve 4: Check valve

FUNCTION OF KCCV SYSTEM (ENG114_6-K-A180-042-00-B)

• In the past, blowby gas (A) was allowed to be released into the atmosphere in the past, but now it is re-
stricted by emission regulations.
• Blowby gas (A) contains ingredients of the engine oil. A filter is installed to KCCV ventilator (1) to remove
the engine oil to prevent the following possible problems if it is recirculated to VGT (3) as it is.
• Deterioration of turbocharger and aftercooler performance caused by sticking engine oil
• Abnormal combustion in engine
• Malfunction of each sensor caused by sticking engine oil

10-78 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ENGINE SYSTEM

KCCV VENTILATOR (ENG125_6-K-A18H-001-00-B)

KCCV
Abbreviation for KOMATSU Closed Crankcase Ventilation

STRUCTURE OF KCCV VENTILATOR (ENG114_6-K-A18H-041-00-B)

REMARK
The shape is subject to machine models.
General view and sectional view

A: Blowby gas inlet (from engine breather) C: Oil drain port (to engine oil pan)
B: Blowby gas outlet (to VGT intake side)
1: Case 4: Relief valve
2: CDR valve 5: Impactor
3: Crankcase pressure sensor 6: Filter
Structure
• Filter (6) is classified by the working direction for filter replacement into the top load type (removed upward)
and bottom load type (removed downward).
• The top load type (removed upward) and bottom load type (removed downward) are different from each
other in the position of the crankcase pressure sensor.
In the top load type (removed upward), the crankcase pressure sensor is installed to the bottom of KCCV
ventilator.
In the bottom load type (removed downward), the crankcase pressure sensor is installed to the top of
KCCV ventilator.

FUNCTION OF KCCV VENTILATOR (ENG114_6-K-A18H-042-00-B)

• If the blowby gas is returned to the intake side of VGT and crankcase pressure becomes negative, the dust
may be sucked in through crank seal.

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COMPONENT PARTS OF ENGINE SYSTEM 10 STRUCTURE AND FUNCTION

The pressure inside the crankcase is controlled by CDR valve (2) to prevent this to occur.
• Crankcase pressure may increase and oil leakage may occur if filter (6) of KCCV ventilator is clogged.
Thus, crankcase pressure sensor detects the clogging of filter (6).
• Relief valve (4) is inside case (1), and it operates to bypass the blowby gas and protect both KCCV ventila-
tor and the engine when filter (6) is blocked.

OPERATION OF KCCV VENTILATOR (ENG114_6-K-A18H-044-00-B)

1. When the blowby gas enters blowby gas inlet (A) and passes through the hole of impactor (5) in filter (6),
large particles in the oil mist are separated.
2. Small particles in the oil mist are separated by filter (6).
3. The separated oil oozes out from the bottom of the filter (6), and flows to oil drain port (C), and then flows to
the engine oil pan.
4. The crankcase pressure sensor senses the crankcase pressure (blowby gas pressure).
If the engine controller judges through detected value of crankcase pressure sensor that the filter is clog-
ged, it displays failure code CA555, and if the pressure increases further, it displays failure code CA556.
5. Relief valve (4) is installed in case (1) and operates when filter (6) is blocked.
6. When the crankcase pressure becomes negative, CDR valve (2) operates for it not to become excessively
negative.

CDR VALVE (ENG125_6-K-A18A-001-00-B)

CDR
Abbreviation for Crankcase Depression Regulator

OPERATION OF CDR VALVE (D155_7-K-A18A-044-00-B)

1. Spring (2) normally pushes up diaphragm (1), and the
blowby gas flows from crankcase side (A) into turbocharg-
er side (air intake side) (B).
2. As the intake air at turbochaeger side (air intake side) (B)
increases, pressure on crankcase side (P1) decreases.
3. The reaction force of spring (2) is overwhelmed by ambient
pressure (P2). Diaphragm (1) shuts the passage and tem-
porarily blocks the flow.
4. When the blowby gas accumulates in the crankcase, pres-
sure (P1) on the crankcase side increases, and it pushes
up diaphragm (1) again and blowby gas starts to flow.

KDPF (ENG125_6-K-A9H0-001-00-B)

KDPF
Abbreviation for KOMATSU Diesel Particulate Filter

STRUCTURE OF KDPF (ENG114_6-K-A9H0-041-00-B)

REMARK
The shape is subject to machine models.

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ENGINE SYSTEM

General view

A: From VGT B: To AdBlue/DEF mixing connector

1: Inlet unit 8: KDPF outlet temperature sensor
2: Hanger bracket 9: Centralized connector box
3: Sensor bracket 10: KDOC outlet temperature sensor
4: Sensor bracket band 11: KDOC inlet temperature sensor
5: Outlet unit 12: KDPF differential pressure sensor port
6: KCSF unit 13: KDPF differential pressure sensor
7: KDOC unit 14: KDPF differential pressure sensor port
Structure
• KDPF consists of inlet unit (1) to introduce the exhaust gas, KDOC unit (7) to store the oxidation catalyst,
KCSF unit (6) to store the soot collecting filter equipped with catalyst, and outlet unit (5) to discharge the
exhaust gas.
• KDOC unit (7) consists of ceramic honeycomb equipped with the oxidation catalyst.
• The ceramic honeycomb is protected with a mat made of special fibers to prevent breakage of the ceramics
under the vibration condition of the engine and machine body.
This mat also thermally insulates the periphery of KDPF from the ceramics which becomes high tempera-
ture during operation.
• KCSF unit (6) consists of ceramic honeycomb equipped with the oxidation catalyst, similarly to KDOC unit
(7).
The inside of KCSF unit (6) consists of many cells partitioned by ceramic walls. The cells blocked on the
inlet side and those blocked on the outlet side are arranged alternately.
• KDPF is equipped with KDPF temperature sensor (assembly of KDOC inlet temperature sensor, KDOC out-
let temperature sensor, and KDPF outlet temperature sensor) and the differential pressure sensor (assem-
bly of KDPF differential pressure sensor and KDPF outlet pressure sensor).

HB365LC-3 10-81
COMPONENT PARTS OF ENGINE SYSTEM 10 STRUCTURE AND FUNCTION

Combination of temperatures detected by these 3 temperature sensors is used to monitor that KCSF unit
(6) and KDOC unit (7) are functioning normally, and to troubleshoot various components.
The differential pressure sensor monitors accumulation of soot in KCSF unit (6) by sensing the pressure
difference between both sides of KCSF unit (6), and uses the obtained data for troubleshooting of various
components, similarly to the temperature sensor.

FUNCTION OF KDPF (ENG114_6-K-A9H0-042-00-B)

A: Flow of exhaust gas
1: KDOC (oxidation catalyst)
2: KCSF
3: Seal (ceramic made)
4: Cell
5: Ceramics honeycomb
• KDPF purifies the exhaust gas by catching large amount of
chainlike soot or PM (Particulate Matter such as soot)
which is contained in the engine exhaust gas.
• KDOC (oxidation catalyst) (1) oxidizes NO (nitrogen mon-
oxide) contained in the exhaust gas into NO 2 (nitrogen di-
oxide), and regenerates (*1) KCSF.
• KCSF (2) captures soot.
• Accumulated soot in KCSF (2) in operation range where
the temperature of exhaust gas is relatively high state is
naturally oxidized and burnt away by the effect of KDOC
(oxidation catalyst) (1). (This is called “passive regenera-
tion”)
REMARK
“Passive regeneration” cannot be performed if the light
load operation and low temperature state of the exhaust
gas continue. Accumulated soot is gradually increased.
• Engine controller always monitors 2 soot accumulation values and compares them. One is presumed soot
accumulation based on the engine operating conditions, and the other is the calculated soot accumulation
based on the signal from the differential pressure sensor which is attached to KCSF (2).
• If the amount of accumulated soot and the temperature of engine exhaust gas exceed the specified level,
engine controller performs “automatic regeneration” to burn (oxydize) the soot.
While performing automatic regeneration, the engine controller calculates the exhaust gas temperature at
KDOC inlet and exhaust gas volume, and controls the engine to raise the temperature of engine exhaust
gas. (This is called “exhaust gas temperature raise control”)
The temperature of engine exhaust gas at KDOC inlet is controlled by the fuel amount injected from the
injector, and exhaust gas volume is controlled by VGT.
The engine controller enhances the oxidation power in KDOC (1) by raising the temperature of engine ex-
haust gas automatically, and improves combustion efficiency of soot captured in KCSF (2).
REMARK
When regeneration function on the machine monitor is disabled, or outside air temperature is extremely
low, or continuous light load operation is carried out, relatively low exhaust temperature continues. In such
case, “automatic regeneration” is not performed and the amount of soot accumulation is increased.
• If “automatic regeneration” is not performed due to the excess amount of accumulated soot in KCSF (2),
perform “manual stationary regeneration” to burn (oxydize) the soot and reduce the amount of soot inside
KCSF (2).

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF ENGINE SYSTEM

REMARK
Excessive amount of the soot interferes the flow of exhaust gas to worsen fuel consumption and engine
combustion state. It may lead to other failures.
If the amount of soot increases further, “manual stationary regeneration” cannot be performed safely. This
will result in a KDPF failure and replacement is unavoidable. Make sure to follow the procedures in the Op-
eration and Maintenance Manual when performing “manual stationary regeneration”.
*1: Soot purification (oxidation) treatment

TYPES OF REGENERATION FUNCTIONS (ENG125_6-K-A9H0-042-10-B)

Regeneration means to purify (oxidize) the soot accumulated on the soot collecting filter (KCSF) in KDPF or
maintain the urea SCR system normal.
Passive regeneration
When the exhaust temperature of the engine is relatively high, the oxidation power of soot in the exhaust gas
components is increased by the catalysis of KDOC to oxidize (burn) the soot accumulated in KCSF naturally.
Active regeneration (engine exhaust temperature rise control + fuel dosing)
• Automatic regeneration
• When soot is accumulated more than a certain level or the urea SCR system makes a request to main-
tain itself normal, the engine enters the exhaust temperature rise control mode (*1) and performs fuel
dosing (*2) and starts regeneration automatically.
The automatic regeneration is also performed by the direction from the engine controller at a set time
after the previous regeneration, regardless of soot accumulation in KCSF.
*1: Control to increase the engine exhaust temperature by controlling the fuel injection timing or VGT.
*2: Fuel injection performed to accelerate regeneration by increasing the exhaust temperature.
• Manual stationary regeneration
• When the exhaust temperature does not reach a certain level, depending on the operating condition of
the machine, or when the operator disables regeneration, the automatic regeneration is not performed
and accumulated soot in KCSF increases. Also, when the automatic regeneration is performed upon
receiving a request from the urea SCR system, the exhaust temperature may not reach a certain level,
depending on the operating condition of the machine. In these cases, a request for the manual station-
ary regeneration request is displayed on the machine monitor, and the operator must perform regener-
ation by the operation on the machine monitor screen.
In addition, when the engine controller is replaced or ash in KCSF is washed, a serviceman performs
regeneration by the operation on the machine monitor screen (“active regeneration for service”).

HB365LC-3 10-83
COMPONENT PARTS OF ENGINE SYSTEM 10 STRUCTURE AND FUNCTION

NOTICE
• For the procedure to start and stop the regeneration of KDPF, see the Operation and Maintenance
Manual for each machine.
• Always use ultra low-sulfur diesel fuel. If any fuel other than the specified one is used, it can cause a
failure in KDPF.
• Always use specified Komatsu genuine engine oil applicable to KDPF. If any oil other than the speci-
fied one is used, it can clog KDPF quickly, and that can increase fuel consumption and cause a fail-
ure in KDPF.
• Do not modify KDPF body and exhaust pipe. If modification is made, KDPF cannot operate normally
and may have trouble.
• Do not give strong impacts to KDPF by standing on it, dropping it, or hitting it, etc. KDPF has ceram-
ic parts in it, and they may be broken by a strong impact.
• During the “automatic regeneration” and the “manual stationary regeneration”, especially at low
temperature, white smoke may be discharged through the exhaust pipe outlet for a short time. This
phenomenon is not abnormal. Be sure to perform regeneration in a well-ventilated area, since car-
bon monoxide may be generated.
• During the “automatic regeneration” and the “manual stationary regeneration”, the temperature of
the exhaust gas discharged from the exhaust pipe may increase above 650 °C. To prevent a fire,
check that there is no combustible around the exhaust pipe. Also, check that there is no person in
the blow-out direction of the exhaust gas and confirm the safety around the machine.
REMARK
• If the mixing ratio of the bio-fuel in the diesel fuel is high, the regeneration of KDPF may become more fre-
quent.
• Even when soot is not accumulated much, the engine controller may start “automatic regeneration”. This is
automatic regeneration to maintain the function of KDPF or urea SCR system normal, and is not an abnor-
mal operation. Automatic regeneration to maintain the function of urea SCR system normal or manual sta-
tionary regeneration takes approximately 1 hour.
• During the “automatic regeneration” and the “manual stationary regeneration”, VGT operates automatically
and the engine sound changes. Also, the exhaust gas flow rate in KDPF changes, and accordingly the ex-
haust sound changes. These phenomena are not abnormal.
• During the “automatic regeneration” and the “manual stationary regeneration”, the exhaust pipe may smell
different from usual. This is not abnormal phenomenon.
• KDPF has “KDPF dry operation” function to prevent excessive accumulation of unburnt fuel in KDPF when
operation is continued at relatively low temperature for long hours.This is a function that the engine control-
ler increases the engine exhaust temperature automatically and performs dry operation of KCSF when the
set condition is satisfied. When the automatic dry operation is insufficient for the treatment, manual station-
ary regeneration may be required.
• The standard temperature of KDPF is shown below.
KDOC In (KDOC inlet KDOC Out (KDOC out- KDPF Out (KDPF outlet
temperature sensor) let temperature sensor) temperature sensor)
While regeneration is not performed
100 to 250 °C
(idling state)
While regeneration is performed (ther-
100 to 250 °C 400 to 550 °C
mal mode)

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10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF COOLING SYSTEM

COOLING SYSTEM (PC400_10-K-B000-001-00-B)

LAYOUT DRAWING OF COOLING SYSTEM (HB335_3-K-B000-04D-00-B)

1: Hybrid radiator 4: Reservoir tank

2: Aftercooler 5: Shroud
3: Fan guard 6: Oil cooler

HB365LC-3 10-85
LAYOUT DRAWING OF COOLING SYSTEM 10 STRUCTURE AND FUNCTION

7: Radiator cap 9: Radiator inlet hose

8: Radiator 10: Radiator outlet hose

SPECIFICATIONS OF COOLING SYSTEM (HB335_3-K-B000-030-00-B)

Radiator
Core type: CF90–4
Fin pitch: 3.5/2 mm
Heat dissipation area: 82.67 m2
Cracking pressure of pressure valve: 0.05 MPa {0.5 kg/cm2}
Cracking pressure of vacuum valve: -0.005 MPa {-0.05 kg/cm2}
Oil cooler
Core type: 62 thickness
Fin pitch: 3.5/2 mm
Heat dissipation area: 28.65 m2
Aftercooler
Core type: Aluminum wave
Fin pitch: 4.0/2 mm
Heat dissipation area: 17.55 m2
Hybrid radiator assembly
Core type: CF58–2
Fin pitch: 4.0/2 mm
Heat dissipation area: 15.68 m2
Cracking pressure of pressure valve: 0.05 MPa {0.5 kg/cm2}
Cracking pressure of vacuum valve: -0.005 MPa {-0.05 kg/cm2}

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10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF HYBRID SYSTEM

HYBRID SYSTEM (HB335_3-K-PQG9-001-00-B)

LAYOUT DRAWING OF HYBRID SYSTEM (HB335_3-K-PQG9-04D-00-B)

1: Capacitor (electric accumulator) (*1) 4: Cooling device

2: Inverter (hybrid controller) (*1) 5: Motor-generator (*1)
3: Electric swing motor (*1) 6: High voltage wiring (orange)(*1)
*1: High voltage portion (400 to 650 V)

HB365LC-3 10-87
SYSTEM DIAGRAM OF HYBRID SYSTEM 10 STRUCTURE AND FUNCTION

SYSTEM DIAGRAM OF HYBRID SYSTEM (HB335_3-K-PQG9-052-00-B)

a: Insulation b: Shield and braided

1: Motor-generator case 8: Electric swing motor
2: Engine 9: Inverter high voltage portion
3: Motor-generator high voltage portion 10: Electric swing motor high voltage portion
4: Connector 11: Capacitor high voltage portion
5: High voltage wiring 12: Swing machinery
6: Capacitor case 13: Machine frame
7: Inverter case 14: Flexible electrical wire
REMARK
• High voltage systems of the hybrid system are not grounded. They are insulated from the machine frame at
the inside of the hybrid component case and high voltage wiring shield braids.
• There will be no risk of electric shock unless damaging the high voltage systems and directly touching the
positive side and the negative side.
• Each hybrid component case and shield braiding are grounded to the machine frame through the flexible
electrical wire or other devices.

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10 STRUCTURE AND FUNCTION STRUCTURE OF HYBRID SYSTEM

STRUCTURE OF HYBRID SYSTEM (HB335_3-K-PQG9-041-00-B)

• This machine is equipped with the hybrid system in order to accomplish the lower fuel consumption, which
combines the electrical motor and diesel engine.
• The hybrid system of this machine has hybrid components (motor-generator, electric swing motor, capaci-
tor, inverter) whose temperature become approximately400 to 650 V, and high voltage portion such as high
voltage wiring connecting devices, and cooling devices whose temperature becomes high during operation.
Low fuel consumption which is achieved by the hybrid system
• Hybrid system drives the swing by electric swing motor, and the swing operation causes the motion energy.
Hybrid system converts the motion energy to the electric energy, and charges the capacitor.
The electric energy charged in the capacitor is supplied to the electric swing motor for the next swing oper-
ation.
• With the hybrid system, the engine runs at the minimum speed when the control lever is in NEUTRAL posi-
tion, and the fuel consumption is reduced.
Hybrid system controls the engine speed corresponding to the lever stroke, the control pattern, and the load
so that the fuel consumption ratio will be optimal.
Hybrid system stop switch
• The hybrid system stop switch is a switch that stops the
actuation directive of motor-generator, swing motor, and in-
verter. It makes only the engine and hydraulic system actu-
ated.
• The work equipment operation and travel operation are
available even when the hybrid system is not enabled.
• Once the hybrid system is stopped, it is not enabled until
the starting switch is turned to “OFF” position.
a: Emergency (when abnormal)
b: Normal (when normal)
NOTICE
• Hybrid system stop switch is a switch that temporarily
stops the hybrid system when an abnormality occurs in
the machine.
Do not use the hybrid system stop switch unless a
trouble occurs.
• The hybrid system stop monitor lights up on the ma-
chine monitor if this switch is wrongly turned to “Emer-
gency (a)” position when the machine is normal.

HB365LC-3 10-89
HYBRID PROTECTION SYSTEM 10 STRUCTURE AND FUNCTION

HYBRID PROTECTION SYSTEM (HB335_3-K-PQJL-001-00-B)

SYSTEM DIAGRAM OF HYBRID PROTECTION SYSTEM (HB335_3-K-PQJL-052-00-B)

a: High temperature d: Connector abnormality

b: Overcurrent (electric swing motor, motor-generator, e: Fuse melt down when capacitor cable is short
capacitor) circuited
c: Overcurrent (high voltage wiring)
1: Key switch 3: Electric leakage sensor (built-in inverter)
2: Hybrid system stop switch

FUNCTION OF HYBRID PROTECTION SYSTEM (HB335_3-K-PQJL-042-00-B)

The hybrid protection system is a system that minimizes the damage to the hybrid components when the elec-
tric leakage occurs. It detects the deterioration of the insulation of high voltage devices and short circuit to the
machine body with electric leakage sensor which is built in the inverter and stops the functions in the inverter
(inverter, booster, driver).
Conditions for the hybrid system to be totally stopped
All or either condition
• When the temperature of each part of swing motor, motor-generator, inverter, and capacitor exceeds the
system stop temperature shown in the table
Example of failure code:
(GA00NS) HYB Equipment Overheat
Name of item in "Self-define Mon- Temperature at where
Equipment name Place
itoring" the system stops
Swing motor Stator coil Swing motor coil temperature 160 °C
Motor-generator Generator coil Motor-generator temperature 190 °C

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10 STRUCTURE AND FUNCTION HYBRID PROTECTION SYSTEM

Name of item in "Self-define Mon- Temperature at where

Equipment name Place
itoring" the system stops
Booster trans Booster inductor temperature 130 °C
Booster IGBT junction (*1) - 135 °C
Booster IGBT base Booster IGBT base temperature 100 °C
Inverter
IGBT junction for PM (*1) Swing inverter JCT temperature 135 °C
Generator driver IGBT base tem-
IGBT junction for SR (*1) 100 °C
perature
Capacitor - - -

*1: Marked item is an estimate value obtained by calculation, not measured.

• When excess current is detected in the swing motor and motor-generator (including a fuse meltdown), or
when an abnormality is detected in current sensor in high voltage wiring
Example of failure code:
(GA62KY) Motor-Generator Phase-A Current Sensor Power Supply Line Short Circuit
(GA0AKZ) DC Line Voltage Sensor after Booster Open and Short Circuit
• When an abnormality is detected in the current sensor of the swing motor and motor-generator, or when an
abnormality is detected in current sensor in high voltage wiring
Example of failure code:
(GA08KG) DC Line Hardware after Booster Power Voltage High Error
(GA0AKZ) DC Line Voltage Sensor after Booster Open and Short Circuit
• When an abnormality is detected in high voltage wiring connector (open circuit, hot short circuit, ground
fault in interlock circuit)
Example of failure code:
(GA01KA) Power Cable Interlock Open Circuit
• When an electric leakage is detected
Example of failure code:
(GA02KZ) DC Line Open and Short Circuit
(GA0BKZ) AC Line Open and Short Circuit
• When an abnormality is detected in the capacitor or in the high voltage wiring in capacitor
Example of failure code:
(GA02KZ) DC Line Open and Short Circuit
(GA04KG)DC Line HW before Booster Power Voltage High Error

HB365LC-3 10-91
COOLING SYSTEM OF HYBRID COMPONENTS 10 STRUCTURE AND FUNCTION

COOLING SYSTEM OF HYBRID COMPONENTS (HB335_3-K-PQJN-001-00-B)

SYSTEM DIAGRAM OF COOLING SYSTEM OF HYBRID COMPONENTS

(HB335_3-K-PQJN-052-00-B)

a: Oil passage for cooling and lubrication c: Temperature sensor

b: Passage for coolant
1: Electric swing motor 11: Coil
2: Stator coil temperature sensor 12: Cooling and lubrication pump
3: Stator coil 13: Inverter (hybrid controller)
4: Radiator 14: Hybrid water pump
5: Hybrid radiator 15: Booster inside temperature sensor
6: Engine 16: Capacitor
7: Motor-generator 17: Capacitor cell
8: Coil temperature sensor 18: Capacitor cell and bath bar temperature sensor
9: Pump 19: Oil cooler
10: Rotor 20: EGR cooler

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10 STRUCTURE AND FUNCTION INTERLOCK SYSTEM OF HYBRID COMPONENTS

INTERLOCK SYSTEM OF HYBRID COMPONENTS (HB335_3-K-PQJM-001-00-B)

SYSTEM DIAGRAM OF INTERLOCK SYSTEM OF HYBRID COMPONENTS

(HB335_3-K-PQJM-052-00-B)

a: High voltage wiring (power cable) c: Interlock output

b: Interlock circuit d: Interlock input
1: Electric swing motor 4: Inverter (hybrid controller)
2: Connector 5: Capacitor
3: Motor-generator

FUNCTION OF INTERLOCK SYSTEM OF HYBRID COMPONENTS (HB335_3-K-PQJM-042-00-B)

• Hybrid system has an interlock circuit (b) in the high voltage wiring connector (2) portion of motor-generator
(3), inverter (hybrid controller)(4), electric swing motor(1).
• Interlock system is a system that stops the hybrid system by sending an error signal to the monitor when an
abnormality such as the looseness and fall of connector (2) of high voltage wiring (power cable) (a) with the
interlock circuit (b) occurs by monitoring with the inverter (hybrid controller)(4).
• Inverter (hybrid controller)(4) stops the hybrid system when it judges that the connector (2) has an abnor-
mality of the open contact of the circuit such as reverse assembling or fall.
• Inverter (hybrid controller)(4) stops the hybrid system by sending an error signal to the monitor when an
abnormality with the interlock circuit (b) occurs by monitoring it.
REMARK
The high voltage wiring (power cable) (a)connector has an interlock circuit (b), which is connected to the inverter
(hybrid controller)(4), it also monitors if there is an abnormality such as looseness or the fall of connector (2).

HB365LC-3 10-93
WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE
HYBRID COMPONENTS 10 STRUCTURE AND FUNCTION

WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE HY-

BRID COMPONENTS (HB335_3-K-PQJK-001-00-B)

SYSTEM DIAGRAM OF WORKER PROTECTION SYSTEM FOR WHEN DISAS-

SEMBLING THE HYBRID COMPONENTS (HB335_3-K-PQJK-052-00-B)

A: Consumed by the motor-generator B: Consumed by the discharge function of machine

monitor with motor-generator
1: Inverter (hybrid controller) 3: One-touch connector
2: Capacitor 4: Contactor

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 WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING THE
10 STRUCTURE AND FUNCTION HYBRID COMPONENTS

5: High voltage wiring 7: Electric leakage protection fuse

6: Discharge resistor

FUNCTION OF WORKER PROTECTION SYSTEM FOR WHEN DISASSEMBLING

THE HYBRID COMPONENTS (HB335_3-K-PQJK-042-00-B)
• All the hydraulic components are shut off from the high voltage electric power supply when the starting
switch is “OFF” position.
• The capacitor (2) has the one-touch connector (3) due to safety consciousness in case the electric charge
remains.
• The contactors (4) (2 pieces) contacting to the inverter (1) are open, and the capacitor (2) is disengaged.
• The electric charge which is charged in the inverter (1) is consumed by motor-generator when the starting
switch is in “OFF” position.
• The electric charge which is charged in the inverter (1) is discharged in minutes with the discharge resistor
(6) inside when the function of the motor-generator is disabled due to occurrence of an error.
• The components are shut off by the interlock switch as previously described even if the starting switch is
“ON” position when the high voltage wiring (5) is removed.
• The electric charge in the capacitor (2) can be consumed and discharged by the discharge function of the
monitor.
One-touch connector
Electrode of the one-touch connector is protected with waterproof seal (2) and insulator (4) so that it is not be
touched easily.

1: Core conductor 3: Solenoid shield

2: Water proof seal 4: Insulator

HB365LC-3 10-95
COMPONENT PARTS OF HYBRID SYSTEM 10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF HYBRID SYSTEM (HB335_3-K-PQG9-001-02-B)

MOTOR-GENERATOR (HB335_3-K-PQH3-001-00-B)

LAYOUT DRAWING OF MOTOR-GENERATOR (HB335_3-K-PQH3-04D-00-B)

1: Level gauge 5: Filter

2: Coolant pipe 6: Oil cooler
3: Motor-generator 7: Coolant pipe
4: Lubrication pump 8: Oil filler pipe

SPECIFICATIONS OF MOTOR-GENERATOR (HB335_3-K-PQH3-030-00-B)

Model: ZG051
Lubricating oil (specified amount): 9.1 ℓ
Lubricating oil (refill amount): 8.5 ℓ
Specified oil: TO10
Weight: 327 kg

FUNCTION OF MOTOR-GENERATOR (HB335_3-K-PQH3-042-00-B)

• The motor-generator is a component that converts the engine rotation and torque to the electrical power,
and provides them to the electric swing motor.
• The motor-generator is a component that assists the engine output by supplying the electrical power from
the capacitor.

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYBRID SYSTEM

ELECTRIC CONTROL UNIT (HB335_3-K-PQGA-001-00-B)

LAYOUT DRAWING OF ELECTRIC CONTROL UNIT (HB335_3-K-PQGA-04D-00-B)

1: Capacitor 3: Mount rubber

2: Inverter (hybrid controller)

SPECIFICATIONS OF ELECTRIC CONTROL UNIT (HB335_3-K-PQGA-030-00-B)

Inverter type: ZD201
Fuse rate: 67 A
Total weight: 170 kg
Inverter weight: 61 kg

FUNCTION OF ELECTRIC CONTROL UNIT (HB335_3-K-PQGA-042-00-B)

The electric control unit is the component that controls motor-generator, electric swing motor, and capacitor dis-
charge.

HB365LC-3 10-97
COMPONENT PARTS OF HYBRID SYSTEM 10 STRUCTURE AND FUNCTION

HIGH VOLTAGE WIRING (POWER CABLE) (HB335_3-K-PQJF-001-00-B)

LAYOUT DRAWING OF HIGH VOLTAGE WIRING (POWER CABLE) (HB335_3-K-PQJF-04D-00-B)

1: High voltage wiring (capacitor) 4: Electric swing motor

2: Electric control unit 5: Motor-generator
3: High voltage wiring (electric swing motor) 6: High voltage wiring (motor-generator)

STRUCTURE OF HIGH VOLTAGE WIRING (POWER CABLE) (HB335_3-K-PQJF-041-00-B)

High voltage wiring (power cable) is waterproof, and has shield structure.

FUNCTION OF HIGH VOLTAGE WIRING (POWER CABLE) (HB335_3-K-PQJF-042-00-B)

• The high voltage wiring is a wiring that provides high voltage electric power.
• The high voltage wiring can be identified with the black lines for preventing connectors from being connect-
ed wrongly.
• The connector for the high voltage wiring has a interlock switch.
Disconnecting the connector releases the switch, and stops the hybrid system.

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYBRID SYSTEM

HYBRID WATER PUMP (HB335_3-K-PQGV-001-00-B)

LAYOUT DRAWING OF HYBRID WATER PUMP (HB335_3-K-PQGV-04D-00-B)

A: Coolant inlet B: Coolant outlet

1: Water pump

SPECIFICATIONS OF HYBRID WATER PUMP (HB335_3-K-PQGV-030-00-B)

Rated voltage: 24 V
Rated current: 2.4 A
Weight: 2.1 kg×2

FUNCTION OF HYBRID WATER PUMP (HB335_3-K-PQGV-042-00-B)

• The hybrid water pump starts operation at the same time as the starting switch is turned to “ON” position.
• The hybrid water pump is driven by electric power from the battery.
• The hybrid water pump circulates the coolant for the hybrid component.
• The hybrid water pump intakes the coolant from the radiator for the hybrid component, and discharges it to
the capacitor.

HB365LC-3 10-99
COMPONENT PARTS OF HYBRID SYSTEM 10 STRUCTURE AND FUNCTION

INVERTER (HYBRID CONTROLLER) (HB335_3-K-PQGK-001-00-B)

STRUCTURE OF INVERTER (HYBRID CONTROLLER) (HB335_3-K-PQGK-041-00-B)

INPUT AND OUTPUT SIGNALS OF INVERTER (HYBRID CONTROLLER)

(HB335_3-K-PQGK-03C-00-B)

DRC-24P“CN-HC01”
Pin No. Signal name Input and output
1 Battery relay terminal M (24 V) Input
2 NC (*1) -
3 Capacitor connector (+) Output
4 NC (*1) -
5 Continuous power supply (24 V) Input
6 Starting switch ACC signal Input
7 Battery relay terminal M (24 V) Input
8 Swing parking brake solenoid valve Output
9 Capacitor connector (-) Input
10 NC (*1) -
11 Continuous power supply (24 V) Input
12 Starting switch ACC signal Input
13 Power supply GND Input
14 Battery relay signal HOLD Output
15 PPC lock switch Input

10-100 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYBRID SYSTEM

Pin No. Signal name Input and output

16 NC (*1) -
17 Power supply GND Input
18 Service connector Input
19 Power supply GND Input
20 NC (*1) -
21 Power supply for swing parking brake solenoid valve output Output
22 System operating lamp Output
23 Power supply GND Input
24 NC (*1) -

*1: Never connect these pins, otherwise it may cause malfunction or failures.
DRC-40P“CN-HC02”
Pin No. Signal name Input and output
1 CAN(C)_H Input and output
2 NC (*1) -
3 Hybrid system stop switch Input
4 SRM position sensor Input
5 Resolver R1 OUT Output
6 Resolver S1 IN Input
7 Sensor power supply 0 (5 V) Output
8 NC (*1) -
9 Right swing PPC oil pressure sensor Input
10 NC (*1) -
11 CAN(C)_L Input and output
12 NC (*1) -
13 NC (*1) -
14 Interlock input Input
15 Resolver R2 OUT Output
16 Resolver S3 IN Input
17 Analog signal GND Input
18 PM motor temperature Input
19 Left swing PPC oil pressure sensor Input
20 NC (*1) -
21 CAN(R)_H Input and output
22 CAN(DEBUG)_H Input and output
23 NC (*1) -
24 Interlock output Output
25 Sensor power supply 0 (5 V) Output
26 Resolver S2 IN Input

HB365LC-3 10-101
COMPONENT PARTS OF HYBRID SYSTEM 10 STRUCTURE AND FUNCTION

Pin No. Signal name Input and output

27 Capacitor Th1 Input
28 SR motor temperature Input
29 NC (*1) -
30 NC (*1) -
31 CAN(R)_L Input and output
32 CAN(DEBUG)_L Input and output
33 Digital signal GND Input
34 Swing lock switch Input
35 Swing prolix Input
36 Resolver S4 IN Input
37 Capacitor Th2 Input
38 Analog signal GND Input
39 NC (*1) -
40 NC (*1) -

*1: Never connect these pins, otherwise it may cause malfunction or failures.

10-102 HB365LC-3
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF CONTROL SYSTEM

CONTROL SYSTEM (PC400_11-K-0H00-001-00-B)

LAYOUT DRAWING OF CONTROL SYSTEM (HB335_3-K-0H00-04D-00-B)

1: Camera

HB365LC-3 10-103
LAYOUT DRAWING OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

2: CAN terminating resistor 3: Engine controller

10-104 HB365LC-3
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF CONTROL SYSTEM

4: Machine monitor 7: Resistor for PC-EPC valve

5: GPS antenna 8: KOMTRAX terminal
6: Pump controller 9: Communication antenna

HB365LC-3 10-105
MACHINE MONITOR SYSTEM 10 STRUCTURE AND FUNCTION

MACHINE MONITOR SYSTEM (PC400_11-K-Q180-001-00-B)

MACHINE MONITOR SYSTEM DIAGRAM (HB335_3-K-Q180-052-00-B)

a: Power supply d: Drive signal

b: CAN signal e: Camera signal
c: Sensor signal and switch signal f: Image signal
1: Machine monitor 7: KOMTRAX terminal
2: Battery 8: Sensors and switches
3: Pump controller 9: Wiper motor and window washer motor
4: Engine controller 10: Rearview camera (*1)
5: Air conditioner controller 11: KomVision controller (*2)
6: Inverter (hybrid controller) 12: KomVision camera (*2)
*1: For machine without KomVision.
*2: For machine with KomVision.

FUNCTION OF MACHINE MONITOR SYSTEM (HB335_3-K-Q170-042-00-B)

• The monitor system is a system that monitors the machine state by obtaining the information with the sen-
sors and switches installed in various parts of the machine, processes the information instantly, and dis-
plays the information on the machine monitor to inform the operator of the machine condition.
The information displayed on the machine monitor falls into the following types:

10-106 HB365LC-3
10 STRUCTURE AND FUNCTION MACHINE MONITOR SYSTEM

• Alarms when the machine has a trouble

• Machine state display (coolant temperature, power train oil temperature, hydraulic oil temperature, fuel
level, etc.)
• Display of camera image (machine with camera)
• The switches on the machine monitor also have the functions to control the machine.

HB365LC-3 10-107
KomVision SYSTEM 10 STRUCTURE AND FUNCTION

KomVision SYSTEM (PC128_11-K-K900-001-00-B)

10-108 HB365LC-3
10 STRUCTURE AND FUNCTION KomVision SYSTEM

KomVision SYSTEM (PC500_8-K-K900-001-00-B)

(Machine with KomVision system)

LAYOUT DRAWING OF KOMVISION SYSTEM (HB335_3-K-K900-04D-00-B)

Chassis part

1: Right front camera 3: Rear camera

2: R.H. camera 4: L.H. camera

HB365LC-3 10-109
KomVision SYSTEM 10 STRUCTURE AND FUNCTION

Around cab and floor

1: Machine monitor 2: KomVision controller

KomVision SYSTEM DIAGRAM (PC128_11-K-K900-052-00-B)

10-110 HB365LC-3
10 STRUCTURE AND FUNCTION KomVision SYSTEM

1: Machine monitor 4: Rear camera

2: KomVision controller 5: R.H. camera
3: L.H. camera 6: R.H. front camera (*1)
*1: When four cameras are installed

FUNCTION OF KomVision SYSTEM (PC128_11-K-K900-042-00-B)

• KomVision system is the system that captures the vision around the machine by cameras attached to the
various positions of the machine, and reflects the vision on the machine monitor.
• The machine monitor shows the bird's eye view and the camera view.
• The bird's eye view displayed on the machine monitor is an image which is electrically composed with im-
ages captured by cameras attached to the machine.
• The camera image displayed on the machine monitor is an image which is captured by camera installed to
the machine. The images to be displayed can be selected freely.
k The image displayed on the machine monitor does not reflect all around the machine. Perform the
visual check always when operating the machine.
k Do not rely only on the image displayed on the machine monitor for the safety.
k The cameras do not capture the objects which are located higher than the cameras. Be careful about
the objects which are located higher than the cameras such as a work equipment of the large ma-
chine, a branch of the tree, etc.
REMARK
• The upper part of the monitor screen does not always mean the front of the machine when the machine is
with swing function.
• The upper part of the monitor screen recognizes the work equipment side of the upper structure as the front
side, and the longitudinal and lateral directions are determined with that. The direction of the undercarriage
is not recognized.
• For the function and the method of operation of KomVision system, see “Operation and Maintenance Man-
ual”.
• Resetting of the items will be required when the blade is replaced or the track length is changed by referring
to TESTING AND ADJUSTING, "SETTING OF KomVision (MAIN SETTING)".
The area KomVision cameras can capture
The area KomVision cameras can capture for the bird's eye view varies as shown below, it depends on how
many cameras are installed to the machine.
When three cameras are installed
1: L.H. camera
2: Rear camera
3: R.H. camera

HB365LC-3 10-111
KomVision SYSTEM 10 STRUCTURE AND FUNCTION

When four cameras are installed

1: L.H. camera
2: Rear camera
3: R.H. camera
4: R.H. front camera

10-112 HB365LC-3
10 STRUCTURE AND FUNCTION KOMTRAX SYSTEM

KOMTRAX SYSTEM (PC400_10-K-Q210-001-00-B)

KOMTRAX SYSTEM DIAGRAM (PC400_10-K-Q210-052-00-B)

KOMTRAX system consists of KOMTRAX terminal, communication antenna, and GPS antenna

FUNCTION OF KOMTRAX SYSTEM (PC400_10-K-Q210-042-00-B)

• KOMTRAX system transmits various types of information on the machine. KOMTRAX administrator sees
the information in the office and supplies various services to the customers.
• KOMTRAX system can transmits the following information.
• Positional information
• Working information
• Alarm and failure information
• Fuel consumption information
• Maintenance information
• Machine working condition information
REMARK
To provide the services, you need to establish radio station for KOMTRAX separately.

HB365LC-3 10-113
PPC LEVERS 10 STRUCTURE AND FUNCTION

PPC LEVERS (PC490_11-K-LTK0-001-00-B)

LH PPC LEVER (PC490_11-K-LTK0-041-00-B)

K3X10003

1. Lever
2. Gaiter
3. Harness
4. Connector

10-114 HB365LC-3
10 STRUCTURE AND FUNCTION PPC LEVERS

RH PPC LEVER (PC490_11-K-LTK0-041-01-B)

K3X10002

1. Lever
2. Gaiter
3. Harness
4. Connector

HB365LC-3 10-115
AUTOMATIC GREASE SYSTEM 10 STRUCTURE AND FUNCTION

AUTOMATIC GREASE SYSTEM (PC490_11-K-Q810-001-00-B)

OUTLINE OF AUTO GREASE SYSTEM (PC240_11-K-Q810-041-00-B)

3 2 5
4 1

10 11
8 6
13 9 7 17 15 K3X10010
12 14 16 18

17 15
Distribution
Block
18 16

13 10
Distribution 11
Block
14 12

6 1

7 2
Distribution
3
Block
8 4

9 5

In-Cab
Display
Pressure
switch

K3X10009

Assembly
Greasing system generally consists of the following components (see figure 1):
1. Electrically-driven plunger-pump with grease reservoir
2. Control unit (integrated in the pump housing)
3. Distribution blocks
4. Metering units
5. Secondary grease lines
6. Grease pressure switch
7. Primary grease line A
8. Primary grease line B

10-116 HB365LC-3
10 STRUCTURE AND FUNCTION AUTOMATIC GREASE SYSTEM

Components
(a) The Grease Pump
The relief valve
A relief valve is mounted in the grease line between the plunger-pump and the diverter-valves. When the grease
pressure exceeds25 MPa during the pumping phase, the relief valve will redirect the grease to the reservoir.
The maximum grease procedure will be exceeded when:
• A malfunction of the grease pressure switch, which is mounted in the system occurs.
• A malfunction in the cable of the grease pressure switch occurs.
The grease pressure switch is intended to end the pumping phase, as soon as the minimum required grease
pressure is reached.
The minimum-level switch
A level switch maintains the grease level in the reservoir. When the grease reaches the minimum level, the level
switch will notify the control unit. At the beginning of every following grease cycle a signal lamp in the cabin will
flash as a warning that the reservoir has to be refilled.
The test push-button
The grease system can be tested by starting one or more test cycles by means of the test push-button on the
pump unit. This button also can be used to reset the control unit.
(b) Distribution Blocks and Metering Units
Various types of metering units with the greasing system are available, each with a different grease output.
Each greasing point can receive the correct dose of grease cycle by a careful choice of the type of metering
unit.

HB365LC-3 10-117
AUTOMATIC GREASE SYSTEM 10 STRUCTURE AND FUNCTION

The metering units are mounted on a brass distribution block per group (see figure 2). These primary grease
lines are connected. The blocks are deliverable with 2, 3, 4, 5, 6, 7, 8, 9, 12, 14, 18, 20, 21 or 22 ports (exits).
Greasing points are connected to these ports through metering units and secondary grease lines. Unused ports
are sealed with a blind plug.
The metering units and distribution blocks are made of brass. The various metering units are distinguished from
each other using numbers (see figure 2).

The table below is an overview of the metering unit numbers and their grease capacity.
Position Metering Unit Grease Capacity
1 8 0.400
2 8 0.400
3 3 0.150
4 2 0.100
5 3 0.150
6 1 0.050
7 8 0.400

10-118 HB365LC-3
10 STRUCTURE AND FUNCTION AUTOMATIC GREASE SYSTEM

8 1 0.050
9 8 0.400
10 4 0.200
11 9 1.000
12 2 0.100
13 9 1.000
14 10 2.000
15 4 0.200
16 4 0.200
17 4 0.200
18 10 2.000

(c) Grease Pressure Switch

The grease pressure switch notifies the control unit that sufficient pressure has been built during the greasing
cycle (in the pumping phase). If the required pressure is not reached in the maximum adjusted pumping time, an
alarm follows.
(d) The Display
The display continuously indicates the adjusted operating mode with green lamps. A yellow lamp lights when
the minimum grease level is reached and a red lamp lights when a malfunction occurs. The display is also
equipped with a push-button with which another operating mode can be chosen at any moment.
The greasing cycle
Every greasing cycle consists of four phases. The greasing cycles are carried out alternately by the grease lines
A and B (see figure 3). The 5/2 valve, which is integrated in the pump housing, determines which primary
grease line is connected to the pump and which is connected to the grease reservoir. The total greasing cycle
has a predetermined time; however, the length of the four phases depend on the circumstances.
The different greasing cycles and phases are discussed below.

HB365LC-3 10-119
AUTOMATIC GREASE SYSTEM 10 STRUCTURE AND FUNCTION

Greasing Cycle A
The pumping phase
The greasing cycle begins with a pumping phase. In this phase the grease is pumped from the reservoir,
through primary grease line A, to the distribution blocks. The pumping phase ends when the pressure at the
pressure switch reaches a predetermined level. The time needed to reach that predetermined pressure depends
on various factors as temperature, grease consistency (thickness) and the dimensions of the greasing system.
The duration of the pumping phase is therefore not directly adjustable. During the pumping phase, the metering
units press a certain amount of grease (the dosage) through the secondary grease lines to the greasing points.
The re-grease phase
The re-grease phase follows the pumping phase; a period in which the pressure in the primary grease lines is
maintained at a certain pressure. During the re-grease phase, the metering units can deliver the grease dosage,
which (for various reasons) was not delivered during the pumping phase. The duration of the regrease phase
depends on the duration of the pumping phase. This dependency is expressed in the parameter bmf, bleeding
multiplication factor.
• Example: When the bmf is 1, the re-grease phase is 1/10th of the length of the pumping phase. When the
bmf is 10, the re-grease is 10/10th of the length of the pumping phase.
The pressure decrease phase
The pressure decrease phase follows the re-grease phase. In this phase, the pressure in the primary grease
line is decreased through the 5/2 valve. To accomplish this, the control unit energises the 5/2 valve, so the
grease pressure in primary grease line A is decreased and the grease flows back to the reservoir.
The duration of the pressure decrease phase is equal to that of the re-grease phase and therefore proportional
to the duration of the pumping phase. When the greasing system needs more time to build up the required
grease pressure (because of low temperature or grease with a high viscosity), the system will also need more
time to decrease that same pressure.
The pause phase
The pause phase is the period between the pressure decrease phase and the beginning of the next pumping
phase. The length of the pause phase is equal to the predetermined cycle-time minus the length of the other
phases. When the cycle-time is adjusted too short to carry out a complete greasing cycle, the program will ig-
nore the cycle-time. The pumping, re-grease and pressure decrease phase will be carried out completely.
However the pause phase will be omitted, because the predetermined cycle-time is exceeded. The greasing
system begins directly with the first phase of the next greasing cycle.
Greasing cycle B
Greasing cycle B begins when the control unit restarts the pump. During pumping phase B and re-grease phase
B, the control unit still has the 5/2 valve energised, causing the pump to be connected to primary grease line B.
Primary grease line A is shut off from the pump during these phases and connected to the reservoir. During the
phase B pressure decrease, the control unit de-energises the 5/2 valve, so the grease pressure in the grease
line decreases and the grease flows back to the reservoir.
Introduction
In this chapter the principles of the operation of the various parts of the automatic greasing system are dis-
cussed. The pump unit, metering units, grease pressure valve, control unit, signal lamp and display are dis-
cussed.
(a) Pump unit
The pump unit consists of various parts. These parts are shown in figure 4.

10-120 HB365LC-3
10 STRUCTURE AND FUNCTION
1. Grease follower piston
2. Grease reservoir
3. Stirring gear
4. Cam
5. Cylinders and plungers (3 x)
6. 5/2 Magnetic valve
7. Primary grease line 'A' coupling
8. Primary grease line 'B' coupling
HB365LC-3
AUTOMATIC GREASE SYSTEM
11. Electro-motor
12. Test push-button
13. Filler coupling with grease filter
14. Relief valve
15. Follower piston guide
16. Electric connector
17. Minimum level switch
18. Bleeding and grease overflow channel
10-121
AUTOMATIC GREASE SYSTEM 10 STRUCTURE AND FUNCTION

9. Mechanical transmission 19. Bleeding and grease overflow channel at right side of
pump connected to the grease overflow channel in fol-
10. Control Unit
lower piston guide (Nos. 15 and 18)

The heart of the pump is an electrical-driven plunger-pump. This pump consists of three radially-placed fixed
cylinders and plungers (5, see figure 4). The electro-motor drives the axle through the mechanical drive.
A cam (4) is fixed on the axle that moves the three plungers to and fro, so the grease is pumped to the distribu-
tion blocks through the primary grease line. In addition to the cam, the axle drives the stirring gear (3) located at
the bottom of the reservoir and pushes the grease downwards. A compression channel is located between the
pump and the grease channels to the primary grease lines. A relief valve (14) and a 5/2 valve (6) are located in
the compression channel.
The relief valve is a protection that leads the grease back to the reservoir when the grease pressure exceeds
25 MPa. The 5/2 valve determines the primary grease line (A or B) through which greasing takes place. It has
an important task in fulfilling the four phases of the greasing cycle.
The grease reservoir and the grease follower piston
The reservoir (2, see figure 4) is made of a transparent, impact-proof plastic that resists the affect of variable
temperatures and other environmental influences. The volume of the reservoir depends on the height of the res-
ervoir. The maximum grease level is indicated on the reservoir. A warning signal in the cabin indicates when the
minimum level has been reached.
A grease follower piston (1) is located in the reservoir, above the grease. This piston follows the level of the
grease. When the grease level falls, the piston also falls under the influence of a draw spring. The grease fol-
lower piston locks out air and condensation, so preventing:
• Oxidation of the grease
• Mingling of the grease with the water of condensation
• Saponifying of the grease
The grease level in the reservoir can always be determined at a glance, because the grease follower piston
scrapes the walls of the reservoir. Also the grease follower piston prevents funnel-forming in the grease, so the
grease supply can and will be used in its entirety.
The 5/2 Magnetic Valve

A: Primary grease line A (port A)

10-122 HB365LC-3
10 STRUCTURE AND FUNCTION AUTOMATIC GREASE SYSTEM

B: Primary grease line B (port B)

P: From pump
RA: Return line A to grease reservoir
RB: Return line B to grease reservoir
When the 5/2 magnetic valve is at stationary (not energised by the control unit, see figure 4.1), greasing will
take place through the primary grease line A and the pressure in primary grease line B will decrease and the
grease will lead back to the reservoir through return line RB.
When the 5/2 magnetic valve is energised by the control unit, the grease supply channel P will be connected to
primary grease line B and primary grease line A will be connected to return line RA in the pump. Greasing takes
place through primary grease line B, the pressure grease line A will decrease and the grease will be lead back
to the reservoir through return line RA .
For an extensive description of the greasing cycle and the influence of the position of the 5/2 magnetic valve on
the greasing cycle , see paragraph ''The Greasing Cycle''.
(b) Metering units
Do not open the metering units. Prevent intrusion of dirt and thus a possible cause of malfunction.

Two grease chambers are located in a metering unit (one for each primary grease line, A and B). These cham-
bers are filled with an exact amount of grease. When the actual greasing takes place through one of both cham-
bers, the grease is pressed from the chambers to the relevant greasing point. The principle of operation of the
metering unit is explained in the four phases below.
Phase 1
In this phase, the metering unit has not yet filled with grease (see figure 4.2)

While in operation (system completely filled with grease) phases 3 and 4 will take place alternately.
Phase 2
Grease is pumped into the metering unit (pumping phase A) through primary channel A (see figure 4.3). Be-
cause of the grease pressure, plunger (3) is pushed to the right, passed channel (1). The grease fills chamber
(2) through channel (1) and presses plunger (4) to the right.

HB365LC-3 10-123
AUTOMATIC GREASE SYSTEM 10 STRUCTURE AND FUNCTION

After a while the pressure drops in primary channel A (during the pressure decrease phase of the greasing cy-
cle). This has no influence on the metering unit.
Phase 3
Grease is pumped into channel (6) of the metering unit (pump phase B) through primary channel B (see figure
4.4). Because of the grease pressure, plunger (3) is pushed back leftwards, passed channel (8). The grease fills
chamber (7) and pushes plunger (4) back to the left. The complete grease volume of chamber (2), to the left of
plunger (4), is pressed through channel (1), plunger (3) and channel (9) and the secondary grease line (5) to the
greasing point. Sphere (10) in the non-return valve is pushed back to clear the path to the secondary grease
line.

After a while, the pressure drops in primary channel B (during the pressure decrease phase of the greasing cy-
cle). This has no influence on the metering unit.
Phase 4
In this phase the same happens as in phase 2. However chamber (7) (see figure 4.4) is now filled with grease.
Plunger (4) is pushed to the right (see figure 4.5) while chamber (2) is filled. The complete grease volume of
chamber (7) is pressed through channel (8), plunger (3) and channel (9) and the secondary grease line (5) to

10-124 HB365LC-3
10 STRUCTURE AND FUNCTION AUTOMATIC GREASE SYSTEM

the greasing point. Sphere (10) in the non-return valve is pushed back to clear the path to the secondary grease
line.

(c) Grease pressure switch

The principle of operation of the grease pressure switch is explained in three phases.
Phase 1
During this phase both channels A and B are not under pressure (see figure 4.6). There is also no pressure in
chamber (1). Spring (10) pushes switch plunger (2) to the left. The electrical contact (3 and 4) is open.

Figure 4.6 Principle of operation of grease pressure switch - rst phase

Phase 2 (pumping phase A)

During pumping phase A grease is pressed into channel A (see figure 4.7). While the grease pressure is built
up, piston (6) is pushed to the right. Chamber (1) is connected to channel A (through the channels 7, 8 and 9).
As soon as the pressure in chamber (1) is more than the pressure force of the spring (10), plunger (2) goes to
the right. The electrical contact (3 and 4) is closed by the contact plate (5).
During the pressure decrease phase, as soon as the grease pressure in channel A is lower than the pressure
force of the spring, the connection of contacts is broken.

HB365LC-3 10-125
AUTOMATIC GREASE SYSTEM 10 STRUCTURE AND FUNCTION

Figure 4.7 Principle of operation of grease pressure switch - second phase

Phase 3 (pumping phase B)

During pumping phase B grease is pressed into channel B (see figure 4.8). While the grease pressure is built
up, chamber (11) fills with grease (through channel 12). The grease pressure pushes piston (6) to the left. Be-
cause of that the channel (8) is opened, causing the grease to flow to chamber (1) through channel (7) and
channel (9).
As soon as the pressure in chamber (1) is greater than the pressure force of the spring (10), the plunger (2)
goes to the right. The electrical contact (3 and 4) is closed by the contact plate (5).
As soon as the grease pressure, during the pressure decrease phase, in channel B is lower than the pressure
force of the spring, spring (10) pushes plunger (2) back to the left and the connection of the contacts is broken.

Figure 4.8 Principle of operation of grease pressure switch - third phase

(d) Control unit

Introduction
The greasing system is controlled by an electronic control unit. The sensors that check specific parts or the
complete greasing system for malfunctions are connected to the control unit.
The control unit controls the greasing system by:
• The parameters that are saved in the control unit. To recall or change the system parameters requires a
laptop and software:
• The signals that the control unit receives from the various sensors and controls applied in the greasing sys-
tem: e.g., grease pressure switch, grease level switch, test push-button, push-button with signal lamp in the
cabin.
The control unit records an automatic log, in which the relevant events are stored. All data in the control unit will
always be retained, even when the power is shut off or when the system is turned off. To view the log requires a
laptop and software.
In this paragraph the following system parameters are discussed:
• The length of the greasing cycles;
• Maximum length of the pumping phase;
• Length of the re-grease phase and the pressure phase;
• Reaction of the system to grease pressure malfunctions;
• Repeating frequency of the flashing code;
• The log.

10-126 HB365LC-3
10 STRUCTURE AND FUNCTION AUTOMATIC GREASE SYSTEM

The length of the greasing cycles

The meaning of the various phases of the greasing cycle is described in paragraph 3. (further see figure 4.9)

The duration of a greasing cycle (adjustment range: 0 ... 1440 minutes) is defined as the period that expires
between two successive pumping phases: beginning from the start of one pumping phase and ending at the
start of the next pumping phase.
A greasing cycle is divided into a pumping phase, a re-grease phase, a pressure decrease phase and a pause
phase. The greasing cycles are alternately taken care of by primary grease lines A and B.
Maximum length of the pumping phase
Normally, the pumping phase will end when the grease pressure switch notifies the control unit that the required
pressure in the greasing system has been reached.
Prevent the pump from pumping indefinitely when the notification does not occur.
A maximum pumping time is therefore stored in the control unit (adjustment range: 1 ... 60 minutes).
At a normal (average) pumping phase, shorter than 5 minutes, the maximum pumping phase is adjusted as fol-
lows: multiply the normal pumping time by 2.
When the normal pumping phase is longer than 5 minutes, the maximum pumping time is adjusted to: normal
duration +5 minutes.
Length of the re-grease and pressure decrease phases
The duration of the re-grease phase is equal to the length of the pressure decrease phase. The pressure de-
crease phase is proportional to the length of the pumping phase. In the control unit a multiplication factor is stor-
ed. The duration of the pressure decrease phase is calculated by the control unit by multiplying the duration of
the pumping phase with that factor. (adjustment range: 1 ... 100 - which corresponds to multiplication factors 0,
1 ... 10).
The standard adjustable value is 1 (multiplication factor 0, 1), when the duration of the re-grease phase and the
pressure decrease phase is one tenth of the duration of the pumping phase. When circumstances require and
extended pressure decrease phase, a higher factor is adjusted.
Reaction of the system to grease pressure malfunctions.
When the required grease pressure during several pumping phases is not reached, it indicates e.g., a leak in a
primary line. To prevent the contents of the reservoir being pumped into the environment, the greasing system

HB365LC-3 10-127
AUTOMATIC GREASE SYSTEM 10 STRUCTURE AND FUNCTION

should be shut down. Greasing is stopped, until the cause of the malfunction is repaired and the control unit is
reset with the test push-button.
Normally the pump is shut off by the control unit when in 10 successive greasing cycles the required grease
pressure has not been reached during the pumping phase. Meaning: the control unit shuts off the pump when
the grease pressure has not been reached 10 successive times while greasing alternately through lines A and
B, thus 5 times A and 5 times B but the control unit also shuts off the pump when the grease pressure is not
reached 10 times successively when greasing through line B, however through line A the pressure is still
reached and also the other way around.
With parameter 'noa' (number of attempts), a different value for the maximum number of attempts can be adjust-
ed. The adjustment depends on the malfunction sensitivity of the connected greasing points. The adjustment
range is 1 to 25 greasing cycles.
Display
A display is also deliverable instead of the operating mode push-button with integrated signal lamp.
On this display green lamps continuously indicate the adjusted operating mode. In addition, this display is equip-
ped with a yellow warning lamp (minimum grease level reached), a red lamp (system malfunction) and a push-
button to adjust the desired operating mode.

10-128 HB365LC-3
10 STRUCTURE AND FUNCTION AUTOMATIC GREASE SYSTEM

In the following table an overview is given of the normal signal

Indication Meaning
The red lamp (6) 1. The pump is not powered. Check fuses and connections to earth. Immediate action re-
flashes as soon as quired.
the ignition has 2. The connection between the in-cab display and pump is defective, replace if necessary.
been switched on.

HB365LC-3 10-129
AUTOMATIC GREASE SYSTEM 10 STRUCTURE AND FUNCTION

No lamp is lighting 1. The system is not powered. Check fuses and connections to earth. Immediate action re-
up when the starting quired.
switch is in the ON 2. The display or wiring of the in-cab display is defective. Check in-cab display and wiring and
position. replace if necessary.
Yellow lamp (5) Minimum level in the reservoir has been reached.
flashing Reset by refilling the reservoir.

Red lamp (6) flash- System out of order. Immediate action required!
ing Possible causes:
• Insufficient grease pressure during 10 consecutive cycles (or 10 consecutive times in
the same main line). Check for cause and reset by depressing the test button at the
pump for at least 1 second while the ignition is switched on.
• Reservoir empty; reset by refilling reservoir and after that depressing the test button
for at least 1 second while the ignition is switched on.
Green lamp (4) Low duty
flashing

Green lamp (4) Normal duty

flashing

Green lamp (4) Heavy duty

flashing

A green lamp is Single test run being executed (see tests).

flashing during one
complete cycle (2.0
sec on/2.0 sec off)
A green lamp is Continuous test run being executed (see tests).
flashing continuous-
ly (0.2 sec on/0.2
sec off)

REMARK
1. The display communicates with the control unit every 20 secs. A started test cycle can only be shown on
the display after 20 secs.
2. The display is equipped with a light-sensitive cell. Therefore the light intensity of the lamps is automati-
cally dimmed when the surroundings become darker.

10-130 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

COMPONENT PARTS OF CONTROL SYSTEM (PC400_11-K-0H00-001-10-B)

MACHINE MONITOR (PC400_10-K-Q180-001-00-B)

FUNCTION OF MACHINE MONITOR (PC400_10-K-Q180-042-10-B)

• The machine monitor has the monitor display function, mode selection function, and switch function of the
electrical components, etc. It also has the built-in warning buzzer.
• CPU (Central Processing Unit) is mounted inside, and it processes, displays, and outputs information.
• The monitor system monitors the machine state by obtaining the information with the sensors and switches
installed in various parts of the machine, processes the information instantly to display on the machine
monitor, and informs the operator of the machine condition.
The information displayed on the machine monitor falls into the following types.
• Alarm when the machine has trouble
• Machine state display (engine coolant temperature, hydraulic oil temperature, fuel level, etc.)
• Display of camera image
• The switches on the machine monitor have functions to control the machine.

HB365LC-3 10-131
COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

REMARK
• The machine monitor consists of the display and switch section. The display is LCD (Liquid Crystal Display),
and the switch section consists of flat sheet switches.
• If there is abnormality in the machine monitor, controller, or wiring between the machine monitor and control-
ler, the machine monitor does not display normally.
• The battery voltage may drop sharply when the engine is started depending on the ambient temperature and
battery condition. In this case, the display may disappear for a while, but it is not an abnormal phenomenon.
• If environmental temperature of the machine monitor is high, brightness may be automatically reduced to
protect the liquid crystal.
• Intensity or color of the objects may change because of the automatic adjustment function of the camera.
• See “Operation and Maintenance Manual” for the following items.
• Display (screen display)
• Switches
• Guidance icons and function switches

INPUT AND OUTPUT SIGNALS OF MACHINE MONITOR (PC400_10-K-Q180-03C-00-B)

070-18P “CM01”
Pin No. Signal name Input/output signal
1 Continuous power supply (24 V) Input
2 Continuous power supply (24 V) Input
3 GND (continuous power supply) -
4 GND (continuous power supply) -
5 External starting signal Input
6 Starting motor cut-off relay (for personal code) Output
7 (*1) -
8 System operating lamp Input/Output
9 Lamp switch Input
10 Starting switch (ACC) Input
11 Starting switch (C) Input
12 Preheating Input
13 Engine shutdown secondary switch Input
14 (*1) -
15 Fuel level sensor Input
16 Charge level (alternator terminal R) Input
17 (*1) -
18 (*1) -

*1: Never connect these pins. Malfunctions or failures may occur.

070-12P “CM02”
Pin No. Signal name Input/output signal
1 Seat belt alarm switch Input
2 Engine oil level sensor Input
3 Radiator coolant level sensor Input

10-132 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

Pin No. Signal name Input/output signal

4 Air cleaner clogging sensor Input
5 Swing lock switch Input
6 (*1) -
7 CAN (C) terminating resistor terminal -
8 CAN (C)_H Input/Output
9 CAN (C)_L Input/Output
10 CAN (R) terminating resistor terminal -
11 CAN (R)_H Input/Output
12 CAN (R)_L Input/Output

*1: Never connect these pins. Malfunctions or failures may occur.

070-20P “CM03”
Pin No. Signal name Input/output signal
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 (*1) -
10 (*1) -
11 (*1) -
12 (*1) -
13 (*1) -
14 (*1) -
15 (*1) -
16 (*1) -
17 (*1) -
18 (*1) -
19 (*1) -
20 (*1) -

*1: Never connect these pins. Malfunctions or failures may occur.

070-8P “CM04”
Pin No. Signal name Input/output signal
1 Power supply for camera (8 V) Output
2 Camera NTSC signal 1 Input
3 Camera NTSC signal 2 Input

HB365LC-3 10-133
COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

Pin No. Signal name Input/output signal

4 Camera NTSC signal 3 Input
5 GND (power supply for camera) -
6 Camera 2 normal image/mirror image selection Output
7 Camera 3 normal image/mirror image selection Output
8 GND (shield) -

TYPES OF GAUGES AND METERS DISPLAYED ON MACHINE MONITOR

(HB335_3-K-Q1LB-042-00-B)

Item to be dis-
Gauge Range and method for display Remarks
played
Monitor • Indicates corresponding tempera-
Tempera-
Range back- ture range.
ture
ground
• Alarm buzzer sounds when the
W1 105 °C Red temperature is 105 °Cor more.
Engine coolant • If monitor background color is
W2 102 °C Red
temperature white, warm up the engine.
gauge (*1) W3 100 °C Blue
W4 85 °C Blue
W5 60 °C Blue
W6 30 °C White
Monitor • Indicates corresponding tempera-
Tempera-
Range back- ture range.
ture
ground
• Alarm buzzer sounds when the
H1 105 °C Red temperature is 105 °Cor more.
Hydraulic oil • If monitor background color is
H2 102 °C Red
temperature white, warm up the hydraulic
gauge (*1) H3 100 °C Blue components.
H4 85 °C Blue
H5 40 °C Blue
H6 20 °C White
Monitor • Indicates corresponding tempera-
Tempera-
Range back- ture range.
ture
ground
• Alarm buzzer sounds when the
E1 102 % Red temperature 102 % or more.
Hybrid tempera-
E2 100 % Red
ture gauge (*1)
(*2) E3 95 % Blue
E4 50 % Blue
E5 20 % Blue
E6 0% White

10-134 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

Item to be dis-
Gauge Range and method for display Remarks
played
Monitor Indicates corresponding remaining lev-
Range Quantity back- el.
ground
F1 462 ℓ Blue
F2 347 ℓ Blue
Fuel gauge (*1)
F3 278 ℓ Blue
F4 139 ℓ Blue
F5 100 ℓ Blue
F6 56 ℓ Red
Segment Load level Indicates instantaneous fuel consump-
tion (average of fuel consumption by 3
Light to
Green 1 to 8 seconds) in 10 steps.
medium
ECO gauge (*2) (Displayed when Energy Saving Guid-
ance → Configurations → ECO Gauge
Orange 9, 10 Heavy Display on the user menu is set to ON.)

Gauge Indicates corresponding remaining lev-

Range Quantity
range el.
A1 100 % Green
A2 75 % Green
adblue/DEF lev- A3 50 % Green
el gauge
A4 25 % Green
A5 10 % Green
A6 2.5 % Red
A7 0% Red
Indicates accumulated engine operating
hours (when alternator is generating).
Service meter 00000.0 h to 99999.9 h
(Press F4 switch to change to clock dis-
play.)
Displays TIME.
• 12 hour display (AM/PM)
Clock (Press F4 switch to change to service
• 24 hour display meter display.)

Indicates the average fuel consumption.

• 1 day
Fuel consump- (Display can be switched by selecting
• Split Time another item in ECO Guidance → Con-
tion gauge (*2)
• None figurations → Average Fuel Consump-
tion Display on user menu.)
*1: The gauge pointer disappears if the gauge signal is not available due to an open circuit in the CAN communica-
tion line.
2: Display can be switched by selecting another item in Energy Saving Guidance → Configurations on user menu.

HB365LC-3 10-135
COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

TYPES OF CAUTION LAMPS DISPLAYED ON MACHINE MONITOR (HB335_3-K-Q1LA-042-10-B)

Range and method for display
Item to be dis- Caution
Symbol Remarks
played Range lamp display Action level
(Color)
When exceeding • Color of caution lamp
Lit (red) L02
102 °C changes corresponding to
30 °C or higher, the detected temperature.
Engine coolant and lower than Lit (blue) - • Alarm buzzer sounds when
temperature 102 °C the temperature exceeds
(*1) 105 °C.
• If monitor background color
Below 30 °C Lit (white) -
is white, warm up the en-
gine.
When exceeding • Color of caution lamp
Lit (red) L02
102 °C changes corresponding to
20 °C or higher, the detected temperature.
Hydraulic oil and lower than Lit (blue) - • Alarm buzzer sounds when
temperature 102 °C the temperature exceeds
(*1) 105 °C.
• If monitor background color
Below 20 °C Lit (white) -
is white, warm up the hy-
draulic components.
Below 56 ℓ Lit (red) - Color of caution lamp changes
corresponding to the remaining
Fuel level (*1) When exceeding
Lit (blue) - level.
56 ℓ

When exceeding • Color of caution lamp

Lit (red) -
100 % changes corresponding to
Hybrid temper- the detected temperature.
ature (*1)(*2) • Alarm buzzer sounds when
Below 100 % Lit (blue) -
the temperature exceeds
100 %.
When it is abnor- Caution lamp lights up when an
mal abnormality is detected while en-
Hybrid temper- (above the speci- Lit (red) L02 gine is running.
ature (*1)(*2) fied value)
When normal Not lit -
For an entire • Caution lamp background
hour color changes depending
Lit (red) L02
(Below specified on the hours detected.
Radiator cool- level) • When the background color
ant level (*1) of caution lamp is red, the
(Below specified
Lit (yellow) L01(*4) warning buzzer sounds.
level)
Normal Not lit -

10-136 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

Range and method for display

Item to be dis- Caution
Symbol Remarks
played Range lamp display Action level
(Color)
When charging Caution lamp lights up and alarm
is faulty buzzer sounds when an abnor-
(charge voltage Lit (red) L03 mality is detected while engine is
Battery charge
< battery volt- running.
(*1)
age)
When normal Not lit -
When it is abnor- Caution lamp lights up and alarm
mal buzzer sounds when an abnor-
Engine oil Lit (red) L03 mality is detected while engine is
(Below specified
pressure (*1) pressure) running.

When normal Not lit -

When it is abnor- Caution lamp lights up when an
mal abnormality is detected while en-
Engine oil lev- Lit (yellow) L01(*4) gine is stopped.
(below specified
el (*1) level)
When normal Not lit -
When it is abnor- Caution lamp lights up when an
mal abnormality is detected while en-
(Above the Lit (yellow) L01(*4) gine is running.
Air cleaner
clogged (*1) specified pres-
sure)
When normal Not lit -
When it is abnor- Caution lamp lights up when an
mal abnormality is detected while en-
(There is water gine is running.
Water separa- Lit (red) -
collected above
tor (*1) the specified
amount.)
When normal Not lit -
When mainte- • The display changes de-
nance due time Lit (red) - pending on how long it has
is over passed since the mainte-
nance due time was over.
Maintenance
due time warn- • After starting switch is
ing When mainte- turned to ON position, cau-
nance notice Lit (yellow) - tion lamp lights up if condi-
time is over (*3) tion for lighting it up is satis-
fied, and then goes out in
30 seconds.
When action lev- • Caution lamp lights up
el L04, L03 is de- Lit (red) L04, L03 when an abnormality is de-
State of sys- tected tected in machine system.
tem When action lev- • Warning buzzer sounds
el L01 is detect- Lit (yellow) L01(*4) when the color of caution
ed lamp is red.

HB365LC-3 10-137
COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

Range and method for display

Item to be dis- Caution
Symbol Remarks
played Range lamp display Action level
(Color)
When there is an Caution lamp lights up when an
State of hybrid abnormality in Lit (red) L03 abnormality is detected while en-
system (*1) hybrid system gine is running.
(*2)
When normal Not lit -
When action lev- • Caution lamp lights up
el L04, L03 is de- Lit (red) L04, L03 when an abnormality is de-
State of en- tected tected in engine system.
gine system When action lev- • Warning buzzer sounds
el L01 is detect- Lit (yellow) L01(*4) when the color of caution
ed lamp is red.
When action lev- • Caution lamp lights up
el L04, L03 is de- Lit (red) L04, L03 when an abnormality is de-
State of hy- tected tected in hydraulic system.
draulic system When action lev- • Warning buzzer sounds
el L01 is detect- Lit (yellow) L01(*4) when the color of caution
ed lamp is red.
When action lev- • Caution lamp lights up
el L04, L03 is de- Lit (red) L04, L03 when an abnormality is de-
State of KDPF tected tected in KDPF system.
system When action lev- • Warning buzzer sounds
el L01 is detect- Lit (yellow) L01(*4) when the color of caution
ed lamp is red.
When action lev- • Caution lamp lights up
el L04, L03 is de- Lit (red) L03 when soot is accumulated
tected in KDPF or when purifying
KDPF soot ac- function deteriorates abnor-
cumulation When action lev- mally.
el L01 is detect- Lit (yellow) L01(*4) • Warning buzzer sounds
ed when the color of caution
lamp is red.
Caution lamp lights up and warn-
Engine over- When engine ing buzzer sounds when engine
Lit (red) L02
run overruns overrun is detected.

Caution lamp lights up when an

When air condi-
State of air abnormality is detected in air con-
tioner is abnor- Lit (yellow) L01(*4)
conditioner ditioner system.
mal

0.09 % or less Lit (red) L04 • Color of caution lamp

changes corresponding to
AdBlue/DEF 2.5 % or less Lit (red) L03
the remaining level.
level 10 % or less Lit (red) - • Alarm buzzer sounds at
Exceeds 10 % Lit (blue) - 5 % or lower.

10-138 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

Range and method for display

Item to be dis- Caution
Symbol Remarks
played Range lamp display Action level
(Color)
When action lev- • Caution lamp lights up
el L04, L03 is de- Lit (red) L04, L03 when an abnormality is de-
State of AdBl- tected tected in AdBlue/DEF sys-
ue/DEF sys- When action lev- tem.
tem el L01 is detect- • Alarm buzzer sounds when
Lit (yellow) L01(*4)
ed the monitor background is
red.
Engine stops Caution lamp lights up when the
while the tem- Stopped 150 engine is stopped due to the high
perature of times or more at Lit (yellow) L01(*4) temperature of AdBlue/DEF sys-
AdBlue/DEF high temperature tem.
system is high.

Seat belt cau- Seat belt is not

- -
tion lamp fastened

Engine abruptly
stops 2000 times Lit (red) L03
or more
Engine abrupt- Engine abruptly
ly stops by AIS stops 1000 times
or more, and Lit (yellow) L01(*4)
less than 2000
times
When action lev- • Caution lamp lights up
el L04 is detect- Lit (red) L04 when abnormality is detect-
ed ed in the machine.
When action lev- • Warning buzzer sounds
el L03 is detect- Lit (red) L03 when the color of caution
ed lamp is red.
Action level
When action lev-
el L02 is detect- Lit (red) L02
ed
When action lev-
el L01 is detect- Lit (yellow) L01(*4)
ed
Caution lamp lights up when an
abnormality caused by open cir-
When action lev-
Camera sys- cuit of cables, looseness of con-
el L01 is detect- Lit (yellow) L01
tem (*5) nectors, or abnormality of camera
ed
signals caused by disconnection
is detected.
Caution lamp lights up when an
When action lev-
Camera sys- abnormality is detected in KomVi-
el L01 is detect- Lit (yellow) L01
tem (*5) sion system.
ed

HB365LC-3 10-139
COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

Range and method for display

Item to be dis- Caution
Symbol Remarks
played Range lamp display Action level
(Color)
*1: These are included in the Check before starting items. these symbols are lit for 2 seconds after the starting
switch is turned to ON position, and returns to the standard state if no failure is found.
*2: Hybrid
*3: Maintenance notice time can be changed on Maintenance Mode Display Setting of service mode.
*4: These items are lit for 2 seconds, and then go out.
*5: For machine with KomVision.

TYPES OF PILOT LAMPS DISPLAYED ON MACHINE MONITOR (PC400_10-K-Q1LA-042-20-B)

Symbol Item displayed Description Remarks

• Operates automatically Indicates the operation status of
at low temperature. preheater.
Automatic (Lights up for approx.
preheating 30 sec. at maximum.)
• Goes off after engine is
started.
Elapsed time
after turning
starting Monitor dis-
Preheating switch to play
HEAT (pre-
heat)
Manual pre-
heating 0 to 30 sec-
Lights up
onds
30 to 40 sec-
Flashes
onds
40 seconds
Goes off
or longer
One-touch Indicates operation status of
power max. Monitor display one-touch power maximizing
switch function.
One-touch pow- Lights up
er maximizing
ON (Goes off approx. 8.5 sec-
onds after, if held down)
OFF Goes off
Swing park- Displays operation state of swing
Swing lock Monitor dis-
ing brake lock.
switch play
cancel switch
OFF OFF Goes off
Swing lock
ON OFF Lights up
OFF ON Flashes
ON ON Flashes

INT: Intermittent operation Displays the operation state of

front window wiper.
Wiper ON: Continuous operation
Goes off: Stopped

10-140 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

Symbol Item displayed Description Remarks

Indicates the operation status of
Lights up: ON air conditioner and blower.
Air conditioner
Goes off: OFF

Indicates whether seat belt is

Lights up: Not fastened fastened.
Seat belt
Goes off: Fastened

Indicates the operation status of

Lights up: When engine is stopped engine.
Engine stopped
Goes off: While engine is running

Lights up: Aftertreatment devices regenera- Indicates regeneration state of

Aftertreatment tion in progress aftertreatment devices.
devices regen-
eration Lights off: Aftertreatment devices regenera-
tion completed
• Indicates regeneration
state of aftertreatment de-
Lights up: Aftertreatment devices regenera-
Aftertreatment vices.
tion disabled
devices regen- • When manual stationary
eration disable Lights off: When aftertreatment devices re-
generation disable is canceled
regeneration is necessary,
KDPF soot accumulation
caution lamp lights up.
Displays the state of message.
Message Lights up: There is unread message.
(Unread) Goes off: No message.

Message Displays the state of message.

Lights up: There is already-read message
(No return mes- but return message for it is not sent yet.
sage, already-
Goes off: No message.
read message)
Displays operation state of auto-
Auto-decelera- Lights up: ON deceleration function.
tion Goes off: OFF

P: Heavy-duty operation Indicates the set working mode.

E: Low-fuel consumption operation
L: Fine control operation
Working mode B: Breaker operation
ATT/P: 2-way attachment operation
ATT/E: 2-way attachment operation with low
fuel consumption

Lo: Low-speed travel Displays the set mode of travel

speed.
Travel speed Mi: Middle-speed travel
Hi: High-speed travel

HB365LC-3 10-141
COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

Symbol Item displayed Description Remarks

• Idle stop guidance Indicates the guidance to sup-
port operation of the machine.
• Deterrence guidance of hydraulic re-
lief
• Economy Mode (recommended) guid-
ECO guidance
ance
• Reduce travel speed recommendation
guidance
• Low fuel level guidance

OPERATOR MODE FUNCTION OF MACHINE MONITOR (PC400_10-K-Q193-042-00-B)

The information items in this mode are displayed ordinarily. The operator can display and set them by operating
the switches. Display and setting of some items need special operations of the switches.
Items available in the operator mode are as follows:
*1: The operator mode items are classified as follows.
A: Display from the time when the starting switch is turned to “ON” position to the time when display changes to
the standard screen, and display after starting switch is turned to “OFF” position
B: Display when the machine monitor switch is operated
C: Display when condition is satisfied
D: Display that requires special operations of switches
*2: Display sequence from the time when the starting switch is turned to ON position to the time when the stand-
ard screen appears varies depending on the settings and conditions of the machine as follows:
V: When engine start lock is enabled
W: When engine start lock is disabled
X: When working mode at start is set to “Breaker mode (B)”
Y: When any abnormality is detected by the check before starting
Z: When any item is detected as the maintenance due time is over
REMARK
• For how to operate the operator mode functions, see the Operation and Maintenance Manual.
• For the operating method of the engine start lock function, see "Password setting and canceling manual".
Category Display order (*2)
Item
(*1) V W X Y Z
Display of KOMATSU logo 1 1 1 1 1
Display of password input 2 - - - -
Display of technician identification status 3 - 2 - -
Display of operator ID input screen 4 - 3 - -
Display to check breaker mode - - 4 - -
Display of check before starting 5 2 5 2 2
A
Display of warning after check before starting - - - 3 -
Display of maintenance due time over - - - - 3
Display to check working mode and travel speed 6 3 6 4 4
Display of standard screen 7 4 7 5 5
Display of engine shutdown secondary switch screen
Display of end screen

10-142 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

Category Display order (*2)

Item
(*1) V W X Y Z
Selection of auto-deceleration
Selection of working mode
Selection of travel speed
Stop operation of alarm buzzer
Operation of windshield wiper
Operation of window washer
Operation of air conditioner
Operation to display camera mode
B
Check of maintenance information
Setting and display of user menu
• ECO Guidance
• Machine Setting
• Aftertreatment Devices Regeneration
• SCR Information
• Maintenance
• Monitor Setting
• Display of message (including KOMTRAX messages for user)
Display of ECO guidance
Display of caution monitor
C
Display of KDPF regeneration
Display of action level and failure symbol
Checking function by LCD (Liquid Crystal Display)
D Function to check service meter
Function of usage limitation setting/change password

SERVICE MODE FUNCTION OF MACHINE MONITOR (PC300_11-K-Q194-042-00-B)

These functions are not displayed normally. A technician can display and set them special operation of
switches. These functions are used for special settings, testing, adjusting, or troubleshooting.
Items available in the service mode are as follows:
REMARK
For operating method of the service mode functions, see TESTING AND ADJISTING, “SERVICE MODE”.
Pre-defined Monitoring
Self-define Monitoring
Abnormality Record Mechanical System Abnormality Record
Electrical System Abnormality Record
Maintenance Record
Maintenance Mode Setting
Phone Number Entry

HB365LC-3 10-143
COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

Default Key-on Mode

Unit setting
With/Without Attachment
Camera
Auto Idle Stop Time Fixing
With/Without KomVision
Diagnostic Tests Cylinder Cutout Mode Operation
Active Regeneration for Service
KDPF Memory Reset
SCR Service Test
Engine Stop at AdBlue/DEF Inj Overheat Count Reset
Engine Controller Active Fault Clear
Ash in Soot Accumulation Correction
Reset Number of Abrupt Engine Stop by AIS
Adjustment Pump Absorption Torque (F)
Pump Absorption Torque (R)
Travel Low speed
Att Flow Adjust in Combined Ope
Calibrate F Pump Swash Plate Sensor
Calibrate R Pump Swash Plate Sensor
KomVision Adjustment
No-Injection Cranking
KOMTRAX Settings Terminal Status
GPS & Communication State
Modem Information
Service Message

KomVision CONTROLLER (PC500_8-K-K910-001-00-B)

(Machine with KomVision controller)

10-144 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

STRUCTURE OF KomVision CONTROLLER (PC128_11-K-K910-041-00-B)

General view

INPUT AND OUTPUT SIGNALS OF KOMVISION CONTROLLER (HB335_3-K-K910-03C-00-B)

AMP-81P“CA01”
Input and output
Pin No. Signal name
signals
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 Power supply for camera (8 V) Output
7 (*1) -
8 (*1) -
9 (*1) -
10 (*1) -
11 (*1) -
12 (*1) -
13 (*1) -
14 (*1) -
15 (*1) -

HB365LC-3 10-145
COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

Input and output

Pin No. Signal name
signals
16 Shield -
17 Shield -
18 Shield -
19 Shield -
20 (*1) -
21 NTSC signal output 3ch Input
22 NTSC signal output 2ch Input
23 NTSC signal output 1ch Input
24 NTSC signal output 0ch Input
25 Power supply for camera (8 V) Output
26 (*1) -
27 (*1) -
28 (*1) -
29 (*1) -
30 (*1) -
31 (*1) -
32 (*1) -
33 (*1) -
34 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -
38 (*1) -
39 (*1) -
40 Image signal system GND 3ch Input
41 Image signal system GND 2ch Input
42 Image signal system GND 1ch Input
43 Image signal system GND 0ch Input
44 Power supply for camera (8 V) Output
45 (*1) -
46 (*1) -
47 (*1) -
48 (*1) -
49 (*1) -
50 (*1) -
51 (*1) -
52 (*1) -
53 (*1) -

10-146 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

Input and output

Pin No. Signal name
signals
54 (*1) -
55 (*1) -
56 (*1) -
57 (*1) -
58 (*1) -
59 (*1) -
60 (*1) -
61 (*1) -
62 (*1) -
63 Power supply for camera (8 V) Output
64 (*1) -
65 (*1) -
66 (*1) -
67 (*1) -
68 (*1) -
69 (*1) -
70 (*1) -
71 (*1) -
72 (*1) -
73 (*1) -
74 (*1) -
75 (*1) -
76 (*1) -
77 (*1) -
78 (*1) -
79 (*1) -
80 (*1) -
81 (*1) -

*1: Never connect these pins, otherwise it may cause malfunction or failures.
AMP-40P“CA02”
Input and output
Pin No. Signal name
signals
82 (*1) -
83 (*1) -
84 (*1) -
85 (*1) -
86 (*1) -
87 System operating lamp output Output

HB365LC-3 10-147
COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

Input and output

Pin No. Signal name
signals
88 (*1) -
89 WAKE Input
90 (*1) -
91 (*1) -
92 (*1) -
93 (*1) -
94 (*1) -
95 (*1) -
96 ACC (key input) Input
97 ACC (key input) Input
98 NTSC output GND Output
99 (*1) -
100 (*1) -
101 (*1) -
102 Shield -
103 Shield -
104 Power supply GND Input
105 Power supply GND Input
106 NTSC signal output Output
107 (*1) -
108 (*1) -
109 (*1) -
110 CAN signal + Input and output
111 CAN0 signal - Input and output
112 Continuous power supply Input
113 Continuous power supply Input
114 (*1) -
115 (*1) -
116 (*1) -
117 (*1) -
118 (*1) -
119 (*1) -
120 (*1) -
121 (*1) -

*1: Never connect these pins, otherwise it may cause malfunction or failures.

KomVision CAMERA (PC128_11-K-K900-001-01-B)

KomVision CAMERA (PC500_8-K-K900-001-01-B)

(Machine with KomVision camera)

10-148 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

STRUCTURE OF KomVision CAMERA (PC128_11-K-K900-041-00-B)

General view

INPUT AND OUTPUT SIGNALS OF KomVision CAMERA (PC128_11-K-K900-03C-00-B)

DT-4P
Input and output
Pin No. Signal name
signals
1 Camera power supply Input
2 Video output Output
3 (*1) -
4 GND -

*1: Never connect these pins. It may cause malfunction or failure.

KOMTRAX TERMINAL (PC400_10-K-Q220-001-00-B)

STRUCTURE OF KOMTRAX TERMINAL (PC400_10-K-Q220-041-00-B)

General view
Model: TC630/TC635

1: GPS antenna connection 3: Machine harness connection (070-12P)

2: Machine harness connection (070-18P) 4: Communication antenna connection

HB365LC-3 10-149
COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

5: LED lamp display

FUNCTION OF KOMTRAX TERMINAL (PC400_10-K-Q220-042-00-B)

• This terminal uses the communication technology of cell phone.
• This terminal is the wireless communication equipment which enables to transmit GPS locational informa-
tion and various machine information which is received from network signal or input signal. It can transmit
the information via communication antenna.
• The condition of KOMTRAX terminal can be checked on the “KOMTRAX Setting” screen in the service
mode of the machine monitor.
• Use of KOMTRAX terminal must be limited for the countries in which such communication is allowed.
• The terminal has LED lamps and 7-segment lamp indicator used for testing and troubleshooting on its dis-
play section.
REMARK
• When commencing the operation of the KOMTRAX system or changing the country in which the system is
used, you must give notice to Komatsu Ltd.
• When operating the system in Japan, it is required to install a terminal for exclusive use in Japan.

INPUT AND OUTPUT SIGNALS OF KOMTRAX TERMINAL (PC400_10-K-Q220-03C-00-B)

070-18P“CK01”
Pin No. Signal name Input and output signals
1 (*1) -
2 (*1) -
3 (*1) -
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 (*1) -
10 CAN (C)_H Input and output
11 CAN (C)_L Input and output
12 (*1) -
13 (*1) -
14 External starting signal Input and output
15 System operating lamp Output
16 (*1) -
17 (*1) -
18 (*1) -

*1: Never connect these pins, otherwise it may cause malfunction or failures.
070-12P“CK02”
Pin No. Signal name Input and output signals
1 GND -
2 GND -

10-150 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

Pin No. Signal name Input and output signals

3 Starting switch (ACC) Input
4 Alternator (R) Input
5 (*1) -
6 Power supply Input
7 Power supply Input
8 (*1) -
9 (*1) -
10 (*1) -
11 Starting switch (C) Input
12 (*1) -

*1: Never connect these pins, otherwise it may cause malfunction or failures.

PUMP CONTROLLER (PC400_10-K-C3V1-001-00-B)

STRUCTURE OF PUMP CONTROLLER (PC400_10-K-C3V1-041-00-B)

General view

HB365LC-3 10-151
COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

INPUT AND OUTPUT SIGNALS OF PUMP CONTROLLER (HB335_3-K-C3V1-03C-00-B)

AMP-81P“CN-CP01”
Pin No. Signal name Input and output
1 Continuous power supply (24 V) Input
2 Continuous power supply return Input
3 Window washer Output
4 Continuous power supply (24 V) Input
5 Continuous power supply return Input
6 Potentiometer power supply (5 V) Output
7 CAN(R)_H Input and output
8 Service oil pressure sensor Input
9 (*1) -
10 (*1) -
11 Front pump oil pressure sensor Input
12 Right swing PPC oil pressure sensor Input
13 Boom LOWER PPC oil pressure switch Input
14 Arm IN PPC oil pressure sensor Input
15 Left travel REVERSE PPC oil pressure sensor Input
16 (*1) -
17 (*1) -
18 GND (analog signal) -
19 (*1) -
20 (*1) -
21 Model selection 3 Input
22 Lock lever automatic lock cancel switch Input
23 (*1) -
24 Starting switch ACC signal Input
25 (*1) -
26 CAN(R)_L Input and output
27 (*1) -
28 Hydraulic oil temperature sensor Input
29 (*1) -
30 Rear pump oil pressure sensor Input
31 Left swing PPC oil pressure sensor Input
32 Boom RAISE PPC oil pressure sensor Input
33 (*1) -
34 Left travel FORWARD PPC oil pressure sensor Input
35 Service PPC oil pressure switch Input
36 (*1) -

10-152 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

Pin No. Signal name Input and output

37 (*1) -
38 Fan speed Input
39 (*1) -
40 Model selection 2 Input
41 PPC lock solenoid valve Input
42 Knob switch Input
43 Starting switch ACC signal Input
44 Pulse input ground Input
45 CAN(C)_H Input and output
46 GND (analog signal) Input
47 GND (analog signal) Input
48 (*1) -
49 Front pump swash plate sensor Input
50 Bucket DUMP PPC oil pressure sensor Input
51 Arm OUT PPC oil pressure sensor Input
52 (*1) -
53 Right Travel REVERSE oil pressure sensor Input
54 (*1) -
55 (*1) -
56 Wiper motor reverse (W) Input
57 (*1) -
58 Model selection 5 Input
59 Model selection 1 Input
60 (*1) -
61 Starting switch C signal Input
62 External starting signal Input
63 Sensor power supply (5 V)1 Output
64 CAN(C)_L Input and output
65 (*1) -
66 (*1) -
67 (*1) -
68 Rear pump swash plate sensor Input
69 Bucket CURL PPC oil pressure sensor Input
70 (*1) -
71 (*1) -
72 Right travel FORWARD PPC oil pressure sensor Input
73 (*1) -
74 (*1) -
75 Wiper motor stop (P) Input

HB365LC-3 10-153
COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

Pin No. Signal name Input and output

76 Cab front window open limit switch Input
77 Model selection 4 Input
78 PPC lock switch Input
79 PPC lock signal Input
80 Starting switch ACC signal Input
81 (*1) -

*1: Never connect these pins, otherwise it may cause malfunction or failures.
AMP-40P“CN-CP02”
Pin No. Signal name Input and output
82 (*1) -
83 (*1) -
84 PPC lock relay Output
85 Travel junction solenoid valve Output
86 Attachment selector solenoid valve Output
87 (*1) -
88 LS-EPC valve Output
89 Merge-divider EPC valve (LS) Output
90 (*1) -
91 BR cut-off relay Output
92 (*1) -
93 Travel speed increase solenoid valve Output
94 (*1) -
95 (*1) -
96 Front pump PC-EPC valve Output
97 Attachment flow adjustment EPC valve Output
98 (*1) -
99 Fan clutch solenoid valve Output
100 System-in-use signal Output
101 Swing parking brake solenoid valve Output
102 (*1) -
103 (*1) -
104 Rear pump PC-EPC valve Output
105 (*1) -
106 (*1) -
107 Travel alarm Output
108 Battery relay drive Output
109 2-stage relief solenoid valve Output
110 (*1) -

10-154 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

Pin No. Signal name Input and output

111 (*1) -
112 Merge-divider EPC valve (main) Output
113 Variable back pressure solenoid valve Output
114 Wiper motor (-) Output
115 GND (solenoid) Input
116 Battery relay secondary power supply Input
117 GND (solenoid) Input
118 Battery relay secondary power supply Input
119 Wiper motor (+) Output
120 GND (solenoid) Input
121 Battery relay secondary power supply Input

*1: Never connect these pins, otherwise it may cause malfunction or failures.

RESISTOR FOR PC-EPC VALVE (PC400_10-K-C3VR-001-00-B)

PC
Abbreviation for Pressure Compensation
EPC
Abbreviation for Electromagnetic Proportional Control

STRUCTURE OF RESISTOR FOR PC-EPC VALVE (PC400_10-K-C3VR-041-00-B)

General view

1: Resistor 2: Connector

SPECIFICATIONS OF RESISTOR FOR PC-EPC VALVE (PC400_10-K-C3VR-030-00-B)

Resistance: 20 Ω

FUNCTION OF RESISTOR FOR PC-EPC VALVE (PC400_10-K-C3VR-042-00-B)

It allows a proper current to flow to EPC valve, according to the condition, when the pump drive secondary
switch is turned to “ON” position.

HB365LC-3 10-155
COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

REMARK
No current flows normally.

CAN TERMINATING RESISTOR (PC400_10-K-AP73-001-00-B)

CAN
Abbreviation for Controller Area Network

STRUCTURE OF CAN TERMINATING RESISTOR (PC400_10-K-AP73-041-00-B)

General view

1: Connector (with built-in resistor)

SPECIFICATIONS OF CAN TERMINATING RESISTOR (PC400_10-K-AP73-030-00-B)

Resistance: 120 Ω

FUNCTION OF CAN TERMINATING RESISTOR (PC400_10-K-AP73-042-00-B)

This function is used to suppress reflection of the high-frequency signals at the CAN communication line termi-
nal so that noises are not mixed in the CAN communication signals sent and received between each terminals.
REMARK
If the CAN terminating resistor is not installed, CAN communication errors occur and the operator cannot oper-
ate the machine.

10-156 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

ENGINE CONTROLLER (PC400_10-K-AP70-001-00-B)

STRUCTURE OF ENGINE CONTROLLER (PC400_10-K-AP70-041-00-B)

General view

INPUT AND OUTPUT SIGNALS OF ENGINE CONTROLLER (HB335_3-K-AP70-03C-00-B)

Delphi96Pin“J1 connector”
Pin No. Signal name Input and output
Ground/Shield/
1 Injector #1 (-)
Return
Ground/Shield/
2 Injector #2 (-)
Return
Ground/Shield/
3 Injector #3 (-)
Return
4 (*1) -
5 (*1) -
6 (*1) -
7 (*1) -
8 (*1) -
9 Sensor power supply relay Output
Ground/Shield/
10 IMV(-)
Return
11 IMV(+) Output

HB365LC-3 10-157
COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

Pin No. Signal name Input and output

12 (*1) -
13 EGR valve solenoid (+) Output
14 Lift pump (+) Output
15 Lift pump (+) Output
Ground/Shield/
16 Turbocharger speed (-)
Return
17 Turbocharger speed (+) Input
18 Engine Bkup speed sensor Input
19 (*1) -
20 (*1) -
21 (*1) -
22 (*1) -
23 (*1) -
24 (*1) -
25 Injector #1 (-) Output
26 Injector #2 (-) Output
27 Injector #3 (-) Output
28 (*1) -
29 (*1) -
30 (*1) -
31 Engine NE speed sensor Input
32 Mass air flow (MAF) sensor Input
33 (*1) -
34 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -
Ground/Shield/
38 Lift pump (-)
Return
Ground/Shield/
39 Lift pump (-)
Return
40 (*1) -
41 (*1) -
42 (*1) -
43 (*1) -
44 Ambient pressure sensor Input
45 Charge pressure sensor Input
46 (*1) -
47 (*1) -
48 (*1) -

10-158 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

Pin No. Signal name Input and output

49 Injector #4 (-) Output
50 Injector #5 (-) Output
51 Injector #6 (-) Output
52 Engine oil pressure switch Input
53 (*1) -
Ground/Shield/
54 GND
Return
Ground/Shield/
55 GND
Return
Ground/Shield/
56 GND
Return
Ground/Shield/
57 GND
Return
Ground/Shield/
58 GND
Return
59 (*1) -
60 (*1) -
61 Intake air temperature sensor Input
62 Charge temperature sensor Input
63 Crankcase pressure sensor Input
64 (*1) -
65 (*1) -
66 (*1) -
67 VGT position sensor Input
68 (*1) -
69 (*1) -
70 Datalink3(+)(KOMNET/r) Communication
71 (*1) -
72 (*1) -
Ground/Shield/
73 Injector #4 (-)
Return
Ground/Shield/
74 Injector #5 (-)
Return
Ground/Shield/
75 Injector #6 (-)
Return
Ground/Shield/
76 EGR valve solenoid (-)
Return
77 (*1) -
78 Sensor 5 V power supply Power supply
79 Sensor 5 V power supply Power supply
80 Sensor 12 V power supply Power supply
81 Sensor 5 V power supply Power supply

HB365LC-3 10-159
COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

Pin No. Signal name Input and output

82 Sensor 5 V power supply Power supply
83 Coolant temperature sensor Input
84 (*1) -
85 Engine oil pressure sensor Input
86 (*1) -
87 Common rail pressure sensor Input
88 EGR valve lift sensor Input
89 (*1) -
90 (*1) -
91 (*1) -
92 (*1) -
93 (*1) -
94 Datalink3(-)(KOMNET/r) Communication
95 (*1) -
96 (*1) -

*1: Never connect these pins, otherwise it may cause malfunction or failures.
Delphi96Pin“J2 connector”
Pin No. Signal name Input and output
1 Power supply (+24 V continuous) Power supply
Ground/Shield/
2 VGT solenoid (-)
Return
3 AdBlue/DEF line heater relay 1 Output
4 (*1) -
5 ACC (Key SW) Input
6 AdBlue/DEF pump temperature sensor/ AdBlue/DEF pump driver Input and output
7 AdBlue/DEF line heater relay 2 Output
8 Sensor 5 V power supply Power supply
9 Sensor 5 V power supply Power supply
10 Throttle sensor Input
11 (*1) -
12 (*1) -
13 Water-in-fuel sensor Input
14 (*1) -
15 (*1) -
16 AdBlue/DEF pump pressure sensor Input
17 (*1) -
18 (*1) -
19 (*1) -

10-160 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

Pin No. Signal name Input and output

20 (*1) -
21 Datalink4 (+) (sensor controller) Communication
22 Datalink1(+)(KOMNET/c) Communication
23 (*1) -
24 (*1) -
25 Power supply (+24 V continuous) Power supply
26 Power supply (+24 V continuous) Power supply
27 Power supply (+24 V continuous) Power supply
28 Power supply (+24 V continuous) Power supply
29 (*1) -
30 (*1) -
31 (*1) -
Ground/Shield/
32 GND
Return
Ground/Shield/
33 GND
Return
34 (*1) -
35 (*1) -
36 (*1) -
37 (*1) -
38 AdBlue/DEF line heater 2 Input
39 AdBlue/DEF line heater 1 Input
40 (*1) -
41 KDPF differential pressure sensor Input
42 KDPF outlet pressure sensor Input
(*1): Machine with fuel control dial
43 -
Idle validation switch 2: Machine with accelerator pedal
(*1): Machine with fuel control dial
44 -
Idle validation switch 1: Machine with accelerator pedal
45 Datalink4 (-) (sensor controller) Communication
46 Datalink1(-)(KOMNET/c) Communication
47 (*1) -
48 System operating lamp Output
Ground/Shield/
49 Power GND
Return
Ground/Shield/
50 Power GND
Return
Ground/Shield/
51 Power GND
Return
Ground/Shield/
52 Power GND
Return

HB365LC-3 10-161
COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

Pin No. Signal name Input and output

Ground/Shield/
53 AdBlue/DEF injector (-)
Return
Ground/Shield/
54 GND
Return
55 (*1) -
56 Ambient temperature sensor Input
Ground/Shield/
57 GND
Return
Ground/Shield/
58 (*1)
Return
59 (*1) -
60 (*1) -
Ground/Shield/
61 GND
Return
Ground/Shield/
62 GND
Return
63 (*1) -
64 (*1) -
65 Engine room temperature sensor Input
66 (*1) -
67 (*1) -
68 (*1) -
69 (*1) -
70 (*1) -
71 (*1) -
72 (*1) -
Ground/Shield/
73 Power GND
Return
74 (*1) -
75 Intake air heater relay Output
76 (*1) -
77 AdBlue/DEF injector (+) Output
78 (*1) -
79 AdBlue/DEF pump voltage Output
80 VGT solenoid (+) Output
81 AdBlue/DEF FCV Output
82 AdBlue/DEF tank heating valve Output
83 AdBlue/DEF pump heater relay Output
84 (*1) -
85 (*1) -
86 (*1) -

10-162 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF CONTROL SYSTEM

Pin No. Signal name Input and output

87 (*1) -
88 (*1) -
89 (*1) -
90 (*1) -
91 (*1) -
92 (*1) -
93 (*1) -
94 (*1) -
95 (*1) -
96 (*1) -

*1: Never connect these pins, otherwise it may cause malfunction or failures.

FUEL CONTROL DIAL (PC400_10-K-AG22-001-00-B)

STRUCTURE OF FUEL CONTROL DIAL (PC300_11-K-AG22-041-00-B)

Sectional view

1: Knob 4: Ball
2: Dial 5: Potentiometer
3: Spring 6: Connector

HB365LC-3 10-163
COMPONENT PARTS OF CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

FUNCTION OF FUEL CONTROL DIAL (PC300_11-K-AG22-042-00-B)

• Fuel control dial is installed in the right console box. Turn knob (1), and potentiometer (5) rotates.
• Resistance of the variable resistor in potentiometer (5) changes as the shaft is turned, and a throttle signal
is sent to the engine controller.
REMARK
The hatched area in the graph is the abnormality detection
area. When the throttle voltage is within this area, the engine
runs at low idle.

10-164 HB365LC-3
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF HYDRAULIC SYSTEM

HYDRAULIC SYSTEM (PC400_11-P-C000-001-00-B)

LAYOUT DRAWING OF HYDRAULIC SYSTEM (HB335_3-K-C000-04D-00-B)

Chassis part

1: Supply pump 6: Rear pump PC-EPC valve

2: Engine controller 7. LS-EPC valve
3: Front pump swash plate angle sensor 8: Hydraulic tank
4: Rear pump swash plate angle sensor 9: Control valve
5: Main pump

HB365LC-3 10-165
LAYOUT DRAWING OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

10: Front pump pressure sensor 13: Front pump PC-EPC valve
11: Rear pump pressure sensor 14: PC valve
12: LS VALVE

10-166 HB365LC-3
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF HYDRAULIC SYSTEM

Around cab and floor

15: Machine monitor 18: Secondary pump drive switch

16: Fuel control dial 19: Resistor for PC-EPC valve
17: Pump controller 20: One-touch power maximizing switch

HB365LC-3 10-167
CLSS 10 STRUCTURE AND FUNCTION

CLSS (PC400_10-P-C201-001-00-B)

CLSS
Abbreviation for Closed-center Load Sensing System

STRUCTURE OF CLSS (PC400_11-P-C201-041-00-B)

• CLSS consists of main pump, control valves, and respective actuators.
• The main pump consists of a pump body, PC valve, and LS valve.
1. Variable displacement piston pump
It is 2 pump type with front and rear, and controls the flow rate by changing the swash plate angle.
2. Servo piston
Piston actuates in accordance with the inlet pressure to change the pump swash plate angle.
3. Valve for control of swash plate angle
1) PC valve (Power Constant)
It prevents the engine from stopping by the large load on the engine.
2) LS Valve (Load Sensing)
It controls the pump flow rate in accordance with the travel of control lever.

10-168 HB365LC-3
10 STRUCTURE AND FUNCTION CLSS

1: Actuator 6: PC valve
2: Control valve 7: LS valve
3: Merge-divider valve 8: Servo piston
4: Main relief valve 9: Pump
5: Unload valve 10: Engine
Unload valve
It returns the minimum discharged volume from the pump to the tank at neutral. (although the flow amount is
little, there is no place for this oil to go)
Operating the lever causes the LS pressure which closes the valve.

HB365LC-3 10-169
CLSS 10 STRUCTURE AND FUNCTION

OPERATION OF UNLOAD VALVE AND LS PRESSURE (PC400_11-P-C780-044-00-B)

Operation of unload valve and LS pressure

• When lever is in NEUTRAL
When lever is in NEUTRAL, spool is closed and the oil in
pump circuit has no where to go, so it opens unload valve
(2) and drain to the tank (unload pressure). LS pressure
(PLS) transmitted to the spring chamber is drained to the
tank through LS bypass valve (3), and it become to 0 MPa.
Note) The pressure is for PC200-10

1 2

PP
3.9MPa
F + PLS
3.9MPa 0MPa

A4P15702

• When lever is operated (before relief)

When lever is operated, spool opens and cylinder is acti-
vated. LS pressure (PLS) is transmitted to the spring
chamber of unload valve (2), and it is closed by LS pres- PLS
sure + set pressure {spring force (F)}. 13MPa

1 2

PP
15MPa
F + PLS
3.9MPa 13MPa

A4P15703

10-170 HB365LC-3
10 STRUCTURE AND FUNCTION CLSS

• At relief
When cylinder comes to the stroke end, pump pressure
(PP) and LS pressure (PLS) increases to the main relief
pressure. Unload valve stays closed.

1 2

PP
34.8MPa
F + PLS
3.9MPa 34.8MPa

A4P15704

PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL (PC400_11-P-C200-001-00-B)

FUNCTION OF PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL

(PC400_11-P-C200-042-00-B)
• The pump swash plate angle (pump discharged volume) is so controlled that LS differential pressure
(ΔPLS), which is the differential pressure between pump discharged pressure (PP) and control valve outlet
LS pressure (actuator load pressure), is constant.
“LS differential pressure (ΔPLS) = Pump discharged pressure (PP) - LS pressure (PLS)” = Constant
• The pump swash plate shifts toward the maximum angle position when LS differential pressure (ΔPLS) is
lower than the set pressure of the LS valve (when the actuator load pressure is high).
• The pump swash plate shifts toward the minimum angle position when LS differential pressure is higher
than the set pressure (when the actuator load pressure is low).

HB365LC-3 10-171
CLSS 10 STRUCTURE AND FUNCTION

OPERATION OF PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL

(PC400_11-P-C200-044-00-B)

When lever is in NEUTRAL

10-172 HB365LC-3
10 STRUCTURE AND FUNCTION CLSS

1: PPC valve 9: Seavo piston

2: Hydraulic cylinder 10: LS valve
3: Control valve 11: PC valve
4: Spool 12: PC-EPC valve
5: 2-stage relief valve 13: LS-EPC valve
6: Unload valve 14: Controller
7: LS bypass valve 15: Self-pressure reducing valve
8: Main pump 16: 2-stage relief solenoid valve

HB365LC-3 10-173
CLSS 10 STRUCTURE AND FUNCTION

When balanced

10-174 HB365LC-3
10 STRUCTURE AND FUNCTION CLSS

When lever is returned to fine control state

HB365LC-3 10-175
CLSS 10 STRUCTURE AND FUNCTION

When lever is pulled at a stroke

10-176 HB365LC-3
10 STRUCTURE AND FUNCTION CLSS

When lever is in stroke end

HB365LC-3 10-177
CLSS 10 STRUCTURE AND FUNCTION

FUNCTION OF LS VALVE (PC400_11-P-C260-042-00-B)

• LS valve controls the pump flow rate so that the LS differ-
ential pressure (ΔPLS = PP - PLS) is constant.
• As ΔPLS lowers, it increases the pump flow rate, and as
ΔPLS rises, it decrease the pump flow rate. The spring
force regulates the set pressure of LS differential pressure.
• When the command current from the controller increases,
the LS-EPC valve lowers the set pressure of LS differential
pressure by increasing the LS-EPC output pressure, and
decreases the pump discharged volume.
• LS-EPC command current is o mA at the normal opera-
tion, however it increases when the control lever is in
NEUTRAL or when travel Lo or Mi is selected or when L mode is setting.
• When the lever is in NEUTRAL, LS pressure is 0 mA. Accordingly, the LS valve is fixed at left position and
the swash plate angle of pump becomes minimum. (pump pressure > spring force)
Relation between travel of lever and differential pressure
• Flow (Q) is in proportion to "(A) x Pressure difference (ΔP)". Accordingly, if the flow rate is constant;
(1) Area is small → Pressure difference is large
(2) Area is large → Pressure difference is small
• LS valve increases and decreases the flow rate until the differential pressure becomes to the set pressure,
and returns to the balanced position.
• LS valve controls the pump discharged volume to keep the LS differential pressure at constant.
• Pump discharged volume is controlled so be in proportion to travel of lever.

10-178 HB365LC-3
10 STRUCTURE AND FUNCTION CLSS

FUNCTION OF PC VALVE (PC400_11-P-C270-042-00-B)

• It controls the engine output horsepower and pump absorbing horsepower to be constant to prevent the en-
gine from stopping.
• When pump pressure (PP) increases, PC valve moves to the right against springs 1 and 2, and decreases
the pump discharged volume.
• PC-EPC command current increases PC-EPC output pressure, and the PC-EPC output pressure pushes
PC valve to the right against spring. This function enables the pump absorbs 100 % of engine horsepower.
• Pump controller controls the PC-EPC current to keep the engine speed at constant by the signal of engine
speed sensor.

HB365LC-3 10-179
CLSS 10 STRUCTURE AND FUNCTION

P-Q DIAGRAM AND PC VALVE (PC400_11-P-C270-044-00-B)

1. When pump pressure is low
Pump (1) swash plate angle becomes maximum and flow rate becomes maximum.

2. Range A in P-Q diagram

Service piston (2) and follow up link (3) are mechanically connected.
As the swash plate angle decreases, follow up link (3) pushes back PC valve spool (4) to the center.

10-180 HB365LC-3
10 STRUCTURE AND FUNCTION CLSS

PC valve spool (4) is balanced.

3. Range A in P-Q diagram

The pump pressure increases further, and springs (6) are compressed.
PC valve spool (4) moves to the right, and pump pressure is transmitted to the large diameter side of piston
(2).

4. Range B in P-Q diagram

As the pump pressure increases further and compressed spring (6) reaches to the stroke end, only spring
(5) is applied.

HB365LC-3 10-181
CLSS 10 STRUCTURE AND FUNCTION

The swash plate angle decreases slowly.

5. Electronic control by PC-EPC valve

In addition to the mechanical control by springs (5), (6) electronic control by PC-EPC valve (8) is prepared
in order to match to the engine horsepower setting.
If PC valve (4) fails, the engine stops due to the excessive pump absorption horsepower.
Controller (7) changes the command current in order to shift the working mode to P, E, B or L.

10-182 HB365LC-3
10 STRUCTURE AND FUNCTION CLSS

FUNCTION OF PC-EPC VALVE AND LS-EPC VALVE (HB335_3-P-C2E5-042-00-B)

1. Engine pump control (working mode)
• The hyperbola of P mode and ATT mode shows the
setting to use maximum output of engine for hydraulic
system, and indicates “Pressure (P) x Discharged vol-
ume (Q) = Constant = Engine output”.
• Command current from the controller to the PC-EPC
valve and LS-EPC valve decreases the pump absorb-
ing horsepower and maximum pump discharged vol-
ume. The command current increases and the dis-
charged volume decreases.
• When E, B or L is selected for the working mode, the
settings of engine speed and pump absorbing horse-
power are decreased simultaneously by the controller.
• When the command current is increased and L mode
is selected, LS-EPC valve controls to decrease the
maximum discharged volume.
• When the pressure sensor detects the high pressure
close to the max. set pressure, it is cut off by PC-EPC
valve.

2. Travel control
• As travel speed selector switch is switched to Hi, Mi or
Lo, command current from controller changes, and the
output pressure from LS-EPC valve to LS valve
changes, and pump discharged volume change point
“LS differential pressure (PLS)” in the LS valve
changes.
• The start-up time of the pump discharged volume is
optimized and the combined operation and fine control
performance are improved.
3. Cut-off function
• This function increases PC-EPC current to reduce the flow rate in the relief state and improve the fuel econ-
omy.
• Operating condition for turning on cut-off function
When the one-touch power maximizing function is not activated and the average of front pump and rear
pump oil pressure sensor values is 31.1 MPa {317 kg/cm2} or higher.
It does not operate when machine is traveling or swing lock switch is “ON”.

HB365LC-3 10-183
CLSS 10 STRUCTURE AND FUNCTION

PRESSURE COMPENSATION CONTROL (PC400_11-P-C790-001-00-B)

FUNCTION OF PRESSURE COMPENSATION CONTROL (PC400_11-P-C790-042-00-B)

• Pressure compensation valves (2) (2 pieces) are installed
at outlet of the downstream and return side of main spool
(4) by each actuator (1).
• The highest LS pressure is transmitted to the back of all
pressure compensation valves (2), and light load side is
throttled.
• When it is throttled until all pressure compensation valves
(2) are balanced, the differential pressures before and after
main spool (4) become the same.
• As a result, the flow rate control in proportion to the travel
of levers (3) in the combined operation becomes available
without influenced by the load.
A: Heavy load
B: Light load
C: LS circuit
1: Actuator
2: Pressure compensation valves
3: Levers
4: Main spool
5: LS shuttle valve
6: Main pump
7: Servo piston
• If the pressure compensation valve is not installed, •••
CLSS is a parallel circuit, so light load side (B) actuates
earlier than heavy load side (A). As a result, performance
of the simultaneous operation becomes worse.

LS BYPASS PLUG (PC400_11-K-PNSH-001-00-B)

LS
Abbreviation for Load Sensing

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10 STRUCTURE AND FUNCTION CLSS

FUNCTION OF LS BYPASS PLUG (PC400_11-K-PNSH-042-00-B)

• LS bypass plug releases the remaining pressure in LS pressure circuit (6) through orifices (a) and (b).
• It reduces the LS pressure rising speed and prevents sudden change of the hydraulic pressure.
• When oil bypasses through LS bypass plug (5), pressure loss occurs due to the resistance in the circuit
from orifice (c) of main spool (2) to LS shuttle valve (4).
• The effective LS differential pressure decreases, and the dynamic stability of the actuator is improved.

a b
5

A a 2
1

A4P15728

LS SELECT VALVE (PC400_11-K-J6PA-001-00-B)

LS
Abbreviation for Load Sensing

FUNCTION OF LS SELECT VALVE (PC400_11-K-J6PA-042-00-B)

The illustration shows the state of simultaneous operation of swing and travel RIGHT. (It shows the state when
pilot pressure (BP) is supplied)

HB365LC-3 10-185
CLSS 10 STRUCTURE AND FUNCTION

1: Valve
2: Spring
3: Piston
4: Piston
5: Swing valve spool
6: R.H. travel valve spool
7: Arm valve spool
8: LS shuttle valve
9: LS circuit
• It prevents entry of the high LS pressure from the swing
circuit into the LS circuit of the work equipment valve at the
combined operation of swing and travel RIGHT.
• It prevents high pressure which is generated when the ma-
chine swings, and improves operability of the work equip-
ment.

OPERATION OF LS SELECT VALVE (PC400_11-K-J6PA-044-00-B)

When pilot pressure (BP) is cut off (OFF)

1. Since pilot pressure (BP) is cut off, piston (3) is pressed to
the left by the reaction force of spring (2).
2. When the swing operation is performed, swing LS pres-
sure (P1) passes through swing spool (5) and enters port
(A).
3. Swing LS pressure (P1) pushes valve (1) to the left, and
port (A) is connected to port (B).
4. Swing LS pressure (P1) flows from port (A) through port
(B) to LS shuttle valve.
When pilot pressure (BP) is supplied (ON)
1. When pilot pressure (BP) is supplied, it moves piston (3) to
the right against the reaction force of spring (2).
2. When piston (3) moves to the right, valve (1) disconnect
port (A) from port (B).
3. Since port (A) is disconnected from port (B), swing LS
pressure (P1) does not flow to LS shuttle valve.
4. Even swing LS pressure (P1) increases, it does not affect
other LS circuits.

10-186 HB365LC-3
10 STRUCTURE AND FUNCTION ENGINE AND PUMP COMBINED CONTROL SYSTEM

ENGINE AND PUMP COMBINED CONTROL SYSTEM (PC400_10-K-C001-001-00-B)

ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM (PC220_11-K-C001-052-00-B)

a: Front pump PC-EPC valve drive signal g: Oil pressure sensor signal
b: Rear pump PC-EPC valve drive signal h: One-touch power maximizing switch signal
c: Solenoid valve GND i: Oil pressure switch signal
d: CAN signal j: 1st throttle signal
e: LS-EPC valve drive signal k: Fuel supply pump control signal
f: Swash plate sensor signal l: Various sensor signals
1: Battery disconnect switch 11: Fuel control dial
2: Battery 12: Fuel supply pump
3: Battery relay 13: Various sensors
4: Fusible link 14: Front pump swash plate sensor
5: Fuse box 15: Rear pump swash plate sensor
6: Resistor for PC-EPC valve 16: One-touch power maximizing switch
7: Pump controller 17: Front pump oil pressure sensor
8: Engine controller 18: Rear pump oil pressure sensor
9: Machine monitor 19: Oil pressure sensor
10: Pump drive secondary switch 20: Oil pressure switch

HB365LC-3 10-187
ENGINE AND PUMP COMBINED CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

21: Front pump 23: Control valve

21a: Servo 23a: Self-pressure reducing valve
21b: LS valve 23b: Merge-divider valve
21c: PC valve 23c: Travel junction valve
22: Rear pump 24: Front pump PC-EPC valve
22a: Servo 25: Rear pump PC-EPC valve
22b: LS valve 26. LS-EPC valve
22c: PC valve

FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM

(HB335_3-K-C001-042-00-B)

Working mode selection function

• The engine and plump combined control system is a sys-
tem that selects a working mode by using the working
mode selector switch on the machine monitor. It can be
chosen from the 6 working modes of P, E, L, ATT/P, ATT/E,
and B. When "Without Attachment" is selected at the initial
setting of service mode, 4 modes of P, E, L and B are
available.
• The pump controller figures out the pump absorption upper
limit torque according to the engine speed being set with
the working mode and the fuel control dial and the actual
engine speed. It controls the pump so that the engine
speed is kept around the matching point set in each mode
even when the heavy load is applied.
• When the engine speed decreases, it reduces the pump
absorption torque to prevent engine from being stopped.

Control method in mode P, E, ATT/P, and ATT/E

Working mode Matching point
P, ATT/P (during operation) 168 kW/1770 rpm{225 HP/1770 rpm}
E, ATT/E (during operation) 125 kW/1390 rpm{168 HP/1390 rpm}

10-188 HB365LC-3
10 STRUCTURE AND FUNCTION ENGINE AND PUMP COMBINED CONTROL SYSTEM

• In mode P, E, ATT/P, or ATT/E, the engine speed is kept

around the matching point set in each mode.
• When the load is light, the engine operates in high speed
range. As the load increases, the engine speed is de-
creased and the torque is increased to a matching point
where the torque is balanced with the pump absorption up-
per limit torque (PT). ((1) in graph)
• If the load increases further, the engine speed decreases
further as well. ((2) in graph)
• The controller decreases pump absorption upper limit tor-
que (PT) to reduce the load applied to the engine. ((3) in
graph)
• As the load on the engine decreases, the engine speed in-
creases. ((4) in graph)
• The controller increases pump absorption upper limit tor-
que (PT) to keep the engine speed at around the matching
point. ((5) in graph)
• The controller controls the engine so that the engine
matching speed (Nm) is decreased when the load is light
(low flow rate and low torque) to improve the fuel economy.
((6) in graph)

Control method in mode B and L

Working mode Partial output
B 81 %
L 65 %

Working mode Matching point

B 136 kW/1825 rpm{182 HP/1825 rpm}
L 110 kW/1560 rpm{147 HP/1560 rpm}

HB365LC-3 10-189
ENGINE AND PUMP COMBINED CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

• In B mode or L mode, engine output is kept constant.

• The controller controls pump absorption upper limit torque
(PT) so that the engine torque is kept constant along the
equal engine horsepower curve.

10-190 HB365LC-3
10 STRUCTURE AND FUNCTION ENGINE AND PUMP COMBINED CONTROL SYSTEM

Control function when the machine travels

• When the machine travels in mode E, ATT/E, or B, the
working mode is kept as it is, and the pump absorption tor-
que and engine speed (N) increase as in traveling in mode
P.
• When the machine travels in mode L, the working mode is
kept as it is, the engine speed (N) is kept as it is but the
pump absorption torque increases.

Control function when emergency pump drive switch is ON

The emergency pump drive switch (1) is a switch that enables the temporary work to be done with absorption
torque equivalent to E mode for the time when an abnormality occurs in the controller, etc., the main pump does
not operate normally, and the machine does not work. Only PC-EPC valve senses the oil pressure since a con-
stant current flows from the battery to PC-EPC valve at this time.
REMARK
The emergency pump drive switch (1) is an alternative type. If the machine is operated with this switch at emer-
gency (a) position while the machine is normal, action level L03 appears on the display.

HB365LC-3 10-191
ENGINE AND PUMP COMBINED CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

a: Emergency (when abnormal)

b: Normal (when normal)

10-192 HB365LC-3
10 STRUCTURE AND FUNCTION PUMP AND VALVE CONTROL SYSTEM

PUMP AND VALVE CONTROL SYSTEM (PC400_10-K-C001-001-10-B)

PUMP AND VALVE CONTROL SYSTEM DIAGRAM (PC220_11-K-C001-052-10-B)

a: Front pump PC-EPC valve drive signal h: Merge-divider EPC valve (for LS spool) drive signal
b: Rear pump PC-EPC valve drive signal i: Travel junction solenoid valve drive signal
c: Solenoid valve GND j: 2-stage relief solenoid valve drive signal
d: CAN signal k: Variable back pressure solenoid valve drive signal
e: LS-EPC valve drive signal l: 1st throttle signal
f: Swash plate sensor signal m: Fuel supply pump control signal
g: Merge-divider EPC valve (for main spool) drive sig- n: Various sensor signals
nal
1: Battery disconnect switch 9: Machine monitor
2: Battery 10: Pump drive secondary switch
3: Battery relay 11: Fuel control dial
4: Fusible link 12: Fuel supply pump
5: Fuse box 13: Various sensors
6: Resistor for PC-EPC valve 14: Front pump swash plate sensor
7: Pump controller 15: Rear pump swash plate sensor
8: Engine controller 16: Front pump

HB365LC-3 10-193
PUMP AND VALVE CONTROL SYSTEM 10 STRUCTURE AND FUNCTION

16a: Servo 18d: Main relief valve

16b: LS valve 18e: Variable back pressure valve
16c: PC valve 19: Front pump PC-EPC valve
17: Rear pump 20: Rear pump PC-EPC valve
17a: Servo 21: LS-EPC valve
17b: LS valve 22: Merge-divider EPC valve (for main spool)
17c: PC valve 23: Merge-divider EPC valve (for LS spool)
18: Control valve 24: Travel junction solenoid valve
18a: Self-pressure reducing valve 25: 2-stage relief solenoid valve
18b: Merge-divider valve 26: Variable back pressure solenoid valve
18c: Travel junction valve

FUNCTION OF PUMP AND VALVE CONTROL SYSTEM (HB335_3-K-C001-042-10-B)

LS control function
• The LS control function is a function that changes the output pressure from the LS-EPC valve to LS valve
and the switching point “LS set differential pressure (DLS) ” of pump discharged volume in LS valve accord-
ing to the operation state of the actuator.
• The start-up time of the pump discharged volume is optimized and the combined operation and fine control
performance are improved.
A: 0 MPa {0 kg/cm2}
B: EPC pressure (Psig)=2.5 MPa {25 kg/cm2}

Cut-off function
The cut-off function is a function that increases PC-EPC current (J) to reduce the flow rate in the relief state and
improve the fuel economy.
The condition for the cut-off function to be enabled: When the one-touch power maximizing function is not acti-
vated and the average of front pump and rear pump oil pressure sensor values is 31.1 MPa {317 kg/cm2} or
higher. It does not operate when machine is traveling or swing lock switch is ON.
A: PC-EPC power supply when cut-off function operates

2-stage relief function

When the operating conditions of 2-stage relief function are satisfied, the relief pressure during work increases.

10-194 HB365LC-3
10 STRUCTURE AND FUNCTION PUMP AND VALVE CONTROL SYSTEM

Operating conditions of 2-stage relief function Relief pressure

• When the machine travels
• When swing lock switch is ON 36 MPa {368 kg/cm2}
• When operating the boom to LOWER ↓
• When one-touch power maximizing function is operated 38.2 MPa {390 kg/cm2}
• In L mode

Variable back pressure function

The variable back pressure function is a function that changes the set pressure of the back pressure valve ac-
cording to the operating condition of the machine.
Operating condition Setting of back pressure valve
During swinging or travel High-pressure set
During state other than swinging or travel Low-pressure set

HB365LC-3 10-195
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

COMPONENT PARTS OF HYDRAULIC SYSTEM (PC400_11-K-C000-001-00-B)

HYDRAULIC TANK (PC400_10-K-PM30-001-00-B)

STRUCTURE OF HYDRAULIC TANK (HB335_3-K-PM30-041-00-B)

General view and sectional view

1: Oil filler cap 5: Filter element

2: Breather 6: Bypass valve
3: Sight gauge 7: Strainer
4: Hydraulic tank 8: Suction strainer

10-196 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

SPECIFICATIONS OF HYDRAULIC TANK (HB335_3-K-PM30-030-00-B)

Hydraulic tank refill capacity: 275 ℓ
Hydraulic tank refill capacity: 188 ℓ
Set pressure when pressure valve (*1) is relieved: 16.7±6.9 kPa {0.17±0.07 kg/cm2}
Bypass valve set pressure: 250±50 kPa {2.5±0.5 kg/cm2}
*1: This valve is installed inside the oil filler cap.

HYDRAULIC TANK OIL FILLER CAP (PC400_10-K-PM37-001-00-B)

STRUCTURE OF HYDRAULIC TANK OIL FILLER CAP (PC300_11-K-PM37-041-00-B)

Sectional view
1: Bottom plate
2: Gasket
3: Spring

FUNCTION OF HYDRAULIC TANK OIL FILLER CAP (PC300_11-K-PM37-042-00-B)

Prevention of pressure rise in hydraulic tank

While the hydraulic circuit is in operation, the pressure in the hydraulic tank increases as the oil level and the
temperature in the hydraulic tank rise corresponding to the operation of the hydraulic cylinders. When the pres-
sure in the tank exceeds the set pressure, bottom plate (1) is pushed up to release the pressure in the tank and
prevent pressure rise.
(Valve set pressure at relief: 16.7±6.9 kPa {0.17±0.07 kg/cm2} )

HYDRAULIC TANK BREATHER (PC400_10-K-PM38-001-00-B)

STRUCTURE OF HYDRAULIC TANK BREATHER (PC300_11-K-PM38-041-00-B)

Sectional view
1: Nut
2: Cover 
 
 
 
3: Filter element
4: Case
5: Valve assembly
6: Body

  

HB365LC-3 10-197
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

FUNCTION OF HYDRAULIC TANK BREATHER (HB335_3-K-PM38-042-00-B)

Prevention of negative pressure in hydraulic tank

Negative pressure is generated if the oil level in it decreases since the hydraulic tank is pressurized and airtight.
The valve (5) opens by the differential pressure between the tank pressure and the ambient pressure, and
outside air is sucked in order to prevent generation of negative pressure in the tank at this time.
(Set pressure of intake valve : 0.002±0.3 MPa {0.02±0.003 kg/cm2} )

MAIN PUMP (PC400_10-K-C200-001-00-B)

STRUCTURE OF MAIN PUMP (HB335_3-K-C200-041-00-B)

This pump consists of 2 variable displacement swash plate type piston pumps, gear pump, LS valve, PC valve,
EPC valve.

10-198 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

General view

Model: HPV140+140
BMP: Breather installation port IMR: Rear pump PC mode selector current
IMF: Front pump PC mode selector current ISIG: LS set pressure selector current

HB365LC-3 10-199
COMPONENT PARTS OF HYDRAULIC SYSTEM
OCP: Oil level check port
PAF: Front pump discharge port
PAR: Rear pump discharge port
PBF: Front pump pressure input port
PBR: Rear pump pressure input port
PD1F: Air bleeder
PD1R: Case drain port
PD2F: Drain plug
PD2R: Drain plug
PD3F: Drain plug
PENF: Front pump control pressure pickup port
PENR: Rear pump control pressure pickup port
PEPC: EPC source pressure input port
PEPB: EPC source pressure pickup port
PFC: Front pump discharged pressure pickup port
PGA1: Gear pump discharge port
PGA2: Gear pump discharge port
1: Front pump
2: Rear pump
3: LS VALVE
4: PC valve
5. LS-EPC valve
10-200
10 STRUCTURE AND FUNCTION
PGS1: Gear pump suction port
PGS2: Gear pump suction port
PSIG: LS set selector pressure pickup port
PLSF: Front pump load pressure input port
PLSFC: Front pump load pressure pickup port
PLSR: Rear pump load pressure input port
PLSRC: Rear pump load pressure pickup port
PMF: Front pump PC mode selector pressure pickup
port
PMR: Rear pump PC mode selector pressure pickup
port
PRC: Rear pump discharged pressure pickup port
PS: Pump suction port
VF: Front pump swash plate angle sensor output volt-
age
VR: Rear pump swash plate angle sensor output volt-
age
6: Front pump PC-EPC valve
7: Rear pump PC-EPC valve
8: Hybrid lubricating gear pump
9: Front pump swash plate sensor
10: Rear pump swash plate sensor
HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

Sectional view (description of part names)

1: Impeller pinion 12: Valve plate

2: Impeller shaft 13: End cap
3: Impeller pump 14: Rear shaft
4: Bevel gear 15: Rear case
5: Front shaft 16: Bearing
6: Cradle 17: Spline
7: Front case 18: PC valve
8: Rocker cam 19: Servo piston
9: Shoe 20: Slider
10: Piston 21: Hybrid lubricating pump pinion
11. Cylinder block 22: Hybrid lubricating gear pump

HB365LC-3 10-201
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

Structure
• The impeller pump (3) and impeller pinion (1) are integrated with an impeller shaft (2). It is connected to the
rear shaft (14) through the bevel gear (4).
• These are rotated with the rear shaft (14), backing the sending of the pressurized oil to the inside of the
cylinder block (11) by centrifugal force.
Sectional view (explanation of structure)

Structure
• Cylinder block (7) is supported on shaft (1) by spline (S).
• Shaft (1) is supported by each bearing (9) and (10) on the front and rear.
• The tip of piston (6) is shaped as a concave sphere and is crimped with shoe (5).
• Piston (6) and shoe (5) form a spherical bearing.
• Rocker cam (4) has flat surface (A), and shoe (5) is always pressed against this surface while sliding in a
circular pattern.
• Rocker cam (4) rocks on cylindrical surface (B) of cradle (2) fixed to case (3). High-pressure oil is supplied
between them to form a static pressure bearing.
• Piston (6) reciprocates in an axial direction in each cylinder chamber in the cylinder block (7).
• Cylinder block (7) rotates relatively to valve plate (8) while sealing the pressurized oil.
The oil pressure is balanced properly on this surface.
• The pressurized oil can be sucked in and discharged from each cylinder chamber in cylinder block (7)
through valve plate (8).

10-202 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

FUNCTION OF MAIN PUMP (HB335_3-K-C200-042-00-B)

This pump converts the engine rotation and engine torque transmitted to the front shaft (1) of pump into hydraul-
ic pressure, and discharges pressurized oil corresponding to the load. The discharged volume can be changed
by changing the swash plate angle.

OPERATION OF MAIN PUM (HB335_3-K-C200-044-00-B)

Selection of discharged volume (selection of swash plate angle)

1. Cylinder block (2) rotates together with shaft (1), and shoe
(3) slides on plane (A).
2. Rocker cam (4) moves along cylindrical surface (B). As a
result, the swash plate angle (a) between center line (X) of
rocker cam (4) and the axis of cylinder block (2) changes.

HB365LC-3 10-203
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

Suction and discharge of pressurized oil

1. The flat surface (A) works as a cam for shoe (3) while the
angle (a) is made between the center line (X) of rocker
cam (4) and the axis of cylinder block (2).
2. The piston (6) slides inside the cylinder block (2) and a dif-
ference is made between volumes (E) and (F) in cylinder
block (2).
3. The oil in amount of (F) minus (E) per each piston (6) is
sucked in and discharged from.
4. As the cylinder block (2) rotates and the volume of cham-
ber (E) decreases, the pressurized oil is discharged on the
process.
5. As the volume of the chamber (F) increases, pressurized oil is sucked on the process.
When the pressurized oil is neither suctioned nor discharged (swash plate an-
gle = 0)
1. The difference between volumes (E) and (F) inside cylin-
der block (2) is zero when center line (X) of rocker cam (4)
matches the axis of cylinder block (2) (the swash plate an-
gle is zero).
2. The pressurized oil is neither suctioned nor discharged.
The pumping action is not performed. (Angle of swash
plate does not become zero actually)

10-204 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

Control of the discharged volume

1. When the swash plate angle (a) is increased, the difference between volumes (E) and (F) is increased, then
discharged volume (Q) is increased.
2. Swash plate angle (a) is changed by servo piston (7).
3. Servo piston (7) moves in a linear reciprocating motion corresponding to the signal pressure from the PC
valve and LS valve.
This linear reciprocating motion is sent to rocker cam (4) through slider (8).
4. Rocker cam (4) supported on the cylindrical surface (B) of cradle (2) slides and pivots on that surface.
5. Output pressure (PEN) of LS valve is supplied to the pressure chamber on large diameter piston side.
6. The areas of servo piston (7) for receiving the pressure are
not identical on the right side and left side. Main pump dis-
charged pressure (self-pressure) (PP) is always sent to the
pressure chamber of the small diameter piston side.
7. The movement of servo piston (7) is controlled by the rela-
tionship of pressure between small diameter piston side
(PP) and large diameter side (PEN) and by the ratio of the
area receiving the pressure between small diameter piston
and large diameter piston.

MAIN PUMP LS VALVE (PC400_10-K-C2J0-001-00-B)

LS
Abbreviation for Load Sensing

HB365LC-3 10-205
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

STRUCTURE OF MAIN PUMP LS VALVE (PC300_11-K-C2J0-041-00-B)

Sectional view

PA: Pump port PP: Pump port

PDP: Drain port PPL: Control pressure input port
PLP: LS control pressure output port PSIG: LS mode selector pilot port
PLS: LS pressure input port
1: Sleeve 5: Seat
2: Piston 6: Sleeve
3: Spool 7: Plug
4: Spring 8: Lock nut

FUNCTION OF MAIN PUMP LS VALVE (HB335_3-K-C2J0-042-00-B)

• The LS (load sensing) valve is a valve that detects the load of the actuator and controls the pump dis-
charged volume.
• This valve controls pump discharged volume (Q) according to differential pressure (∆PLS) [= (PP) - (PLS)]
(called LS differential pressure) between pump discharged pressure (PP) and control valve outlet port pres-
sure (PLS).
• This valve receives main pump pressure (PP), pressure (PLS) (called LS pressure) from the control valve
output, and pressure (PSIG) (called LS set selector pressure) from the proportional solenoid valve.
• The relationship between differential pressure (∆PLS) =
“(PP) - (PLS)”, the difference between main pump pres-
sure (PP) and LS pressure (PLS), and discharged volume
(Q) varies with LS set pressure selector current (ISIG) of
LS-EPC valve as shown in the figure.
• When (ISIG) changes from 0 A to 1 A, The set force of the
spring changes, too. As the result, the specified median of
LS set changes in the range of 0.98 to 2.45 MPa {10 to
25 kg/cm2} as shown in the figure below.

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

OPERATION OF MAIN PUMP LS VALVE (HB335_3-K-C2J0-044-00-B)

When control valve is in NEUTRAL position

1. LS valve is a 3-way selector valve, and LS pressure (PLS) (actuator load pressure) at the control valve out-
let is supplied to the spring chamber (B), and the pump discharged pressure (PP) is supplied to the port (H)
of the sleeve (8).
The position of spool (3) is determined by the difference between the force caused by LS pressure (PLS),
the force of spring (2), and the force caused by pump discharged pressure (self-pressure) (PP).
The position of the spool (3) changes corresponding to the output pressure (PSIG) (also called LS setting
selector pressure) entering the port (G) of EPC valve for the LS valve. (set force of the spring changes)
2. Before the engine starts, servo piston (4) is pushed to the
left. (See the figure below)
3. When the engine is started with the control lever in NEU-
TRAL, the LS pressure (PLS) is 0 MPa {0 kg/cm2} . (It is in-
terconnected with the drain circuit via the control valve
spool).
4. Spool (3) is pushed to the right, and port (C) and port (D)
are connected.
5. Pump discharged pressure (PP) is sent from the port (K) to
the large diameter side of piston.
6. The same pump discharged pressure (PP) is sent to the
small diameter side of piston.

HB365LC-3 10-207
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

7. It moves in the direction (rightward) which makes the swash plate angle minimum corresponding to the
area difference of servo piston (4). (See the previous figure)
When the pump discharged volume is increased

1. When the difference between pump discharge pressure (PP) and LS pressure (PLS), or LS differential
pressure (∆PLS), decreases (for example, when the opening of the control valve increases and pump dis-
charge pressure (PP) decreases), the combined force of LS pressure (PLS) and force of spring (2) pushes
spool (3) to the right.
2. As spool (3) moves, port (D) is connected to port (E) and connected to PC valve.
3. The PC valve is connected to the drain port, and the oil pressure between circuits (D) and (K) is set to drain
pressure (PT). (The operation of PC valve is explained later.)
4. The pressure at the large end of servo piston (4) becomes drain pressure (PT) and pump pressure (PP) is
constantly transmitted to port (J) at the small end. Accordingly, servo piston (4) is pushed to the left and
moves the swash plate in the direction to increase the discharged volume.
5. If the output pressure of EPC valve for LS valve enters port (G) at this time, a force occurs on the right side
of piston (5).
6. If piston (5) is pushed to the right, the set force of spring (2) is reduced, and LS differential pressure (∆PLS)
“difference between oil pressures (PLS) and (PP)” changes when port (D) and port (E) of spool (3) are con-
nected.

10-208 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

When the pump discharged volume is decreased

1. When servo piston (4) moves to the right (in the direction to reduce the discharged volume) and LS differen-
tial pressure (∆PLS) increases (for example, when the open area of the control valve decreases and pump
discharge pressure (PP) increases), the force caused by pump discharge pressure (PP) pushes spool (3) to
the right.
2. As spool (3) moves, the pump discharged pressure (PP) flows from the port (C) to the port (D), and then
through port (K) to the large diameter side of the piston.
3. Although the pump discharge pressure (PP) is sent to the small diameter side port (J) of piston, servo pis-
ton (4) is pushed to the right by the area difference between the large diameter side and small diameter
side of servo piston (4). As a result, the pump swash plate angle decreases.
4. When LS set select pressure (PSIG) enters port (G), the set force of spring (2) is decreased.

HB365LC-3 10-209
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

When servo piston is balanced

Suppose that the pressure receiving area on the large diameter piston side is (A1), that on the small diameter
piston side is (A0), and the pressure entering the large diameter piston side is (PEN).

1. When the main pump pressure (PP) of LS valve is balanced with the combined force of LS pressure (PLS)
and spring (2) and (A0) x (PP) = (A1) x (Pen), the servo piston (4) stops at that position.
2. The swash plate of the pump is held at the intermediate position. “The swash plate stops at a position
where the openings from port (D) to port (E) and from port (C) to port (D) of spool (3) are approximately
equal.”
3. The relationship between the pressure receiving areas at both ends of servo piston (4) is (A0):(A1) = 3:5.
Under the balanced state, the ratio of the pressures applied to both ends is (PP) : (PEN)C 5 : 3.
4. The force of spring (2) is so adjusted that the balanced and stopped position of spool (3) is determined
when (PP) - (PLS) = 2.45 MPa {25 kg/cm2} at the standard center.
5. When (PSIG) “output pressure of LS-EPC valve, 0 to 2.9 MPa {0 to 30 kg/cm2} ” is applied to port (G), the
balanced position changes in the range of (PP) - (PLS) = 2.45 to 0.98 MPa { kg/cm2} 25 to 10“” in propor-
tion to pressure (PSIG).

MAIN PUMP PC VALVE (PC400_10-K-C2K0-001-00-B)

PC
Abbreviation for Pressure Compensation

STRUCTURE OF MAIN PUMP PC VALVE (HB335_3-K-C2K0-041-00-B)

PC: Abbreviation for Pressure Compensation

10-210 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

Sectional view

PA: Pump port PM: Mode selector pressure pilot port

PA2: Pump pressure pilot port PPL: Control pressure output port (to LS valve)
PDP: Drain port
1: Plug 5: Retainer
2: Servo piston assembly 6: Seat
3: Pin 7: Cover B
4: Spool 8: Wire ring

FUNCTION OF MAIN PUMP PC VALVE (PC300_11-K-C2K0-042-00-B)

• The PC valve limits the oil flow to a certain level depending on the discharged pressure, even if the travel of
the control valve is increased extremely so that the horsepower absorbed by the pump does not exceed the
engine horsepower, when pump discharged pressures (PP1) (self pressure) and (PP2) (the other pump
pressure) are high.
• When the load increases and the pump discharged pressure (PP) also increases during work, PC valve de-
creases the pump discharged volume.
• When the pump discharged pressure decreases, PC valve increases the pump discharged volume.
The relation between the average of front and rear pump
discharged pressures “(PP1) + (PP2)”/2 and pump dis-
charged volume (Q) in this case is shown in the figure be-
low by using current values (X) given to PC-EPC valve sol-
enoid as parameters.
• When the load increases and the rotation speed decreas-
es, the pump discharged volume is decreased to recover
the rotation speed.
• When the load increases and the engine speed drops be-
low the set value, the command current from the controller
to PC-EPC valve solenoid increases according to the de-
crease of the engine speed, and the pump inclination an-
gle decreases.
• The controller counts the actual engine speed.

HB365LC-3 10-211
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

OPERATE MAIN PUMP PC VALVE (PC300_11-K-C2K0-044-00-B)

Function of PC-EPC valve solenoid (1) when pump controller is normal and ac-
tuator load is low and pump pressures (PP1) and (PP2) are low

1. Command current (X) flows from the pump controller into PC-EPC valve solenoid (1).
2. Command current (X) acts on PC-EPC valve and outputs signal pressure to change the force to push pis-
ton (2).
3. Spool (3) stops at a position where the spring set force of springs (4) and (6) is balanced with the combined
force of pump pressures (PP1) (self pressure) and (PP2) (pressure of the other pump) which pushes spool
(3).
The pressure output from PC valve “Pressure in port (C)” varies, depending on the above position.
4. The level of command current (X) depends on the contents of work (lever operation), selected working
mode, and set value and actual value of the engine speed.
REMARK
The other pump pressure means the pressure of the pump on the opposite side.
The other pump pressure for the front pump is the rear pump pressure, and that for the rear pump is the front
pump pressure.

10-212 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

Function of spring when pump controller is normal and actuator load is low and
pump pressures (PP1) and (PP2) are low

1. The spring load of springs (4) and (6) in the PC valve is determined by the angle of the swash plate.
2. When servo piston (9) moves to the right, spring (6) is compressed.
When the servo piston moves to the right further, it touches seat (5) and spring (6) is fixed.
After this, only spring (4) operates.
3. Servo piston (9) expands or compress springs (4) and (6) to change the spring loads.
4. When command current (X) input to PC-EPC valve solenoid (1) changes, the force pressing piston(2)
changes.
5. The spring loads of springs (4) and (6) also varies with command current (X) of PC-EPC valve solenoid.
6. Port (C) of PC valve is connected to port (E) of LS valve.
7. Self-pressure (PP1) enters the small diameter piston side of servo piston (9) and port (B), and other pump
pressure (PP2) enters port (A).
8. When pump pressures (PP1) and (PP2) are low, spool (3) is at the left position.
9. Port (C) is connected to port (D), and the pressure entering LS valve becomes drain pressure (PT).
10. When port (E) and port (G) of LS valve are connected, the pressure entering from port (J) to large diameter
piston side becomes drain pressure (PT), and servo piston (9) moves to the left.
The pump discharged volume increases.
11. As servo piston (9) moves, springs (4) and (6) expand, and their reaction forces decrease.

HB365LC-3 10-213
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

12. When the reaction forces of the springs decrease, spool (3) moves to the right, port (C) is disconnected
from port (D), and pump discharged pressure port (B) is connected to port (C).
13. Since the pressure in port (C) increases and the pressure on the large diameter piston side increases, ser-
vo piston (9) stops moving to the left.
14. The stop position (= pump discharged volume) of servo piston (9) is determined by the position where the
thrust caused by pressures (PP1) and (PP2) applied to spool (3) is balanced with the thrust of PC-EPC
valve solenoid and forces of springs (4) and (6).
When pump controller is normal and actuator load is high and pump pressures
(PP1) and (PP2) are high

1. When the load is high and pump discharged pressures (PP1) and (PP2) are high, the force pushing spool
(3) to the right increases and spool (3) is positioned as shown in the previous figure.
2. Part of the pressure from port (B) flows through LS valve and port (C) to port (D) as shown in the previous
figure, and the pressure flowing from port (C) to LS valve becomes approximately a half of pump pressure
(PP2).
3. When spool (3) moves to the left, the openings of port (C) and port (D) increase further.
4. The pressure (= J) in port (C) decreases and servo piston (9) stops moving to the right.
At this time, servo piston (9) stops at a position on the right side of the position when pump pressures (PP1)
and (PP2) are low.
5. When port (E) of LS valve and port (G) are connected, this pressure enters from port (J) to the large diame-
ter piston side of servo piston, and servo piston (9) stops.

10-214 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

6. When pump pressure (PP2) increases further and spool (3) moves to the right further, pump pressure
(PP1) flows to port (C) to minimize the discharged volume.
7. When servo piston (9) moves to the right, springs (4) and (6) are compressed and push back spool (3).
8. The positional relation between average of pump pressures (PP1 + PP2)/2 and servo piston (9) is angled
since springs (4) and (6) are 2-stage springs.
9. The relation between average of pump pressures (PP1 +
PP2)/2 and average of pump discharged volume (Q) is
shown in the figure below.
10. When command current (X) sent to PC-EPC valve sole-
noid (1) increases, the relation between average of pump
pressures (PP1 + PP2)/2 and pump discharged volume
(Q) is translated in proportion to the thrust of PC-EPC
valve solenoid.

11. Since the thrust of PC-EPC valve solenoid (1) is added to

the rightward thrust caused by the pump pressure applied
to spool (3), the relation between average of pump pres-
sures (PP1 + PP2)/2 and pump discharged volume (Q) is
translated from (A) to (B) as command current (X) increas-
es.

HB365LC-3 10-215
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

When the pump secondary drive switch is turned on due to failure in pump con-
troller, and the light load is applied to the main pump

1. If the pump controller is faulty, turn on the pump secondary drive switch and switch it to the resistor side.
At this time, the power is supplied directly from the battery. Since the current is too high, the resistor is in-
serted to control the current flowing to PC-EPC valve solenoid (1).
Since the current is stabilized, the force pressing piston (2) is stabilized.
2. When main pump pressures (PP1) and (PP2) are low, the combined force of the force of PC-EPC valve
solenoid (1) and pump pressure is lower than the spring set force, and accordingly spool (3) is balanced at
the left side.
3. Port (C) is connect to the drain pressure in port (D). The large diameter piston side of servo piston (9) is
also set to the drain pressure (PT) through LS valve.
4. Since the pressure on the small diameter piston side is high, servo piston (9) moves in the direction to in-
crease the discharged volume.

10-216 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

When the pump secondary drive switch is turned on due to failure in pump con-
troller, and the heavy load is applied to the main pump

1. The command current (X) sent to PC-EPC valve solenoid (1) is constant similarly to the above explanation
when the pump secondary drive switch is turned on.
Accordingly, the piston (2) pushes spool (3) with a constant force.
2. When main pump pressures (PP1) and (PP2) increase, spool (3) moves right more, compared with when
the main pump load is low, and is balanced at the position shown in the previous figure.
3. Since the pressure from port (B) flows in port (C), servo piston (9) moves to the right (small discharged vol-
ume) and the pump stops on a more right position than when the pump load is low.
4. The curve of pump discharged pressure (PP) and discharged volume (Q) is determined corresponding to
the current value supplied to PC-EPC valve solenoid through the resistor when the pump secondary drive
switch is turned on as shown in the figure.

HB365LC-3 10-217
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

The curve when the pump secondary drive switch is turned

on, the curve (B) is further to the left than that of when the
pump controller is normal (A).

MAIN PUMP LS-EPC VALVE (PC400_10-K-C2M0-001-00-B)

LS
Abbreviation for Load Sensing
EPC
Abbreviation for Electromagnetic Proportional Control

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

STRUCTURE OF MAIN PUMP LS-EPC VALVE (PC300_11-K-C2M0-041-00-B)

General view and sectional view

C: To LS valve T: To hydraulic tank

P: From self-pressure reducing valve
1: Connector 5: Spool
2: Coil 6: Rod
3: Body 7: Plunger
4: Spring

HB365LC-3 10-219
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

FUNCTION OF MAIN PUMP LS-EPC VALVE (PC400_10-K-C2M0-042-00-B)

Upon receiving signal current (i) from the pump controller, this
valve generates EPC output pressure in proportion to that sig-
nal current and outputs it to LS valve.

OPERATION OF MAIN PUMP LS-EPC VALVE (PC220_11-K-C2M0-044-00-B)

When signal current from pump controller is zero (coil de-energized)

1. When the signal current from the controller is not flowing
through coil (2), coil (2) is de-energized.
2. Spool (5) is pushed to the left by spring (4).
3. Port (P) is closed, and the pressurized oil from the self-
pressure reducing valve does not flow to LS valve.
4. The pressurized oil from LS valve is drained to the tank
through port (C) and port (T).

10-220 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

When signal current from pump controller is low (coil energized)

1. When low signal current flows through coil (2), coil (2) is
energized and generates thrust to push plunger (7) to the
right.
2. Rod (6) pushes spool (5) to the right, and the pressurized
oil from port (P) flows to port (C).
3. When the pressure in port (C) increases, the total of the
force acting on the surface of spool (5) and the reaction
force of spring (4) becomes larger than the thrust of plung-
er (7).
4. Spool (5) is pushed to the left, and port (P) is disconnected
from port (C).
5. Port (C) is connected to port (T).
6. Spool (5) so moves that the thrust of plunger (7) is bal-
anced with the total of the pressure in port (C) and the re-
action force of spring (4).
7. The circuit pressure between the EPC valve and the LS
valve is controlled in proportion to the amperage of the sig-
nal current.

When signal current from pump controller is maximum (coil energized)

1. When signal current flows through coil (2), coil (2) is ener-
gized.
Since the signal current is maximum at this time, the thrust
of plunger (7) is also maximum.
2. Spool (5) is pushed to the right by spring (6).
3. The pressurized oil flows from port (P) to port (C) at the
maximum rate, and the circuit pressure between the EPC
valve and LS valve is maximized.
4. Since port (T) closes, the pressurized oil does not flow into
the tank.

MAIN PUMP PC-EPC VALVE (PC400_11-P-C2E5-001-00-B)

PC
Abbreviation for Pressure Compensation

HB365LC-3 10-221
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

EPC
Abbreviation for Electromagnetic Proportional Control

STRUCTURE OF MAIN PUMP PC-EPC VALVE (HB335_3-P-C2E5-041-00-B)

PC: Abbreviation for Pressure Compensation
EPC: Abbreviation for Electromagnetic Proportional Control
General view and sectional view

C: To PC valve T: To hydraulic tank

P: From self-pressure reducing valve
1: Connector 5: Spool
2: Coil 6: Rod
3: Body 7: Plunger
4: Spring

10-222 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

FUNCTION OF MAIN PUMP PC-EPC VALVE (PC400_11-P-C2E5-042-01-B)

Upon receiving signal current (i) from the pump controller, it
generates EPC output pressure in proportion to that signal cur-
rent and outputs it to the PC valve.

OPERATION OF MAIN PUMP PC-EPC VALVE (PC400_11-P-C2E5-044-00-B)

When signal current from pump controller is zero (coil de-energized)

1. When the signal current from the pump controller does not
flow through coil (2), coil (2) is de-energized.
2. Spool (5) is pushed to the left by spring (4).
3. Port (P) is closed, and the pressurized oil from the self-
pressure reducing valve does not flow to PC valve.
4. The pressurized oil from PC valve is drained to the tank
through port (C) and port (T).

HB365LC-3 10-223
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

When signal current from pump controller is low (coil energized)

1. When low signal current flows through coil (2), coil (2) is
energized and generates thrust to push plunger (7) to the
right.
2. Rod (6) pushes spool (5) to the right, and the pressurized
oil from port (P) flows to port (C).
3. When the pressure in port (C) increases, the total of the
force acting on the surface of spool (5) and the reaction
force of spring (4) becomes larger than the thrust of plung-
er (7).
4. Spool (5) is pushed to the left, and port (P) is disconnected
from port (C).
5. Port (C) is connected to port (T).
6. Spool (5) so moves that the thrust of plunger (7) is bal-
anced with the total of the pressure in port (C) and the re-
action force of spring (4).
7. The circuit pressure between the EPC valve and the PC
valve is controlled in proportion to the amperage of the sig-
nal current.

When signal current from pump controller is maximum (coil energized)

1. When signal current flows through coil (2), coil (2) is ener-
gized.
Since the signal current is maximum at this time, the thrust
of plunger (7) also becomes maximum.
2. Spool (5) is pushed to the right by spring (6).
3. The pressurized oil flows from port (P) to port (C) at the
maximum rate, and the circuit pressure between the EPC
valve and PC valve is maximized.
4. Since port (T) closes, the pressurized oil does not flow into
the tank.

10-224 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

CONTROL VALVE (PC400_10-K-C030-001-00-B)

STRUCTURE OF CONTROL VALVE (HB335_3-K-C030-041-00-B)

The control valve consists of a 7-spool valve (single unit type) and a service valve, and it is equipped with a
merge-divider valve, variable back pressure valve, boom hydraulic drift prevention valve, and arm quick return
valve.
Since these valves are formed in one unit with connecting bolts and the passages are connected inside, the
control valve is compact and serviced very easily.
Structure of this control valve is simple with actuator-to-spool type.
The structure of the 8-spool valve (7-spool valve + service valve) is described below.

HB365LC-3 10-225
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

General view

A1: To bucket cylinder bottom A6: To arm cylinder head

A2: To left travel motor (reverse) A-1: To boom cylinder bottom
A3: To boom cylinder bottom A-2: To attachment 1
A4: Plug B1: To bucket cylinder head
A5: To right travel motor (reverse) B2: To left travel motor (forward)

10-226 HB365LC-3
10 STRUCTURE AND FUNCTION
B3: To boom cylinder head
B4: Plug
B5: To right travel motor (forward)
B6: To arm cylinder bottom
B-1: To arm cylinder bottom
B-2: To attachment 1
BP5: From machine push-up solenoid valve
BP6: From attachment selector solenoid valve
P1: From R.H. work equipment PPC valve (bucket
CURL)
P2: From R.H. work equipment PPC valve (bucket
DUMP)
P3: From travel PPC valve (left travel REVERSE)
P4: From travel PPC valve (Left travel FORWARD)
P5: From R.H. work equipment PPC valve (boom
LOWER)
P6: From R.H. work equipment PPC valve (boom
LOWER)
P9: From travel PPC valve (right travel REVERSE)
P10: From travel PPC valve (right travel FORWARD)
P11: From L.H. work equipment PPC valve (arm OUT)
P12: From L.H. work equipment PPC valve (arm IN)
P-3: From R.H. attachment PPC valve
1: Variable back pressure valve
2: Variable back pressure solenoid valve
3: Merge-divider EPC valve (for main spool)
4: Merge-divider EPC valve (for LS spool)
5. Arm hydraulic drift prevention valve
6: Boom hydraulic drift prevention valve
HB365LC-3
COMPONENT PARTS OF HYDRAULIC SYSTEM
P-4: From R.H. attachment PPC valve
PLS1: To front pump LS valve
PLS2: To rear pump LS valve
PP1: From front pump
PP2: From rear pump
PPC: Pilot source pressure pickup port
PP1S: Front pump oil pressure sensor mounting port
PP2S: Rear pump oil pressure sensor mounting port
PPS2: To rear pump LS valve
PR: To solenoid valve, PPC valve, and EPC valve
PST: From travel junction solenoid valve
PX1: From 2-stage relief solenoid valve
PX2: From 2-stage relief solenoid valve
T: To tank
T1: To tank
TS: To tank
TSW: Plug
IS1: Merge-divider EPC valve (main spool) drive sig-
nal
IS2: Merge-divider EPC valve (LS spool) drive signal
CN: Variable back pressure solenoid valve drive signal
7: Boom Hi valve, arm Hi valve
8: Boom Hi check valve
9: 8-spool valve
10: Merge-divider valve
11: Self-pressure reducing valve
10-227
COMPONENT PARTS OF HYDRAULIC SYSTEM
Sectional views (A-A, B-B)
1: Pressure compensation valve (arm OUT)
2: Pressure compensation valve (right travel RE-
VERSE)
3: Pressure compensation valve (boom RAISE)
4: Pressure compensation valve (left travel RE-
VERSE)
10-228
10 STRUCTURE AND FUNCTION
5: Pressure compensation valve (bucket CURL)
6: Pressure compensation valve (boom Hi RAISE)
7: Pressure compensation valve (service 1)
8: Pressure compensation valve (service 1)
9: Pressure compensation valve (arm Hi IN)
HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

10: Pressure compensation valve (bucket DUMP) 18: Spool (service 2)

11: Pressure compensation valve (left travel FOR- 19: Spool (arm Hi)
WARD) 20: Spool (bucket)
12: Pressure compensation valve (boom LOWER) 21: Spool (left TRAVEL)
13: Pressure compensation valve (right travel FOR- 22: Spool (boom)
WARD)
23: Spool (right TRAVEL)
14: Pressure compensation valve (arm IN)
24: Spool (arm)
15: Main relief valve
25: Spool (boom Hi)
16: Unload valve
17: Main relief valve

HB365LC-3 10-229
COMPONENT PARTS OF HYDRAULIC SYSTEM
Sectional views (C-C, D-D)
1: Suction valve (arm OUT)
2: Suction valve (right TRAVEL REVERSE)
3: Suction valve (boom RAISE)
4: Suction valve (left TRAVEL REVERSE)
5: Suction safety valve (service)
6: 2-stage suction safety valve (service)
7: Suction safety valve (arm Hi IN)
8: Suction safety valve (bucket DUMP)
9: Suction valve (left TRAVEL FORWARD)
10-230
10 STRUCTURE AND FUNCTION
10: 2-stage suction safety valve (boom LOWER)
11: Suction valve (right TRAVEL FORWARD)
12: Suction safety valve (arm IN)
13: LS shuttle valve (arm)
14: LS shuttle valve (right TRAVEL)
15: LS shuttle valve (boom)
16: LS shuttle valve (left TRAVEL)
17: LS shuttle valve (bucket)
18: LS shuttle valve (service 1)
HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

19: LS slow return valve 20: LS check valve

Sectional views (E-E, F-F, G-G, H-H)

1: Unload valve
2: Safety valve for hydraulic drift prevention valve (boom RAISE and arm OUT)
3: Main relief valve
4: Variable back pressure valve
Arm valve
5. Arm hydraulic drift prevention valve
6. LS shuttle valve

HB365LC-3 10-231
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

7: Pressure compensation valve (CURL)

8: Spool
9: Suction safety valve (CURL)
10. Check valve for regeneration circuit
11: Suction valve (OUT)
12: Pressure compensation valve (OUT)
Right travel valve
13. LS shuttle valve
14: Pressure compensation valve (FORWARD)
15: Spool
16: Suction valve (FORWARD)
17: Suction valve (REVERSE)
18: Pressure compensation valve (REVERSE)

10-232 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

Sectional views (J-J, K-K, L-L, M-M)

1: Return spring
2: Merge-divider valve (for LS)
3: Valve (sequence valve)
4: Spring (sequence valve)
5: Merge-divider valve (main)
6: Return spring
Boom valve
7: Boom hydraulic drift prevention valve

HB365LC-3 10-233
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

8. LS shuttle valve
9: Pressure compensation valve (LOWER)
10: Spool
11: Suction safety valve (LOWER)
12. Check valve for regeneration circuit
13: Suction valve (RAISE)
14: Pressure compensation valve (RAISE)
Left travel valve
15: Merge-divider valve (travel junction valve)
16: Return spring
17. LS shuttle valve
18: Pressure compensation valve (FORWARD)
19: Spool
20: Suction valve (FORWARD)
21: Suction valve (REVERSE)
22: Pressure compensation valve (REVERSE)
Bucket valve
23. LS shuttle valve
24: Pressure compensation valve (DUMP)
25: Spool
26: Suction safety valve (DUMP)
27: Suction safety valve (CURL)
28: Pressure compensation valve (CURL)

10-234 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

Sectional views (N-N, AA-AA, AB-AB, AD-AD, BB-BB)

Boom Hi valve, arm Hi valve

1: Boom Hi check valve
2. Arm quick return valve
3: Pressure compensation valve (arm Hi IN)
4: Spool (arm Hi)
5: Suction safety valve (arm Hi IN)
6: Spool (boom Hi)
7: Suction valve (boom Hi RAISE)

HB365LC-3 10-235
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

Service valve
8. LS shuttle valve
9: Pressure compensation valve
10: Spool
11: 2-stage suction safety valve
12: Suction safety valve
2: Block
13: Unload valve
14: Main relief valve
15: LS bypass plug

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

HYDRAULIC CIRCUIT DIAGRAMS OF CONTROL VALVE AND NAMES OF

VALVES (HB335_3-K-C010-054-00-B)

1: Arm valve 5: Bucket valve

2: R.H. travel valve 6: Boom Hi valve, arm Hi valve
3: Boom valve 7: Service 1 valve
4: L.H. travel valve 8: Arm valve spool

HB365LC-3 10-237
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

9: R.H. travel valve spool Set pressure: 36.0±0.25 MPa {367.5±2.5 kg/cm2}
10: Boom valve spool When digging force is increased: 38.2 ± 0.25 MPa
11: L.H. travel valve spool {389.5 ± 2.5 kg/cm2}
12: Bucket valve spool 34: Main relief valve (arm, R.H. travel, and swing)
13: Boom Hi spool Set pressure: 36.0±0.25 MPa {367.5±2.5 kg/cm2}
14: Arm Hi spool When digging force is increased: 38.2 ± 0.25 MPa
{389.5 ± 2.5 kg/cm2}
15: Service 1 spool
35: Unload valve (boom, L.H. travel, bucket)
16: Pressure compensation valve
Cracking pressure3.1 MPa {32 kg/cm2}
17: Suction valve
36: Unload valve (arm, R.H. travel, and swing)
18: Check valve (for boom regeneration circuit)
Cracking pressure3.1 MPa {32 kg/cm2}
19: Check valve (for arm regeneration circuit)
37: Suction safety valve
20: Merge-divider EPC valve (for LS spool)
Set pressure: 38.2±0.5 MPa {390±5 kg/cm2}
21: Merge-divider EPC valve (for main spool)
38: 2-stage suction safety valve
22. LS shuttle valve
1st-stage set pressure: 28.4±0.5 MPa {290±5 kg/cm2}
23: LS bypass valve
2nd-stage set pressure: 14.7±0.5 MPa
24: Merge-divider valve
{150±5 kg/cm2}
25: Boom Hi check valve
39: 2-stage suction safety valve
26. Arm quick return valve
1st-stage set pressure: 24.5±0.5 MPa {250±5 kg/cm2}
27: Arm check valve (suction safety valve) (if equip-
2nd-stage set pressure: 20.1±0.5 MPa
ped)
{205±5 kg/cm2}
28: Self-pressure reducing valve
40: Suction safety valve
29: Travel junction valve
Set pressure24.5 MPa {250 kg/cm2}
30: Variable back pressure valve
41: Suction safety valve for hydraulic drift prevention
31: Variable back pressure solenoid valve valve
32: Boom hydraulic drift prevention valve Set pressure: 38.2±0.5 MPa {390±5 kg/cm2}
33: Main relief valve (boom, L.H. travel, bucket, and
attachment)

PRESSURE COMPENSATION VALVE OF CONTROL VALVE (PC400_10-K-L6D0-001-00-B)

FUNCTION OF PRESSURE COMPENSATION VALVE OF CONTROL VALVE

(PC300_11-K-L6D0-042-00-B)
The bucket valve (cylinder bottom), arm Hi valve (cylinder bottom), and service valve in this machine have re-
spective built-in pressure compensation valves.

10-238 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

When load pressure is higher than other actuator in combined operation, in sin-
gle operation, or at maximum load pressure

1: Main pump 4. Piston

2: Valve 5: Spring
3: Shuttle valve 6: LS shuttle valve
• The pressure compensation valve works as a load check valve.
• When pump pressure (LS pressure) is lower than the load on port (c), shuttle valve (3) in pressure compen-
sation valve piston (4) connects spring chamber (E) and port (c).
• Piston (4) and valve (2) are moved in the closing direction by the force of spring (5).
• When high peak pressure occurs in the actuator circuit or when continuous repeated pressure occurs (ex-
ample: when the breaker is used), valve (2) collides with valve chamber seat (C), and high pressure can
occur.
To prevent this, the pressure compensation valve having
valve (2) and piston (4) as one unit in it is used.
• Valve (7) does not hit valve chest even when high peak
pressure is generated in port (C).

HB365LC-3 10-239
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

When load pressure is lower than other actuators during combined operation,
or when compensated

1: Main pump 4. Piston

2: Valve 5: Spring
3: Shuttle valve 6: LS shuttle valve
• The pressure compensation valve is closed by LS pressure in port (D), and the spool meter-in downstream
pressure at port (B) becomes equal to the maximum pressure in the other actuator.
• Since the spool meter-in upstream pressure at port (A) is the pump pressure, the spool meter-in differential
pressure <Upstream pressure “Port (A) pressure” - Downstream pressure “Port (B)”> is the same in all the
spools in operation.
• The pump discharged volume is divided at the meter-in opening area ratio.

10-240 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

OPERATION OF PRESSURE COMPENSATION VALVE OF CONTROL VALVE

(PC400_10-K-L6D0-044-00-B)

When load pressure is lower than it of other work equipments during combined
operation, or when compensated

1. Spring chamber (E) is interconnected with port (D).

2. Piston (4) and valve (2) move in the closing direction (right side) with the LS circuit pressure from other
work equipment of port (F).
3. The valve upstream pressure (= spool meter-in downstream pressure) at port (B) is controlled by LS pres-
sure.

HB365LC-3 10-241
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

SURFACE AREA RATIO OF PRESSURE COMPENSATION VALVE OF CONTROL

VALVE (PC400_10-K-L6D0-001-01-B)

FUNCTION OF SURFACE AREA RATIO OF PRESSURE COMPENSATION VALVE

OF CONTROL VALVE (PC400_10-K-L6D0-042-01-B)

• The oil flow division state varies according to the surface area ratio of portion (A1) and portion (A2) of the
pressure compensation valve. Surface area ratio = (A2)/(A1)
• When the surface area ratio is 1, the spool meter-in downstream pressure is equal to the maximum load
pressure, and the oil flow is divided according to the surface area ratio.
• When the surface area ratio is larger than 1, the spool meter-in downstream pressure is higher than the
maximum load pressure, and the oil flow is divided less than the surface area ratio.
• When the surface area ratio is smaller than 1, the spool meter-in downstream pressure is lower than the
maximum load pressure, and the oil flow is divided more than the surface area ratio.

10-242 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

SHUTTLE VALVE IN PRESSURE COMPENSATION VALVE OF CONTROL VALVE

(PC400_10-K-L6D0-001-10-B)

STRUCTURE OF SHUTTLE VALVE IN PRESSURE COMPENSATION VALVE OF

CONTROL VALVE (PC400_10-K-L6D0-041-00-B)

During travel

1: Main pump 5: Pressure compensation valve

Since no holding pressure occurs in port (A) of the travel circuit, pressure compensation valve (5) having no
shuttle valve is employed.

HB365LC-3 10-243
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

OPERATION OF SHUTTLE VALVE IN PRESSURE COMPENSATION VALVE OF

CONTROL VALVE (PC400_10-K-L6D0-044-10-B)

When holding pressure in port (A) exceeds LS pressure in spring chamber (B)

1: Main pump 4: Piston

2: Valve 5: Pressure compensation valve
3: Shuttle valve
1. Shuttle valve (3) is pressed to the right by port (A) pressure and disconnects ports (A) and (C).
2. The holding pressure in port (A) is supplied to spring chamber (B) and presses piston (4) to the left so that
piston (4) and valve (2) do not separate from each other.

INTRODUCTION OF LS PRESSURE IN CONTROL VALVE (PC400_10-K-C2A4-001-00-B)

LS
Abbreviation for Load Sensing

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

FUNCTION OF INTRODUCTION OF LS PRESSURE IN CONTROL VALVE

(PC400_10-K-C2A4-042-00-B)

1: Main pump 5: Check valve

2: Main spool 6: LS circuit
3: Pressure compensation valve 7: LS shuttle valve
4: Valve
• The upstream pressure of pressure compensation valve (3) (spool meter-in downstream pressure) is intro-
duced as LS pressure into LS shuttle valve (7).
• Then, this pressure is connected to port (B) of the actuator through valve (4), and LS pressure ≒ Actuator
load pressure.
• Introduction hole (a) in main spool (2) is small in diameter and used as an orifice.
• LS pressure is used as source pressure for closing the unload valve and as operating pressure when the
pressure compensation valve is compensated.

HB365LC-3 10-245
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

OPERATION OF INTRODUCTION OF LS PRESSURE IN CONTROL VALVE

(PC400_10-K-C2A4-044-00-B)

1. When main spool (2) is operated, the pump pressure enters port (c) through introduction hole (a), and is
introduced into LS circuit.
2. When the pump pressure increases up to the load pressure on port (B), check valve (5) opens and the
pressurized oil flows.

LS BYPASS PLUG OF CONTROL VALVE (PC400_10-K-PNSH-001-00-B)

LS
Abbreviation for Load Sensing

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

STRUCTURE OF LS BYPASS PLUG OF CONTROL VALVE (PC300_11-K-PNSH-041-00-B)

LS: Abbreviation for Load Sensing

1: Main pump 4: LS shuttle valve

2: Main spool 5: LS bypass plug
3: Pressure compensation valve 6: LS circuit

HB365LC-3 10-247
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

FUNCTION OF LS BYPASS PLUG OF CONTROL VALVE (PC300_11-K-PNSH-042-00-B)

• LS bypass plug releases the remaining pressure in LS pressure circuit (6) through orifices (a) and (b).
• LS bypass plug reduces the LS pressure rising speed and prevents sudden change of the hydraulic pres-
sure.
• When oil bypasses through LS bypass plug (5), pressure loss occurs due to the resistance in the circuit
from orifice (c) of main spool (2) to LS shuttle valve (4).
• The effective LS differential pressure decreases, and the dynamic stability of the actuator is improved.

10-248 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

HI VALVE OF CONTROL VALVE (PC400_11-K-L439-001-00-B)

FUNCTION OF HI VALVE OF CONTROL VALVE (PC400_11-K-L439-042-00-B)

• By operating Lo valve and Hi valve simultaneously, the Boon raise Arm digging
opening of spool becomes double so that the pressure
loss is reduced and enough flow is secured.
Arm dumpimg
• When the boom is raised, boom Hi valve operates simulta-
neously with boom Lo valve, and increases the flow to the
Hi valve
cylinder bottom side.
Boon Hi Arm Hi
• When the arm is moved IN, arm Hi valve operates simulta-
neously with arm Lo valve, and increases the flow to the Bucket
cylinder bottom side.
R.H. Travel
• When the arm is moved OUT, arm Hi valve operates simul-
taneously with arm Lo valve, and decreases the flow from Boom Lo
the cylinder head side.
Swing

L.H. Travel

Arm Lo

A4P15732

OPERATION OF HI VALVE OF CONTROL VALVE (PC400_11-K-L439-044-00-B)

Hi valve looks like to have 1 spool, but it has 2 divided spools. L.H. is boom Hi spool and R.H. is arm Hi spool.
The arm Hi spool moves both directions of right and left, and 2 spools are controlled separately.

1 2

c b

A B

d a

D
5 3

4
A4P15733

A: From boom Lo valve C: Arm IN PPC pressure

B: From Arm Lo valve D: Arm OUT PPC pressure

HB365LC-3 10-249
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

E: Boom RAISE PPC pressure

1: Boom cylinder 4: Pump
2: Arm cylinder 5: Boom Hi spool
3: Arm Hi spool
1. During boom RAISE operation, boom RAISE PPC pressure (E) is transmitted to small chamber d and push-
es boom Hi spool (5) to the left, and the pump pressure is transmitted to the bottom circuit of boom cylinder
(1).
2. During arm IN operation, arm IN PPC pressure (C) is transmitted to chamber a and pushes arm Hi spool (3)
to the left, and the pump pressure is transmitted to the bottom circuit of arm cylinder (2).
3. During arm OUT operation, arm OUT PPC pressure (D) is transmitted to chamber b and push arm HI spool
(3) to the right, and transmitted to the drain circuit. At the same time, it is transmitted to the L.H. spring
chamber through passage c in the boom Hi spool, and pushes the boom Hi spool to the right and fix it.

BOOM REGENERATION CIRCUIT OF CONTROL VALVE (PC400_10-K-L511-001-00-B)

FUNCTION OF BOOM REGENERATION CIRCUIT OF CONTROL VALVE

(PC400_10-K-L511-042-00-B)

When the cylinder head pressure is lower than the bottom pressure (when
boom lowers by its own weight, etc.)

1: Main pump 3: Pressure compensation valve

2: Boom valve spool 4: Suction safety valve

10-250 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

5: Suction valve 7: LS shuttle valve

6: Check valve
When the boom is lowered, a regeneration circuit is formed from the cylinder bottom to the cylinder head to in-
crease the oil flow to the cylinder head.
When cylinder head pressure is higher than the bottom pressure (when digging,
etc.)

Check valve (6) installed to regeneration circuit (C) closes to stop the oil flow from the cylinder bottom to the
cylinder head.

HB365LC-3 10-251
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

OPERATION OF BOOM REGENERATION CIRCUIT OF CONTROL VALVE

(PC400_10-K-L511-044-00-B)

When the cylinder head pressure is lower than the bottom pressure (when
boom lowers by its own weight, etc.)

When the cylinder head pressure is lower than the bottom pressure, part of pressurized oil (A) from the cylinder
bottom flows to drain circuit (B) through the notch of boom valve spool (2).
Other part flows to regeneration circuit (C), opens valve (6), and flows to the cylinder head through circuit (D).
The flows from regeneration circuit (C) and main pump (1) merge in circuit (E).

10-252 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

ARM REGENERATION CIRCUIT OF CONTROL VALVE (PC400_10-K-L911-001-00-B)

FUNCTION OF ARM REGENERATION CIRCUIT OF CONTROL VALVE

(PC400_10-K-L911-042-00-B)

When cylinder head pressure is higher than bottom pressure

1: Main pump 5: Suction valve

2: Arm valve spool 6: Check valve
3: Pressure compensation valve 7: LS shuttle valve
4: Suction safety valve
When the arm is moved IN, both of the pump discharged volume and regeneration volume flow through the re-
generation circuit from the cylinder head to the cylinder bottom and increase the cylinder speed.

HB365LC-3 10-253
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

When cylinder head pressure is lower than bottom pressure

Check valve (6) installed to regeneration circuit (C) closes and stops the flow from the cylinder head to the bot-
tom.

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

OPERATION OF ARM REGENERATION CIRCUIT OF CONTROL VALVE

(PC400_10-K-L911-044-00-B)

When cylinder head pressure is higher than bottom pressure

When the cylinder head pressure is higher than the bottom pressure, part of pressurized oil (A) from the cylinder
head flows to drain circuit (B) through the notch of arm valve spool (2).
Other part flows to regeneration circuit (C), opens valve (6), and flows to the cylinder bottom through circuit (D).
The flows from regeneration circuit (C) and main pump (1) merge in circuit (E).

HB365LC-3 10-255
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

MERGE-DIVIDER VALVE OF CONTROL VALVE (PC400_10-K-C082-001-00-B)

FUNCTION OF MERGE-DIVIDER VALVE OF CONTROL VALVE (PC300_11-K-C082-042-00-B)

When pumps are merged “when merge-divider valve selector signals (IS1) and
(IS2) are OFF”

Connected

IS2 OFF IS1 OFF

Connected
Arm side Bucket side
(Front Pump) (Rear Pump)
5 8 A B C D 3 4 7 6
PC200-8
2 x EPC valve
10 9

E F
To control valve

To control valve

P1 P2
A4P15736

1: Main spool 6: LS circuit (bucket side)

2: Spring 7: LS circuit (arm side)
3: LS spool 8: LS circuit (arm side)
4: Spring 9: Merge-divider EPC valve (for selecting main spool)
5: LS circuit (bucket side) 10: Merge-divider EPC valve (for selecting LS spool)
• This valve merges pressurized oils (P1) and (P2) discharged from the 2 pumps, or divides them (supply
them to their respective control valve groups).
• This valve merges or divides the LS circuit pressure.

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

OPERATION OF MERGE-DIVIDER VALVE OF CONTROL VALVE (PC400_10-K-C082-044-00-B)

When pumps are merged “when merge-divider valve selector signals (IS1) and
(IS2) are OFF”

Connected

IS2 OFF IS1 OFF

Connected
Arm side Bucket side
(Front Pump) (Rear Pump)
5 8 A B C D 3 4 7 6
PC200-8
2 x EPC valve
10 9

E F
To control valve

To control valve

P1 P2
A4P15736

1. Since EPC valve drive signal (IS1) to the main spool is OFF, the output pressure of merge-divider EPC
valve is 0 MPa {0 kg/cm2} .
2. Main spool (1) is pressed to the right by spring (2), and ports (E) and (F) are connected.
3. Pressurized oils (P1) and (P2) discharged from the 2 pumps are merged in ports (E) and (F) and sent to the
control valve that requires them.
4. EPC valve drive signal (IS2) to LS spool (3) is also OFF, LS spool (3) is pressed to the right, and ports (A)
and (D), and ports (B) and (C) are connected respectively.
5. LS pressures supplied from each control valve spool to LS circuits (5), (6), (7), and (8) are transmitted to all
of the pressure compensation valve.

HB365LC-3 10-257
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

When pumps are divided “when merge-divider valve selector signals (IS1) and
(IS2) are ON”

IS2 ON IS1 ON
Connected
Arm side Bucket side
(Front Pump) (Rear Pump)
5 8 A B C D 3 4 7 6

10 9

E F
To control valve

To control valve

P1 P2
A4P15737

1. Since EPC valve drive signal (IS1) to the main spool is ON, the output pressure from merge-divider EPC
valve moves main spool (1) to the left, and ports (E) and (F) are disconnected.
2. The pressurized oils discharged from the 2 pumps are sent to the respective control valve groups.
Pressure P1: To bucket, L.H. travel, and boom
Pressure P2: To swing, R.H. travel, and arm
3. When EPC valve drive signal (IS2) to LS spool (3) is turned ON, the output pressure from merge-divider
EPC valve moves the LS spool to the left, ports (A) and (C) are connected, and other ports are disconnect-
ed.
4. LS pressures supplied from each control valve spool to LS circuits (5), (6), (7), and (8) are transmitted to
the respective control valves.

SELF-PRESSURE REDUCING VALVE OF CONTROL VALVE (PC400_10-K-PL30-001-00-B)

FUNCTION OF SELF-PRESSURE REDUCING VALVE OF CONTROL VALVE

(PC400_10-K-PL30-042-00-B)
This valve reduces the discharged pressure of the main pump and supplies it as control pressure to the solenoid
valves, EPC valves, etc.

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

OPERATION OF SELF-PRESSURE REDUCING VALVE OF CONTROL VALVE

(PC400_10-K-PL30-044-00-B)

When engine is stopped

1. Since poppet (11) is pressed to the seat by spring (12), the
circuit between ports (PR) and (TS) is closed.
2. Since valve (14) is pressed to the left by spring (13), the
circuit between ports (P2) and (TS) is closed.
3. Since valve (7) is pressed to the left by spring (8), the cir-
cuit between ports (P2) and (A2) is closed.

HB365LC-3 10-259
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

When load pressure (A2) is lower than self-pressure reducing valve output pres-
sure (PR) and control valve is in neutral or when load pressure (P2) is low
1. Spring (8) and pressure (PR) (0 MPa {0 kg/cm2} when the
engine is stopped) apply force to valve (7) in the direction
to close the circuit between ports (P2) and (A2).
2. When pressurized oil flows in from port (P2), “(Area of di-
ameter d x Pressure P2) = Force of spring (8) + (Area of
diameter d x Pressure PR)”, and the valve is balanced.
3. The opening of valve (7) is so adjusted that pressure (P2)
is kept higher than pressure (PR).
4. When pressure (PR) exceeds the set pressure, poppet
(11) opens.
5. The pressurized oil flows from port (PR) to orifice (a) in
spool (14), and then flows to seal drain port (TS) through
the opening of poppet (11).
6. Differential pressure occurs between the upstream side
downstream side of orifice (a) in spool (14), and spool (14)
moves in the direction to close the opening between ports
(P2) and (PR).
Pressure (P2) is reduced and adjusted to a constant pres-
sure (set pressure) by the opening at this time, and it is
supplied as pressure (PR).

When load pressure (P2) is high

1. Load pressure (A2) is increased by the operation of dig-
ging, etc., and the pump discharged volume increases.
2. Pressure (P2) increases and “(Area of diameter d x Pres-
sure P2) > Force of spring (8) + (Area of diameter d x
Pressure PR)”, and valve (7) moves to the right stroke
end.
3. The opening between ports (P2) and (A2) increases and
the passage resistance decreases, and the engine horse-
power loss reduces.
4. When pressure (PR) exceeds the set pressure, poppet
(11) opens.
5. The pressurized oil flows from port (PR) to orifice (a) in
spool (14), and then flows to seal drain port (TS) through
the opening of poppet (11).
6. Differential pressure occurs between the upstream side
downstream side of orifice (a) in spool (14), and spool (14)
moves in the direction to close the opening between ports
(P2) and (PR).
Pressure (P2) is reduced and adjusted to a constant pres-
sure (set pressure) by the opening at this time, and it is
supplied as pressure (PR).

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

When abnormally high pressure occurs

1. When pressure (PR) of the self-pressure reducing valve in-
creases abnormally, ball (16) compresses spring (15) and
leaves the seat.
2. The pressurized oil flows from port (PR) to port (TS), and
pressure (PR) decreases.
3. The devices such as PPC valves, solenoid valves, etc. are
protected from abnormal pressure.

TRAVEL JUNCTION VALVE OF CONTROL VALVE (PC400_10-K-C6C0-001-00-B)

FUNCTION OF TRAVEL JUNCTION VALVE OF CONTROL VALVE (PC400_10-K-C6C0-042-00-B)

• When the travel lever is operated for straight travel, the travel junction valve does not receive pilot pressure
(PST) from the travel junction solenoid valve, and accordingly R.H. and L.H. travel circuits are connected,
and oil is supplied evenly to R.H. and L.H. travel motors to keep the straight travel performance.
• When the travel lever is operated for steering, the travel junction valve receives pilot pressure (PST) from
the travel junction solenoid valve, and accordingly R.H. and L.H. travel circuits are disconnected, and inde-
pendent oils are supplied individually to R.H. and L.H. travel motors to keep the steering performance.

HB365LC-3 10-261
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

OPERATION OF TRAVEL JUNCTION VALVE OF CONTROL VALVE (PC400_10-K-C6C0-044-00-B)

When pilot pressure (PST) is cut off (travel circuits are connected to each other)

1. When pilot pressure (PST) from the travel junction solenoid valve is cut off, travel junction spool (2) is push-
ed back to the left by the reaction force of spring (1), and port (PTL) and port (PTR) are connected.
2. When there is difference between the inflow rates to R.H. and L.H. travel motors, oil is supplied from the
port on the high pressure side through the opening of travel junction spool (2) to the port on the low pres-
sure side to compensate for the differential pressure, and oil is supplied to R.H. and L.H. motors evenly.

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

When pilot pressure (PST) is supplied (travel circuits independent from each
other)

1. When pilot pressure (PST) from the travel junction solenoid valve is supplied, travel junction spool (2) com-
presses spring (1) and moves to the right, and port (PTL) and port (PTR) are disconnected.
2. Independent oil flows are supplied to R.H. and L.H. travel motors.

TRAVEL PPC SHUTTLE VALVE OF CONTROL VALVE (PC400_10-K-C6V1-001-00-B)

PPC
Abbreviation for Proportional Pressure Control

HB365LC-3 10-263
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

FUNCTION OF TRAVEL PPC SHUTTLE VALVE OF CONTROL VALVE

(PC400_10-K-C6V1-042-00-B)
• This valve controls the stroke of arm spool with pilot pressure of travel PPC valve to limit the flow to the
cylinder if arm IN is operated when traveling uphill.
• When the arm stroke is restricted, the pilot pressure of the travel PPC valve acts through the internal circuit
of the control valve.

OPERATION OF TRAVEL PPC SHUTTLE VALVE OF CONTROL VALVE

(PC400_10-K-C6V1-044-00-B)

When travel lever is in NEUTRAL

1. The oil in stroke limit signal chamber (a) flows through orifices (5) and (6) of pistons (3) and (4) in the travel
spring case, and flows through travel PPC valve and then drained.
2. When the arm is moved IN, spool (1) moves to the left until it touches the end surface of spring case (2)
(st0).

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

When travel lever is operated

1. By performing right travel REVERSE (or FORWARD) operation, the pilot pressure from travel PPC valve
pushes spool (7) to the left side (or right side).
2. Spool (7) pushes piston (3), and orifice (5) closes and cuts off the drain circuit of stroke control signal cham-
ber (a) and travel PPC valve.
3. By performing right travel REVERSE (or FORWARD) operation, the pilot pressure from travel PPC valve is
transmitted through orifice (6) of piston (4) to the left end surface of piston (8) to push piston (8) to the right
side.
4. When the arm is moved IN, spool (1) moves to the left.
5. Maximum stroke of spool is reduced by the moving amount of piston (8) to the right side (st2), and be-
comes (st1).

HB365LC-3 10-265
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

BOOM HYDRAULIC DRIFT PREVENTION VALVE OF CONTROL VALVE

(PC400_10-K-L6C0-001-00-B)

FUNCTION OF BOOM HYDRAULIC DRIFT PREVENTION VALVE OF CONTROL

VALVE (PC300_11-K-L6C0-042-00-B)

When the boom is not operated with the R.H. work equipment control lever, this function is used to prevent the
pressurized oil in the boom cylinder bottom from leaking through spool (1) and causing boom hydraulic drift.

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

OPERATION OF BOOM HYDRAULIC DRIFT PREVENTION VALVE OF CONTROL

VALVE (HB335_3-K-L6C0-044-00-B)

When the boom is operated to “RAISE” position

1. When the boom is operated to “RAISE” position, the pressurized oil from the control valve acts leftward to
the right side of the ring area (S) whose outside diameter is diameter (d1) of the poppet (5) and inside di-
ameter is seat diameter (d2).
2. The force acting leftward on area (S) pushes and compresses spring (4) and moves poppet (5) to the left.
3. The oil from the control valve flows through the opening of poppet (5) to the bottom side of the boom cylin-
der.

HB365LC-3 10-267
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

When the boom is in “NEUTRAL”

1. When the boom is operated to “NEUTRAL” position, the pressurized oil flowing through orifice (a) into pop-
pet (5) is stopped by pilot piston (2).
2. The holding pressure of the boom cylinder bottom acts rightward on the left side of area (S) of the ring
formed by the difference between outside diameter (d1) of poppet (5) and seat diameter (d2).
3. The combined force of the force acting rightward on area (S) and the reaction force of spring (4) moves
poppet (5) to the right.
4. The circuit from the control valve to he boom cylinder bottom is shut off, and the oil pressure on the boom
cylinder side is hold.

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

When the boom “LOWER” operation is performed

1. When the boom is operated to “LOWER”, the pilot pressure from the PPC valve pushes the pilot piston (2).
2. The pressurized oil in the boom cylinder bottom flows to drain port (T) through orifice (a), chamber (b), and
orifice (c).
3. Chamber (b) in the poppet is connected to drain port (T), and the pressure in chamber (b) decreases.
4. When the pressure in chamber (b) decreases below the pressure in port (B), poppet (5) opens.
5. When poppet (5) opens, the pressurized oil from port (B) flows to port (A), and then flows to the control
valve.

HB365LC-3 10-269
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

SAFETY VALVE FOR HYDRAULIC DRIFT PREVENTION VALVE OF CONTROL

VALVE (PC300_11-K-L9K2-001-00-B)

OPERATION OF SAFETY VALVE FOR HYDRAULIC DRIFT PREVENTION VALVE

OF CONTROL VALVE (HB335_3-K-L9K2-044-00-B)

When the abnormally high pressure occurs

If abnormally high pressure occurs in the boom cylinder bottom circuit, the pressurized oil in port (B) pushes
open the check valve (6), and the safety valve (3) operates.

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

When the arm hydraulic drift prevention valve (optional) is installed to the arm cylinder head circuit, the higher
one of the boom cylinder bottom circuit pressure and the arm cylinder head circuit pressure pushes open check
valve (6) or (6A), and the safety valve (3) operates.

ARM QUICK RETURN VALVE OF CONTROL VALVE (PC400_10-K-L9K1-001-00-B)

FUNCTION OF ARM QUICK RETURN VALVE OF CONTROL VALVE (PC300_11-K-L9K1-042-00-B)

When the arm is moved OUT, a large quantity of oil returns from the cylinder bottom. This function is used to
decrease the pressure loss in this process.

OPERATION OF ARM QUICK RETURN VALVE OF CONTROL VALVE

(HB335_3-K-L9K1-044-00-B)

When the arm "OUT" operation is performed

1. The arm is operated to "arm OUT", the pilot pressure from the PPC valve pushes the pilot piston (1).
2. The pressurized oil in the chamber (b) inside the valve is drained through the orifice (c).
3. The pressurized oil in the arm cylinder bottom flows to drain port (T) through orifice (a), chamber (b), and
orifice (c).
4. Chamber (b) is connected to drain port (T), and the pressure in chamber (b) decreases.
5. When pressure in chamber (b) decreases below that in port (A), the receiving pressure of pressure receiv-
ing portion “ϕd2 area (S2)(seat diameter area)” on the port (A)side is larger than the total of receiving pres-
sure of “ϕd1 area (S1)” of pressure receiving portion on the (b) chamber side of the valve (2) and the reac-
tion force of the spring.

HB365LC-3 10-271
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

6. That is; (ϕd2 receiving pressure>ϕd1 receiving pressure + reaction force of the spring)
7. Valve (2) moves to the left, and pressurized oil flows from port (A) to port (B).
8. The pressurized oil on the arm cylinder bottom side is drained from port (B) directly to the tank.
When arm is in NEUTRAL

1. When the arm is operated from "arm OUT" to "NEUTRAL" operation, the pilot pressure from the PPC valve
is shut off.
2. The pressurized oil which is sent from the orifice (a) of the valve (2) and drained is hold by the pilot piston
(1).
3. The holding pressure of the arm cylinder bottom side acts rightward on the left side of the area of the ring
formed by the difference between area (S2) of valve (2) and area (S1).
4. The combined force of the force acting rightward on the area of the ring and the reaction force of spring (3)
moves valve (2) to the right, and port (A) and port (B) are disconnected.

VARIABLE BACK PRESSURE VALVE OF CONTROL VALVE (PC400_10-K-PQ81-001-00-B)

FUNCTION OF VARIABLE BACK PRESSURE VALVE OF CONTROL VALVE

(PC400_10-K-PQ81-042-00-B)
• This valve applies back pressure to the drain circuit to prevent cavitation which is caused by negative pres-
sure of each actuator (motor, cylinder, etc.)
• Lower the back pressure of the drain circuit except for travel operations in order to reduce output loss.

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

OPERATION OF VARIABLE BACK PRESSURE VALVE OF CONTROL VALVE

(PC400_10-K-PQ81-044-00-B)

When engine is stopped

1. No pressurized oil is supplied from the main pump to self-
pressure reducing valve (1).
2. No hydraulic pressure is supplied from variable back pres-
sure solenoid valve (3) to spring chamber (C), and valve
(6) is pressed to the right by the reaction force of spring
(5).
3. Drain circuit (A) of the control valve is interconnected with
port (T) through orifice (b) of valve (6).

When engine is in operation (swing or travel operation)

1. Pressurized oil (PR) output from self-pressure reducing
valve (1) flows to variable back pressure solenoid valve
(3).
2. Since drive signal (IS3) to variable back pressure solenoid
valve (3) is “OFF”, pressurized oil (PR) flows to spring
chamber (C) of variable back pressure valve.
3. Pressurized oil (PR) flowing to spring chamber (C) acts on
the left end surface (area of diameter d) of valve (6) and
pushes valve (6) to the right together with the reaction
force of spring (5).
4. Pressure (PA) in drain circuit (A) of the control valve acts
on the right end surface (area of diameter d1) of valve (6)
and pushes valve (6) to the left.
5. Valve (6) keeps balance so that the back pressure be-
comes (PA) in the following equation. PA = (Area of diame-
ter d x Pressure (PR) + Reaction force of spring (5) ) /
Area of diameter d1
6. The oil flow from drain circuit (A) of the control valve to
port (T) is adjusted to the set pressure of variable back
pressure valve (4).

HB365LC-3 10-273
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

When engine is in operation (other than swing and travel operations)

1. Pressurized oil (PR) output from self-pressure reducing
valve (1) flows to variable back pressure solenoid valve
(3).
2. Since drive signal (IS3) to variable back pressure solenoid
valve (3) is turned “ON”, pressurized oil (PR) from self-
pressure reducing valve (1) that is flowing into spring
chamber (C) of variable back pressure valve (4) is drained
through variable back pressure solenoid valve (3).
3. Only the reaction force of spring (5) acts on valve (6), and
pushes valve (6) to the right.
4. Pressure (PA) in drain circuit (A) of the control valve acts
on the right end surface (area of diameter d1) of valve (6)
and pushes valve (6) to the left.
5. Valve (6) keeps balance so that the back pressure be-
comes (PA) in the following equation. PA = Reaction force
of spring (5) / Area of diameter d1
6. The oil flow from drain circuit (A) of the control valve to
port (T) is adjusted to the set pressure of variable back
pressure valve (4).

MAIN RELIEF VALVE OF CONTROL VALVE (PC400_10-K-AB80-001-00-B)

STRUCTURE OF MAIN RELIEF VALVE OF CONTROL VALVE (PC400_10-K-AB80-041-00-B)

Sectional view

1: Spring 2: Poppet

10-274 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

FUNCTION OF MAIN RELIEF VALVE OF CONTROL VALVE (PC400_10-K-AB80-042-00-B)

• The set pressure is changed to 2 stages.

• When power is required, high pressure is set by receiving pilot pressure (P) from the 2-stage relief solenoid
valve.
• The set pressure of the relief valve depends on the load at installed height of the spring (1). (The first level)
• When the 1st stage is set again, as for the 2nd stage as well, the set pressure of the same amount as in-
crease and decrease of the 1st stage changes.

OPERATION OF MAIN RELIEF VALVE OF CONTROL VALVE (PC400_10-K-AB80-044-00-B)

When pilot pressure (P) is cut off (low pressure setting)

The set pressure is determined by the installed load of spring (1).

HB365LC-3 10-275
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

When pilot pressure (P) is supplied (high pressure setting)

Pilot pressure (P) is applied to diameter (d1) of poppet (2) and added to the installed load of spring (1), and the
set pressure becomes high.

2-STAGE SUCTION-SAFETY VALVE OF CONTROL VALVE (PC400_10-K-PQJ2-001-00-B)

STRUCTURE OF 2-STAGE SUCTION-SAFETY VALVE OF CONTROL VALVE

(PC400_10-K-PQJ2-041-00-B)

Sectional view
“Port (B) of boom valve and port (B) of service valve”

1: Spring 3: Spring
2: Piston 4: Holder

10-276 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF HYDRAULIC SYSTEM

FUNCTION OF 2-STAGE SUCTION-SAFETY VALVE OF CONTROL VALVE

(PC400_10-K-PQJ2-042-00-B)
“Port (B) of the boom valve and port (B) of the service valve”

• Pressure is set to 2 stages.

• Low-pressure set is obtained by receiving pilot pressure from the attachment selector solenoid valve.
• The set pressure can be changed by turning ON/OFF the pilot pressure, corresponding to the types of the
attachments (for examples, breaker and crusher).
• The set pressure depends on the load at installed height of spring (1). (High-pressure side)
• The set pressure on the low-pressure side depends on the moving distance of the piston (2).

OPERATION OF 2-STAGE SUCTION-SAFETY VALVE OF CONTROL VALVE

(PC400_10-K-PQJ2-044-00-B)

When pilot pressure (P) is cut off (high pressure setting)

1. Since pilot pressure (P) is cut off, piston (2) is pressed to
the left by the reaction force of spring (3). “Installed load of
spring (1) < Installed load of spring (3)”
2. The installed load of spring (1) becomes maximum and the
set pressure increases.
3. Passage (B) is connected through passages (C) and (D) to
the drain circuit.

HB365LC-3 10-277
COMPONENT PARTS OF HYDRAULIC SYSTEM 10 STRUCTURE AND FUNCTION

When pilot pressure (P) is supplied (low pressure setting)

1. When pilot pressure (P) is supplied, it flows through pas-
sage (B) to portion (A).
2. The pilot pressure acts on the pressure receiving diameter
“(d1) - (d2)” of portion (A) of piston (2).
3. Upon receiving the pilot pressure, piston (2) compresses
spring and moves to the right until it touches holder (4).
4. Since spring (1) expands and its installed load decreases,
the set pressure decreases.
5. The pressurized oil for the stroke of piston (2) is drained
from passage (C) through chamber (D).

10-278 HB365LC-3
10 STRUCTURE AND FUNCTION
WORK EQUIPMENT SYSTEM
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
Chassis part
1: Bucket cylinder
2: Arm cylinder
3: Arm anti-drop valve(*1)
4: Selector valve for attachment
5: Supply pump
*1: European Union specification
HB365LC-3
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM
(PC400_11-K-L400-001-00-B)
(HB335_3-K-L400-04D-00-B)
6: Engine controller
7: Accumulator for attachment
8: Boom anti-drop valve(*1)
9: Boom cylinder
10-279
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

10: Main pump 11: LS-EPC valve

10-280 HB365LC-3
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM

12: Control valve 17: Machine push-up solenoid valve

13: Pilot circuit accumulator 18: PPC lock solenoid valve
14: Solenoid valve 19: Rear pump pressure sensor
15: 2-stage relief solenoid valve 20: Front pump PC-EPC valve
16: 1st line attachment solenoid valve 21: Front pump pressure sensor

HB365LC-3 10-281
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

Around cab and floor

1: Machine monitor 5: One-touch power maximizing switch

2: R.H. work equipment PPC valve 6: L.H. work equipment PPC valve
3: Fuel control dial 7: PPC lock lever
4: Machine push-up switch 8: PPC lock switch

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10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM

9: Pump controller 11: Lock lever automatic lock cancel switch

10: Pump secondary drive switch 12: Resistor for PC-EPC valve

HB365LC-3 10-283
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

13: 1st-line attachment EPC valve 15: Service pressure switch

14: Attachment flow adjustment EPC valve

10-284 HB365LC-3
10 STRUCTURE AND FUNCTION STRUCTURE OF VALVE CONTROL

STRUCTURE OF VALVE CONTROL (HB335_3-K-C015-041-00-B)

1. 1st-line attachment control pedal (*1) 10: Junction block

2: Right travel lever 11. L.H. PPC valve for work equipment
3. R.H. PPC valve for work equipment 12: Lock lever
4: R.H. work equipment control lever (for boom and 13: Left travel lever
bucket operation) 14. 2nd-line attachment control pedal (*1)
5: L.H. work equipment control lever (for arm and 15: 2nd-line attachment PPC valve (*1)
swing operation)
16: Travel pedal
6: Control valve
17: Travel PPC valve
7: Solenoid valve
18: 1st-line attachment PPC valve (*1)
8: Pilot circuit accumulator
19: Lock pin (*1)
9: Main pump
*1: For attachment specification

HB365LC-3 10-285
ONE-TOUCH POWER MAXIMIZING SYSTEM 10 STRUCTURE AND FUNCTION

ONE-TOUCH POWER MAXIMIZING SYSTEM (PC400_10-K-PT28-001-00-B)

ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM (PC300_11-K-PT28-052-00-B)

a: Front pump PC-EPC valve drive signal f: Pump oil pressure sensor signal
b: Rear pump PC-EPC valve drive signal g: One-touch power maximizing switch signal
c: Solenoid valve GND h: 1st throttle signal
d: CAN signal i: Fuel supply pump control signal
e: 2-stage relief solenoid valve drive signal j: Various sensor signals
1: Battery disconnect switch 17: Front pump
2: Battery 17a: Servo
3: Battery relay 17b: LS valve
4: Fusible link 17c: PC valve
5: Fuse box 18: Rear pump
6: Resistor for PC-EPC valve 18a: Servo
7: Pump controller 18b: LS valve
8: Engine controller 18c: PC valve
9: Machine monitor 19: Control valve
10: Pump secondary drive switch 19a: Self-pressure reducing valve
11: Fuel control dial 19b: Merge-divider valve
12: Fuel supply pump 19c: Travel junction valve
13: Various sensors 19d: Main relief valve
14: One-touch power maximizing switch 20: Front pump PC-EPC valve
15: Front pump oil pressure sensor 21: Rear pump PC-EPC valve
16: Rear pump oil pressure sensor 22: 2-stage relief solenoid valve

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10 STRUCTURE AND FUNCTION ONE-TOUCH POWER MAXIMIZING SYSTEM

FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM (HB335_3-K-PT28-042-00-B)

• The one-touch power maximizing system is a system that increases the power for a certain time by operat-
ing the one-touch power maximizing switch installed to the knob of L.H. work equipment control lever.
• This function is used to increase the digging force for a certain time for digging out rocks, etc. during exca-
vation work.
• If the one-touch power maximizing switch is pressed when the load pressure in mode P, E, ATT/P, or ATT/E,
the hydraulic force increases approximately 7 %, and the digging force increases.
Each function is set automatically as follows;
Function Setting
Engine and pump combined control Matching at rated horsepower point
36.0 MPa {368 kg/cm2}
2-stage relief function ↓
38.2 MPa {390 kg/cm2}
Cut-off function Cancel

The one-touch power maximizing system keeps increasing the

power while one-touch power maximizing switch (1) is pressed.
But this function is canceled automatically in approximately 8.5
seconds even if the switch is kept pressed.

HB365LC-3 10-287
MACHINE PUSH-UP SYSTEM 10 STRUCTURE AND FUNCTION

MACHINE PUSH-UP SYSTEM (PC400_10-K-PTL0-001-00-B)

MACHINE PUSH-UP SYSTEM DIAGRAM (PC300_11-K-PTL0-052-00-B)

a: Front pump PC-EPC valve drive signal f: Pump oil pressure sensor signal
b: Rear pump PC-EPC valve drive signal g: One-touch power maximizing switch signal
c: Solenoid valve GND h: 1st throttle signal
d: CAN signal i: Fuel supply pump control signal
e: 2-stage relief solenoid valve drive signal j: Various sensor signals
1: Battery disconnect switch 10: Pump secondary drive switch
2: Battery 11: Fuel control dial
3: Battery relay 12: Fuel supply pump
4: Fusible link 13: Various sensors
5: Fuse box 14: Machine push-up switch
6: Resistor for PC-EPC valve 15: Front pump oil pressure sensor
7: Pump controller 16: Rear pump oil pressure sensor
8: Engine controller 17: Front pump
9: Machine monitor 17a: Servo

10-288 HB365LC-3
10 STRUCTURE AND FUNCTION MACHINE PUSH-UP SYSTEM

17b: LS valve 19b: Merge-divider valve

17c: PC valve 19c: Travel junction valve
18: Rear pump 20: Front pump PC-EPC valve
18a: Servo 21: Rear pump PC-EPC valve
18b: LS valve 22: Machine push-up solenoid valve
18c: PC valve 23: Suction safety valve
19: Control valve 24: Boom valve
19a: Self-pressure reducing valve 25: Boom cylinder

FUNCTION OF MACHINE PUSH-UP SYSTEM (PC300_11-K-PTL0-042-00-B)

• The push force of the boom is increased by operating ma-
chine push-up switch (1).
• This function is used to increase the push force of the
boom for ditching or excavating hard ground.
Function Setting
Boom cylinder head
OFF Safety valve set pressure
14.7 MPa {150 kg/cm2}
Boom cylinder head
ON Safety valve set pressure
28.4 MPa {290 kg/cm2}

HB365LC-3 10-289
PPC LOCK SYSTEM 10 STRUCTURE AND FUNCTION

PPC LOCK SYSTEM (PC400_10-K-C016-001-00-B)

PPC
Abbreviation for Proportional Pressure Control

PPC LOCK SYSTEM DIAGRAM (PC300_11-K-C016-052-00-B)

a: PPC lock signal g: Breaker operating switch signal

b: PPC lock signal h: Oil pressure sensor signal
c: Lock lever automatic lock cancel switch signal i: Oil pressure switch signal
d: Lock lever automatic lock relay drive signal j: 1st-line attachment flow adjustment EPC valve sig-
e: PPC lock solenoid valve drive signal nal

f: Switch potentiometer signal

1: Battery disconnect switch 11: 1st-line attachment proportional switch
2: Battery 12: Breaker operating switch
3: Battery relay 13: PPC lock solenoid valve
4: Fusible link 14: Control valve
5: Fuse box 14a: Merge-divider valve
6: Starting switch 14b: Self-pressure reducing valve
7: Lock lever 15: Main pump
8: PPC lock switch 16: Lock lever automatic lock cancel switch
9: Pump controller 17: 1st-line attachment flow adjustment EPC valve
10: Work equipment automatic lock relay

FUNCTION OF PPC LOCK SYSTEM (PC400_10-K-C016-042-00-B)

• PPC lock switch is interlocked with the lock lever. When the lock lever is set to LOCK position, PPC lock
switch is turned “OFF”.
• When PPC lock switch is turned OFF, the current flowing into PPC lock solenoid valve is cut out, and the
work equipment and machine body do not move even if any control lever or pedal is operated.

10-290 HB365LC-3
10 STRUCTURE AND FUNCTION WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM

WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM

(PC400_11-K-L409-001-00-B)

WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM

(PC400_11-K-L409-052-00-B)

a: PPC lock signal g: Breaker operating switch signal

b: PPC lock signal h: Oil pressure sensor signal
c: Lock lever automatic lock cancel switch signal i: Oil pressure switch signal
d: Lock lever automatic lock relay drive signal j: 1st-line attachment flow adjustment EPC valve sig-
e: PPC lock solenoid valve drive signal nal

f: Switch potentiometer signal

1: Battery disconnect switch 11: 1st-line attachment proportional switch
2: Battery 12: Breaker operating switch
3: Battery relay 13: PPC lock solenoid valve
4: Fusible link 14: Control valve
5: Fuse box 14a: Merge-divider valve
6: Starting switch 14b: Self-pressure reducing valve
7: Lock lever 15: Main pump
8: PPC lock switch 16: Lock lever automatic lock cancel switch
9: Pump controller 17: 1st-line attachment flow adjustment EPC valve
10: Work equipment automatic lock relay

FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM

(PC400_11-K-L409-042-00-B)
This function automatically sets the lock lever in the same state as when it is locked to prevent the work equip-
ment or the machine continues its operation when the lock lever is unlocked while the work equipment control
lever or the travel lever is operated.

HB365LC-3 10-291
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 10 STRUCTURE AND FUNCTION

OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM

(PC300_11-K-L409-044-00-B)
When an oil pressure switch or a sensor detects pressure high-
er than specified pressure (D) or an attachment drive signal is
input within certain time (C) after the lock lever is unlocked (A),
this function judges that the operation is abnormal and the
pump controller outputs the lock lever automatic lock relay
drive signal to shut off the current to PPC lock solenoid to lock
the machine (B).
A: PPC lock lever is canceled
B: Lock lever automatic lock operates
C: Within 0.4 seconds
D: : 5 kPa
E: 0.1 seconds
REMARK
When the hydraulic oil temperature is low or high-viscosity hydraulic oil is used, the pressure does not increase
within time (C), and the lock lever automatic lock control may not operate.
Control when lock lever automatic lock cancel switch is “ON”
When any abnormality occurs in controller, PPC solenoid valve
does not operate normally, and operation cannot be performed,
operate the lock lever automatic lock cancel switch (1) to ena-
ble operation.
At this time, the lock lever automatic lock control function does
not work.
a: Emergency (when abnormal)
b: Normal (when normal)
REMARK
Lock lever automatic lock cancel switch (1) is an alternate type
switch. If it is set to “Emergency” position (a) while PPC lock
lever is in the free state, the lock lever automatic lock cancel pi-
lot lamp lights up on the display.
The following failure codes are recorded when this switch is “ON”.
Action level Failure code Failure (displayed on screen)
L00 DDNS00 Lock Lever Auto Lock Release Switch On

10-292 HB365LC-3
10 STRUCTURE AND FUNCTION OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT

OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT (PC400_10-K-PT24-001-00-B)

OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT (PC300_11-K-PT24-052-00-B)

(Machines ready for installation of attachment)

a: Front pump PC-EPC valve drive signal f: Attachment flow adjustment EPC valve drive signal
b: Rear pump PC-EPC valve drive signal g: Oil pressure switch signal
c: Solenoid valve GND h: 1st throttle signal
d: CAN signal i: Fuel supply pump control signal
e: Attachment selector solenoid valve drive signal j: Various sensor signals
1: Battery disconnect switch 15a: Servo
2: Battery 15b: LS valve
3: Battery relay 15c: PC valve
4: Fusible link 16: Rear pump
5: Fuse box 16a: Servo
6: Resistor for PC-EPC valve 16b: LS valve
7: Pump controller 16c. PC valve
8: Engine controller 17: Control valve
9: Machine monitor 17a: Self-pressure reducing valve
10: Pump secondary drive switch 17b: Merge-divider valve
11: Fuel control dial 17c: Travel junction valve
12: Fuel supply pump 18: Attachment selector solenoid valve
13: Various sensors 19: PPC lock solenoid valve
14: Oil pressure switch 20: Attachment flow adjustment EPC valve
15: Front pump 21: Front pump PC-EPC valve

HB365LC-3 10-293
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 10 STRUCTURE AND FUNCTION

22: Rear pump PC-EPC valve 24: Attachment

23: Attachment circuit selector valve 25: Accumulator

FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT

(PC400_10-K-PT24-042-00-B)
When the attachment control pedal is depressed fully, the oil flow to the attachment is controlled by setting the
working mode and oil flow with the machine monitor.
The operation of the attachment changes as shown in the table below, depending on the working mode.
Working mode Operation of attachment
ATT/P, ATT/E Double-acting
B Single-acting

10-294 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

COMPONENT PARTS OF WORK EQUIPMENT SYSTEM (PC400_11-K-L400-001-01-B)

WORK EQUIPMENT AND SWING PPC VALVE (PC400_10-K-PL28-001-00-B)

PPC
Abbreviation for Proportional Pressure Control

STRUCTURE OF WORK EQUIPMENT AND SWING PPC VALVE (PC400_10-K-PL28-041-00-B)

General view

HB365LC-3 10-295
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

L.H. work equipment control lever

P: From self-pressure reducing valve
P1: To control valve (arm OUT port)
P2: To control valve (arm IN port)
P3: To control valve (swing LEFT port)
P4: To control valve (swing RIGHT port)
T: To hydraulic tank
R.H. work equipment control lever
P: From self-pressure reducing valve
P1: To control valve (boom LOWER port)
P2: To control valve (boom RAISE port)
P3: To control valve (bucket CURL port)
P4: To control valve (bucket DUMP port)
T: To hydraulic tank

10-296 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

Sectional view

1: Spool 3: Disc
2: Piston 4: Nut (for connecting lever)

HB365LC-3 10-297
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

5: Joint 8: Body
6: Plate 9: Filter
7: Retainer

OPERATION OF WORK EQUIPMENT AND SWING PPC VALVE (PC400_10-K-PL28-044-00-B)

When in NEUTRAL
Ports (A) and (B) of the control valve and ports (P1) and P2) of
PPC valve are connected to drain chamber (D) through fine
control hole (f) of spool (1).

10-298 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

In fine control (when fine control is started from neutral state)

1. When piston (4) is pushed by disc (5), retainer (9) is push-
ed and spool (1) is also pushed and moved down through
metering spring (2).
2. Almost at the same time when fine control hole (f) is dis-
connected from drain chamber (D), it is connected to pump
pressure chamber (PP).
3. The pilot pressure oil of the main pump flows to port (A)
through fine control hole (f) and port (P1).
4. When the pressure in port (P1) increases, spool (1) is
pushed back. Almost at the same time when fine control
hole (f) is disconnected from pump pressure chamber
(PP), it is connected to drain chamber (D), and the pres-
sure in port (P1) is released.
5. Spool (1) moves up and down so that the force of metering
spring (2) is balanced with the pressure in port (P1).
6. The positional relationship between spool (1) and body
(10) “fine control hole (f) is in an intermediate position be-
tween drain chamber (D) and pump pressure chamber
(PP)” does not change until retainer (9) touches spool (1).
7. Metering spring (2) is compressed in proportion to the trav-
el of control lever.
8. The pressure in port (P1) also increases in proportion to
the travel of control lever.
9. The control valve spool moves to a position where the pressure in port (A) “which is the same as the pres-
sure in port (P1)” is balanced with the reaction force of the control valve spool return spring.
In fine control (when control lever is returned)
1. When disc (5) starts being returned, spool (1) is pushed up
by the force of centering spring (3) and the pressure in port
(P1).
2. Fine control hole (f) is connected to drain chamber (D),
and the pressurized oil in port (P1) is released.
3. If the pressure in port (P1) decreases too much, spool (1)
is pushed down by metering spring (2).
4. Almost at the same time when fine control hole (f) is dis-
connected from drain chamber (D), it is connected to pump
pressure chamber (PP).
5. The pump pressure is supplied until the pressure in port
(P1) recovers to the pressure corresponding to the lever
position.
6. When the control valve spool returns, the pressurized oil in
drain chamber (D) flows in through fine control hole (f) of
the valve on the stationary side, and then it flows through
port (P2) to port (B).

HB365LC-3 10-299
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

When control lever is fully operated

1. Disc (5) pushes down piston (4), and retainer (9) pushes
down spool (1).
2. Fine control hole (f) is disconnected from drain chamber
(D) and connected to pump pressure chamber (PP).
3. The pilot pressure oil from the self-pressure reducing valve
flows to port (A) through fine control hole (f) and port (P1),
and pushes the control valve spool.
4. The return oil from port (B) flows to drain chamber (D)
through port (P2) and fine control hole (f).

1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) (PC400_10-K-PL29-001-00-B)

PPC
Abbreviation for Proportional Pressure Control
EPC
Abbreviation for Electromagnetic Proportional Control

STRUCTURE OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)

(PC400_10-K-PL29-041-00-B)
(Machines ready for installation of attachment)

10-300 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

General view and sectional view

A

7 P A T

P1 P2
3

2 4

1 Ful l s t r ok e 6 A - A
A - A A4P14879

P: From self-pressure reducing valve P2: To control valve (service valve 1 port)
P1: To control valve (service valve 1 port) T: To hydraulic tank
1: Spool 5: Retainer
2: Piston 6: Body
3: Lever 7: EPC valve
4: Plate

HB365LC-3 10-301
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE (PC400_10-K-PL2B-001-00-B)

PPC
Abbreviation for Proportional Pressure Control
EPC
Abbreviation for Electromagnetic Proportional Control

STRUCTURE OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE

(PC400_10-K-PL2B-041-00-B)
(Machines ready for installation of attachment)
General view and sectional view

6 5 4 3 C

P
A - A

A4P14880

P: From self-pressure reducing valve T: To hydraulic tank

C: To attachment PPC valve (R.H. attachment)
1: Body 3: Spool
2: Plug 4: Push pin

10-302 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

5: Coil 6: Plunger

FUNCTION OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE

(PC400_10-K-PL2B-042-00-B)
Upon receiving signal current (i) from the pump controller, this
valve generates EPC output pressure in proportion to that sig-
nal current and outputs it to the control valve.

HB365LC-3 10-303
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

OPERATION OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE

(PC400_10-K-PL2B-044-00-B)

When signal current is zero (coil de-energized)

1. When the signal current from the controller does not flow
through coil (5), coil (5) is de-energized.
2. Spool (2) is pressed to the right by spring (3).
3. Port (P) is closed and no pressurized oil from the pump
flows to the control valve.
4. The oil from the control valve is drained into the tank from
port (C) through port (T).

When signal current is minute (coil is energized)

1. When minute signal current flows through coil (5), coil (5)
is energized to generate thrust in rightward direction of
plunger (6).
2. Push pin (4) pushes spool (2) to the left, and the pressur-
ized oil from port (P) flows to port (C).
3. When the pressure at port (C) increases, combined force
on surface (a) of spool (2) and the reaction force of spring
(3) becomes larger than the thrust of plunger (6).
4. Spool (2) is pushed to the right and port (P) and port (C)
are disconnected, and port (C) and port (T) are connected.
5. Spool (2) moves up and down so that the thrust of plunger
(6) is balanced with the total of the pressure in port (C) and
load of spring (3).
6. The circuit pressure between EPC valve and control valve
is controlled in proportion to the signal current.

10-304 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

When signal current is maximum (coil is energized)

1. When the signal current flows to coil (5), coil (5) is ener-
gized.
Since the signal current is maximum at this time, the thrust
of plunger (6) is also maximum.
2. Spool (2) is pressed to the left by push pin (4).
3. The pressurized oil flows from port (P) to port (C) at the
maximum rate, and the circuit pressure between EPC
valve and control valve becomes maximum.
4. Port (T) closes and no pressurized oil flows to the hydraul-
ic tank.

2ND-LINE ATTACHMENT PPC VALVE (PC220_11-K-PL2A-001-00-B)

PPC
Abbreviation for Proportional Pressure Control

STRUCTURE OF 2ND-LINE ATTACHMENT PPC VALVE (PC220_11-K-PL2A-041-00-B)

(Machines ready for installation of attachment)

HB365LC-3 10-305
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

General view and sectional view

P: From self-pressure reducing valve P2: To control valve (service valve 2 port)
P1: To control valve (service valve 2 port) T: To hydraulic tank
1: Spool 4: Plate
2: Piston 5: Retainer
3: Lever 6: Body

10-306 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

OPERATION OF 2ND-LINE ATTACHMENT PPC VALVE (PC210_11-K-PL2A-044-00-B)

REMARK
For explanation of operation of PPC valve, see “Operation of work equipment and swing PPC valve”.

SOLENOID VALVE (PC400_10-K-C020-001-00-B)

STRUCTURE OF SOLENOID VALVE (HB335_3-K-C020-041-00-B)

For PPC lock, travel junction, travel speed, swing parking brake, machine push-p, and 2-stage relief
General view

A1: To PPC valve A7: To main valve (service valve)

A3: To main valve (travel junction)
A4: To right and left travel motors
A5: To electric swing motor
A6: To main valve (boom cylinder head 2-stage safety
valve)
1: PPC lock solenoid valve
2: Travel junction solenoid valve
3: Travel speed solenoid valve
4: Swing parking brake solenoid valve
*1: For attachment specification
A8: To main valve (2-stage relief valve)
ACC: To accumulator
P1: From main pump
T: To hydraulic tank
5: Machine push-up solenoid valve
6: 1st-line attachment solenoid valve (*1)
7: 2-stage relief solenoid valve

HB365LC-3 10-307
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

10-308 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

1: Connector 4: Spool
2: Movable iron core 5: Block
3: Coil 6: Spring

OPERATION OF SOLENOID VALVE AND CHECK VALVE (PC300_11-K-C020-044-00-B)

When solenoid of solenoid valve is “de-energized” (circuit is cut off)

1. Coil (1) is de-energized when the signal current does not
flow to coil (1).
2. Spool (2) is pushed back to the left with the reaction force
of spring (3).
3. The circuit between port (P) and port (A) closes and pilot
pressure does not flow from port (A) to the actuator. At the
same time, port (T) opens and oil from the actuator is
drained to the hydraulic tank.

When solenoid of solenoid valve is “energized” (circuit is connected)

1. Coil (1) is energized when the signal current flows to coil
(1).
2. Accordingly, spool (2) is pushed to the right by push pin
(4).
3. The circuit between port (P) and port (A) opens and pilot
pressure flows from port (A) to the actuator. At the same
time, port (T) closes and oil from the actuator does not flow
to the hydraulic tank.

HB365LC-3 10-309
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

Check valve
1. The check valve is installed between port (P) and PPC sol-
enoid valve. When the engine is stopped, the reaction
force of spring (2) pushes plunger (1) to the left and port
(ACC) and port (P) are disconnected, thus the accumulat-
ed pressure in the accumulator is held.
2. When the engine is running, the pilot pressure in port (P)
pushes plunger (1) to the right, and port (P) and port
(ACC) are interconnected.

ANTI-DROP VALVE FOR BOOM (PC78_10-K-LA1Q-001-01-B)

(Machine with anti-drop valve for boom)

STRUCTURE OF ANTI-DROP VALVE FOR BOOM (HB335_3-K-LA1Q-041-00-B)

General view

10-310 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

Sectional view

CY: To work equipment cylinder V: From control valve

PCY: For pressure pickup and equalize circuit 1: Pilot spool
PI: From PPC valve 2: Safety valve
T: To hydraulic tank 3: Check valve

FUNCTION OF ANTI-DROP VALVE FOR BOOM (PC78_10-K-LA1Q-042-00-B)

This valve prevents the work equipment from sudden lowering by thwarting the counterflow of pressurized oil
from the work equipment when the piping between the control valve and the work equipment cylinder breaks.

HB365LC-3 10-311
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

OPERATION OF ANTI-DROP VALVE FOR BOOM (HB335_3-K-LA1Q-044-00-B)

When work equipment is in NEUTRAL

When there is no damage in the piping
1. Holding pressure of the work equipment cylinder is led
from port (CY) to chamber (b), and it closes check valve
(5).
2. The pilot pressure which is led from PPC valve to port (PI)
is 0 MPa{0 kg/cm2} when work equipment is in NEUTRAL.
3. Spool (1) is pressed to the left by the force of spring (2)
and (3).
4. Chamber (a) and chamber (b) are shut off.
5. The pressurized oil does not flow from control valve to
work equipment cylinder. The work equipment is held.
6. When the pressure inside the work equipment cylinder is
abnormally high, holding pressure of the work equipment
cylinder operates safety valve (4).
7. Chambers (b) of anti-drop valves on the right and left are
interconnected at port (PCY).
8. The pressures of chambers (b) are the same even when
there is a difference of leakage amount between the anti-
drop valves on the right and left.
When there is a damage in the piping
1. When there is a damage in the piping (A) between the control valve and the work equipment cylinder,
chamber (a) and chamber (b) are not connected.
2. The pressure of the work equipment is held to prevent the work equipment from dropping suddenly.
When the pressurized oil flows from the con-
trol valve to the work equipment cylinder
When there is no damage in the piping
1. The pressurized oil which is led from the control valve to
chamber (a) becomes higher than the combined force of
the pressure of chamber (b) of work equipment cylinder
circuit and spring (6).
2. Check valve (5) opens, and chamber (a) and chamber (b)
are connected.
3. The pressurized oil flows from the control valve to the work
equipment cylinder.
When there is a damage in the piping
1. When there is a damage in the piping (A) between the
control valve and the work equipment cylinder, the pres-
surized oil of chamber (a) leaks through the damaged part
to the outside.
2. The pressure of chamber (b) drops. The pressure of cham-
ber (a) becomes lower than the combined force of the
pressure of chamber (b) and spring (6).
3. Check valve (5) closes, and chamber (a) and chamber (b) are shut off.
4. The pressure of the work equipment is held to prevent the work equipment from dropping suddenly.

10-312 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

When the pressurized oil returns from the

work equipment cylinder to the control valve
When there is no damage in the piping
1. Holding pressure of the work equipment cylinder is led to
chamber (b), and it closes check valve (5).
2. The pilot pressure is led from PPC valve to port (PI). The
pilot pressure is larger than the force of spring (2) (area of
circle "d").
3. Spool (1) moves rightward to the standby position. (The
first stroke)
4. Chamber (a) and chamber (b) are not interconnected.
5. The pilot pressure rises further. The pilot pressure is larger
than the force of spring (2) (area of circle "d").
6. Spool (1) moves rightward further, and chamber (a) and
chamber (b) are interconnected. (The second stroke)
7. The pressurized oil returns from the work equipment cylin-
der to the control valve.
When there is a damage in the piping
1. When there is a damage in the piping (A) between the
control valve and the work equipment cylinder, the pres-
surized oil of chamber (a) leaks through the damaged part
to the outside, but it is supplied from chamber (b).
2. The oil pressure flows through the opening (C) of spool
(1), and it prevents the work equipment cylinder from drop-
ping suddenly.

ANTI-DROP VALVE FOR ARM (PC78_10-K-LA1B-001-01-B)

(Machine with anti-drop valve for arm)

HB365LC-3 10-313
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

STRUCTURE OF ANTI-DROP VALVE FOR ARM (HB335_3-K-LA1B-041-00-B)

General view

10-314 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

Sectional view

CY: To work equipment cylinder V: From control valve

PCY: For pressure pickup and equalize circuit 1: Pilot spool
PI: From PPC valve 2: Safety valve
T: To hydraulic tank 3: Check valve

FUNCTION OF ANTI-DROP VALVE FOR ARM (PC78_10-K-LA1B-042-00-B)

This valve prevents the work equipment from sudden lowering by thwarting the counterflow of pressurized oil
from the work equipment when the piping between the control valve and the work equipment cylinder breaks.

HB365LC-3 10-315
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

OPERATION OF ANTI-DROP VALVE FOR ARM (HB335_3-K-LA1B-044-00-B)

When work equipment is in NEUTRAL

When there is no damage in the piping
1. Holding pressure of the work equipment cylinder is led
from port (CY) to chamber (b), and it closes check valve
(5).
2. The pilot pressure which is led from PPC valve to port (PI)
is 0 MPa{0 kg/cm2} when work equipment is in NEUTRAL.
3. Spool (1) is pressed to the left by the force of spring (2)
and (3).
4. Chamber (a) and chamber (b) are shut off.
5. The pressurized oil does not flow from control valve to
work equipment cylinder. The work equipment is held.
6. When the pressure inside the work equipment cylinder is
abnormally high, holding pressure of the work equipment
cylinder operates safety valve (4).
7. Chambers (b) of anti-drop valves on the right and left are
interconnected at port (PCY).
8. The pressures of chambers (b) are the same even when
there is a difference of leakage amount between the anti-
drop valves on the right and left.
When there is a damage in the piping
1. When there is a damage in the piping (A) between the control valve and the work equipment cylinder,
chamber (a) and chamber (b) are not connected.
2. The pressure of the work equipment is held to prevent the work equipment from dropping suddenly.
When the pressurized oil flows from the con-
trol valve to the work equipment cylinder
When there is no damage in the piping
1. The pressurized oil which is led from the control valve to
chamber (a) becomes higher than the combined force of
the pressure of chamber (b) of work equipment cylinder
circuit and spring (6).
2. Check valve (5) opens, and chamber (a) and chamber (b)
are connected.
3. The pressurized oil flows from the control valve to the work
equipment cylinder.
When there is a damage in the piping
1. When there is a damage in the piping (A) between the
control valve and the work equipment cylinder, the pres-
surized oil of chamber (a) leaks through the damaged part
to the outside.
2. The pressure of chamber (b) drops. The pressure of cham-
ber (a) becomes lower than the combined force of the
pressure of chamber (b) and spring (6).
3. Check valve (5) closes, and chamber (a) and chamber (b) are shut off.
4. The pressure of the work equipment is held to prevent the work equipment from dropping suddenly.

10-316 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

When the pressurized oil returns from the

work equipment cylinder to the control valve
When there is no damage in the piping
1. Holding pressure of the work equipment cylinder is led to
chamber (b), and it closes check valve (5).
2. The pilot pressure is led from PPC valve to port (PI). The
pilot pressure is larger than the force of spring (2) (area of
circle "d").
3. Spool (1) moves rightward to the standby position. (The
first stroke)
4. Chamber (a) and chamber (b) are not interconnected.
5. The pilot pressure rises further. The pilot pressure is larger
than the force of spring (2) (area of circle "d").
6. Spool (1) moves rightward further, and chamber (a) and
chamber (b) are interconnected. (The second stroke)
7. The pressurized oil returns from the work equipment cylin-
der to the control valve.
When there is a damage in the piping
1. When there is a damage in the piping (A) between the
control valve and the work equipment cylinder, the pres-
surized oil of chamber (a) leaks through the damaged part
to the outside, but it is supplied from chamber (b).
2. The oil pressure flows through the opening (C) of spool
(1), and it prevents the work equipment cylinder from drop-
ping suddenly.

ATTACHMENT CIRCUIT SELECTOR VALVE (PC400_10-K-PQJ3-001-00-B)

(Machine with attachment)

HB365LC-3 10-317
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

STRUCTURE OF ATTACHMENT CIRCUIT SELECTOR VALVE (PC400_10-K-PQJ3-041-00-B)

General view and sectional view

P1: From attachment selector solenoid valve ATT: to attachment

V: To control valve attachment 1 port T: To hydraulic tank
ACC: To accumulator TS: To hydraulic tank
1: Spool

FUNCTION OF ATTACHMENT CIRCUIT SELECTOR VALVE (PC400_10-K-PQJ3-042-00-B)

When the breaker is installed, this function is used to connect the main circuit between the control valve and
breaker to the accumulator. When another attachment (crusher, etc.) is installed, this function is used to discon-
nect the main circuit from the accumulator.

10-318 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF WORK EQUIPMENT SYSTEM

OPERATE ATTACHMENT CIRCUIT SELECTOR VALVE (PC400_10-K-PQJ3-044-00-B)

When attachment other than breaker is installed

1. Spool (1) is pressed to the left by the force of spring (2).
2. Port (ATT) is connected to port (V), and port (ATT) is dis-
connected from port (T), and the attachment is connected
to the control valve.

When breaker is installed

1. Pilot pressure (PI) from the attachment circuit selector sol-
enoid valve compresses spring (2), and spool (1) moves
rightward to the stroke end.
2. Port (ATT) is disconnected from port (V), and port (ATT) is
connected to port (T).
3. The pressurized oil returning from the breaker returns di-
rectly to the hydraulic tank through port (T) without passing
through the control valve.

HB365LC-3 10-319
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 10 STRUCTURE AND FUNCTION

PILOT CIRCUIT ACCUMULATOR (ALL-K-C021-001-00-B)

STRUCTURE OF PILOT CIRCUIT ACCUMULATOR (PC400_10-K-C021-041-00-B)

General view and sectional view

1: Gas plug
2: Shell
3: Poppet
4: Holder
5: Bladder
6: Oil port

SPECIFICATIONS OF PILOT CIRCUIT ACCUMULATOR (PC400_10-K-C021-030-00-B)

Gas used: Nitrogen gas
Volume of gas: 300 cc
Charged gas pressure: 1.18 MPa {12 kg/cm2} (at 80 °C)
Max. using pressure: 4.91 MPa {50 kg/cm2}

FUNCTION OF PILOT CIRCUIT ACCUMULATOR (PC400_10-K-C021-042-00-B)

This accumulator (for Pilot circuit) is installed to the solenoid valve. Even if the engine is stopped while the work
equipment is raised, pilot oil pressure can be supplied to the work equipment control valve with the pressure of
the compressed nitrogen gas in the accumulator to operate the spool and lower the work equipment by its own
weight.

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10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF SWING SYSTEM

SWING SYSTEM (PC400_10-K-JA00-001-00-B)

LAYOUT DRAWING OF SWING SYSTEM (HB335_3-K-JA00-04D-00-B)

Chassis part

1: Swing circle 3: Main pump

2: Electric swing motor 4: Swing machinery

HB365LC-3 10-321
LAYOUT DRAWING OF SWING SYSTEM 10 STRUCTURE AND FUNCTION

5: Control valve 7: Swing parking brake solenoid valve

6: Solenoid valve

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10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF SWING SYSTEM

8: Right swing PPC oil pressure sensor 9: Left swing PPC oil pressure sensor
Around cab and floor

1: Machine monitor 3: Pump controller

2: Swing lock switch 4: Swing parking brake cancel switch

HB365LC-3 10-323
SWING CONTROL SYSTEM DIAGRAM 10 STRUCTURE AND FUNCTION

SWING CONTROL SYSTEM DIAGRAM (HB335_3-K-JA00-052-00-B)

a: Swing parking brake cancel switch signal e: Oil pressure sensor signal
b: Swing parking brake solenoid valve drive signal f: Oil pressure switch signal
c: CAN signal g: Starting switch ACC signal
d: Swing lock switch signal
1: Battery disconnect switch 12: Main pump
2: Battery 13: Control valve
3: Battery relay 13a: Self-pressure reducing valve
4: Fusible link 13b: Merge-divider valve
5: Fuse box 13c: Travel junction valve
6: Swing parking brake cancel switch 14: Electric swing motor
7: Swing lock switch 15: Swing parking brake solenoid valve
8: Pump controller 16: Starting switch
9: Machine monitor 17: Engine shutdown secondary switch
10: Oil pressure switch 18: Inverter (hybrid controller)
11: Oil pressure sensor

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10 STRUCTURE AND FUNCTION SWING CONTROL SYSTEM DIAGRAM

FUNCTION OF SWING CONTROL SYSTEM (HB335_3-K-JA00-042-00-B)

Swing lock and swing parking brake function

• The swing lock system (manual type) is a system that ena-
bles the operator to lock the swing operation at any posi-
tion by setting swing lock switch (1) to ON.
• The swing parking brake (automatic) is interlocked with the
swing operation, and it prevents hydraulic drift after swing
is stopped.
• To reduce the load on the swing device during digging
work, the swing parking brake is released simultaneously
with operations of R.H. and L.H. work equipment control
levers and attachment control pedal.
Swing lock
OFF ON
switch
Swing lock
Not lit Lit
monitor
Function Swing parking brake Swing lock
• The swing parking
brake operates ap-
proximately 7 sec-
• The swing park-
onds later when the
ing brake oper-
R.H. and L.H. work
ates to lock the
equipment control
swing operation.
levers and attach-
ment control pedal • Even if the L.H.
are set to NEU- work equipment
Actuated TRAL. control lever is
operated to
• The swing parking
swing, the swing
brake is released
parking brake is
and the upper struc-
not released and
ture can swing free-
the upper struc-
ly when R.H. or L.H.
ture does not
work equipment
swing.
control lever or the
attachment control
pedal is operated.

A: Work equipment control lever or attachment control pedal is

operated (swing parking brake is released)
B: Work equipment control lever and attachment control pedal
are in NEUTRAL
C: Swing parking brake operates
D: Approximately 7 seconds

Swing parking brake cancel function

k While the swing parking brake is released, only the hydraulic brake is applied by the relief valve. If
swing is stopped on a slope, the hydraulic drift may occur. Take care.

HB365LC-3 10-325
SWING CONTROL SYSTEM DIAGRAM 10 STRUCTURE AND FUNCTION

If the swing parking brake does not operate normally, and the upper structure cannot swing because of trouble
in the controller, etc., cancel the swing parking brake with the swing parking brake cancel switch (2), and swing
operation can be performed.
Swing parking brake
Cancel (when controller is abnormal) Normal (when controller is normal)
cancel switch
Swing lock switch ON OFF ON OFF
Swing parking brake Swing parking brake
Swing brake Swing lock is applied Swing lock is applied
is canceled is applied

k Swing stop function is disabled if the swing lock is canceled when there is an abnormality in the hy-
brid system.
k The machine may swing down, and it is dangerous if this operation is performed on a slope. Never
perform this operation on a slope, otherwise a serious accident may occur.
REMARK
• Even if swing parking brake cancel switch (2) is set to CANCEL position (a), the swing parking brake is not
released while the swing lock switch is ON.
• Swing parking brake cancel switch (2) is a momentary type. When it is set to RELEASE (a) position, the
swing lock monitor on the machine monitor flashes.
• While the swing parking brake is canceled, the machine may swing down by gravity on a slope. Take care.
a: Cancel (when abnormal)
b: Normal (when normal)

Quick warm-up function

When swing lock switch (1) is turned ON, the pump cut-off
function is canceled and the main relief pressure increases. If
the work equipment is relieved while the main relief pressure is
high, the hydraulic oil temperature increases quickly, and the
warm-up time is shortened.
Operating condition Main relief pressure
36.0 MPa {368 kg/cm2}
Swing lock switch: ON ↓
38.2 MPa {390 kg/cm2}

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF SWING SYSTEM

COMPONENT PARTS OF SWING SYSTEM (PC400_11-K-JA00-001-01-B)

ELECTRIC SWING MOTOR (HB335_3-K-PQHH-001-00-B)

LAYOUT DRAWING OF ELECTRIC SWING MOTOR (HB335_3-K-PQHH-04D-00-B)

A: Lubricating oil inlet D: Lubricating oil drain

B: Coolant inlet E: Lubricating oil outlet
C: Coolant outlet
1: Electric swing motor 3: Oil filler pipe
2: Level gauge

SPECIFICATIONS OF ELECTRIC SWING MOTOR (HB335_3-K-PQHH-030-00-B)

Model: ZM201
Type: Permanent magnet type synchronous motor
Rated output: 3199 to 5686 rpm (at 67 kW)
Maximum regeneration input: 4528 to 5686 rpm(at110 kW)
Max. applied voltage: 700 V

FUNCTION OF ELECTRIC SWING MOTOR (HB335_3-K-PQHH-042-00-B)

• The electric swing motor is a motor that converts the electric power provided from the generator and capac-
itor to the rotation torque for the motor output shaft, and conveys it to the swing machinery.
• The electric swing motor is motor that converts the kinetic energy of the upper structure to electric power,
and provides it to the capacitor.

HB365LC-3 10-327
COMPONENT PARTS OF SWING SYSTEM 10 STRUCTURE AND FUNCTION

SWING MACHINERY WITH SWING PARKING BRAKE (HB335_3-K-J6A0-001-00-B)

STRUCTURE OF SWING MACHINERY WITH SWING PARKING BRAKE

(HB335_3-K-J6A0-041-00-B)

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF SWING SYSTEM

1: Swing pinion (number of teeth: 13) 12: No. 1 ring gear (number of teeth: 62)
2: Cover 13: No. 1 planetary gear (number of teeth: 23)
3: Plate 14: No. 1 sun gear (number of teeth: 16)
4: No. 3 sun gear (number of teeth: 24) 15: Cover B
5: No. 3 planetary gear (number of teeth: 21) 16: Spring
6: No. 3 planetary carrier 17: No. 1 planetary carrier
7: No. 2 ring gear (number of teeth: 68) 18: Brake disc
8: No. 2 planetary carrier 19: Brake plate
9: No.2 planetary gear (number of teeth: 24) 20: Brake gear
10: Case 21: No. 2 sun gear (number of teeth: 19)
11: Brake piston

SPECIFICATIONS OF SWING MACHINERY WITH SWING PARKING BRAKE

(HB335_3-K-J6A0-03D-00-B)
Reduction ratio: ((16+62)/16)x((19+68)/19)x((24+68)/24)=85.569
Swing reduction ratio: 85.569x-90/13=-592.400

FUNCTION OF SWING MACHINERY WITH SWING PARKING BRAKE

(HB335_3-K-J6A0-042-00-B)
The swing machinery with the swing parking brake is a device that reduces the electric swing motor speed, in-
creases the swing force, and reduces the swing speed to proper speed.

HB365LC-3 10-329
COMPONENT PARTS OF SWING SYSTEM 10 STRUCTURE AND FUNCTION

SWING CIRCLE (PC400_10-K-J110-001-00-B)

STRUCTURE OF SWING CIRCLE (PC300_11-K-J110-041-00-B)

General view and sectional view

1: Greasing port of swing circle pinion 4: Outer race

2: Inner race (number of teeth: 90) 5: Seal
3: Ball
a: “S” position of inner race soft zone b: “S” position of outer race soft zone

SPECIFICATIONS OF SWING CIRCLE (PC300_11-K-J110-030-00-B)

Reduction ratio: -90/13 = -6.923
Grease: G2-LI
Quantity of grease: 33.0 ℓ

FUNCTION OF SWING CIRCLE (PC300_11-K-J110-042-00-B)

The swing circle connects the upper structure and carrier unit.

10-330 HB365LC-3
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF TRAVEL SYSTEM

TRAVEL SYSTEM (PC400_10-K-C150-001-00-B)

LAYOUT DRAWING OF TRAVEL SYSTEM (HB335_3-K-C150-04D-00-B)

Chassis part

1: Center swivel joint 5: Main pump

2: Travel motor 6. LS-EPC valve
3: Supply pump 7: Final drive
4: Engine controller 8: Travel alarm

HB365LC-3 10-331
LAYOUT DRAWING OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION

9: Control valve 12: Travel junction solenoid valve

10: Solenoid valve 13: Rear pump pressure sensor
11: Travel speed solenoid valve 14: Front pump pressure sensor

10-332 HB365LC-3
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF TRAVEL SYSTEM

Around the cab and floor

1: Machine monitor 3: Pump controller

2: Fuel control dial 4: Travel lever

HB365LC-3 10-333
LAYOUT DRAWING OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION

5: Travel PPC valve 8: Right travel REVERSE pressure sensor

6: Left travel FORWARD pressure sensor 9: Right travel FORWARD pressure sensor
7: Left travel REVERSE pressure sensor

10-334 HB365LC-3
10 STRUCTURE AND FUNCTION TRAVEL CONTROL SYSTEM DIAGRAM

TRAVEL CONTROL SYSTEM DIAGRAM (HB335_3-K-C150-052-00-B)

a: Oil pressure sensor signal g: Oil pressure sensor signal

b: CAN signal h: Travel alarm operation signal
c: LS-EPC valve drive signal i: 1st throttle signal
d: Solenoid valve GND j: Fuel supply pump control signal
e: Travel junction solenoid valve drive signal k: Signal from various sensors
f: Travel speed solenoid valve drive signal
1: Pump controller 12: Rear pump
2: Engine controller 12a: Servo
3: Machine monitor 12b: LS valve
4: Fuel control dial 12c: PC valve
5: Fuel supply pump 13: Control valve
6: Various sensors 13a: Self-pressure reducing valve
7: Front pump oil pressure sensor 13b: Merge-divider valve
8: Rear pump oil pressure sensor 13c: Travel junction valve
9: Oil pressure sensor 14: Travel motor
10: Travel alarm 15: Travel speed solenoid valve
11: Front pump 16: Travel junction solenoid valve
11a: Servo 17. LS-EPC valve
11b: LS valve 18: Inverter (hybrid controller)
11c: PC valve

HB365LC-3 10-335
TRAVEL CONTROL SYSTEM DIAGRAM 10 STRUCTURE AND FUNCTION

FUNCTION OF TRAVEL CONTROL SYSTEM (PC300_11-K-C150-042-00-B)

Travel speed selector function

Manual change of travel speed
The operator can change the travel speed by setting the travel speed selector switch to Hi, Mi, or Lo position to
change the motor capacity.
Travel speed selector switch Lo (Low speed) Mi (Mid-range speed) Hi (High speed)
Motor flow 96 % 82 % 100 %
Motor capacity Max. Min. Min.
Travel speed 3.2 km/h 4.5 km/h 5.5 km/h

Automatic change of travel speed

• Automatic change in accordance with engine speed
When the engine speed is decreased to 1200 rpm or below by using the fuel control dial, the travel speed
does not change to "Hi" if the current speed is Mi, but changes to Mi automatically if the current speed is Hi.
• Automatic change in accordance with pump discharged pressure
• While traveling with the travel speed selector switch at Hi position, if the load increases on uphill slope,
etc., and the travel pressure is 32.3 MPa {330 kg/cm2} or higher for 0.5 seconds or more, the motor
capacity is changed automatically and the travel speed is changed to a middle speed (a speed equiva-
lent to Mi) (however, travel speed selector switch is kept at Hi position).
• While traveling at low speed set by the automatic travel speed change with load, when the load de-
creases on a flat or downhill slope and the travel pressure is 18.6 MPa {190 kg/cm2} or less for 0.5
seconds or more, the motor capacity is changed automatically and the travel speed is returned to the
set speed of Hi.
A: 18.6 MPa {190 kg/cm2}
B: 32.3 MPa {330 kg/cm2}
C: 0.5 seconds or more
D: 0.5 seconds or more

Pump control function when traveling

For details, see "FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM".
Travel junction function
• When the travel lever is operated, the control system detects the pilot pressure and judges if the operation
is straight travel or steering.
• In the straight travel operation, signals are sent to the travel junction solenoid valve to set the flow rates to
the right and left travel motors to almost the same level to prevent travel deviation and improve the straight
travel performance.
• In the steering operation, signals to the travel junction solenoid valve are blocked to set the flow rates to the
right and left travel motors independently to improve the travel performance during steering.

10-336 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF TRAVEL SYSTEM

COMPONENT PARTS OF TRAVEL SYSTEM (PC400_11-K-C150-001-01-B)

TRAVEL MOTOR (PC400_10-K-C400-001-00-B)

STRUCTURE OF TRAVEL MOTOR (PC300_11-K-C400-041-00-B)

General view

L.H. travel motor Common to R.H. and L.H. travel motors

PA: From control valve (left travel FORWARD port)
PB: From control valve (left travel REVERSE port)
R.H. travel motor
PA: From control valve (right travel REVERSE port)
PB: From control valve (right travel FORWARD port)
P: From travel speed increase solenoid valve
T: To hydraulic tank
B: Brake cancel pressure pickup port
MA: Port (MA) pressure pickup port
MB: Port (MB) pressure pickup port

HB365LC-3 10-337
COMPONENT PARTS OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION

Sectional view

1: Output shaft 8: Slow return valve

2: Motor case 9: Brake spring
3: Rocker cam 10: Brake piston
4: Piston 11: Brake ring
5: Cylinder block 12: Plate
6: Valve plate 13: Disc
7: End cover 14: Regulator piston

10-338 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF TRAVEL SYSTEM

15: Suction valve 21: Spool return spring

16: Piston 22: Check valve spring
17: Safety valve 23: Regulator piston spring
18: Retainer 24: Regulator piston spring
19: Regulator valve 25: Counterbalance valve
20: Spring

SPECIFICATIONS OF TRAVEL MOTOR (PC300_11-K-C400-030-00-B)

Model: HMV180ADT-2
Theoretical displacement (Min.): 106.7 cm3/rev
Theoretical displacement (Max.): 182.4 cm3/rev
Rated pressure: 37.3 MPa {380 kg/cm2}
Rated speed (at min. delivery): 2460 rpm
Rated speed (at max. delivery): 1140 rpm
Brake releasing pressure: 1.18 MPa {12 kg/cm2}
Travel speed selector pressure: 0.78 MPa {8.0 kg/cm2}

FUNCTION OF TRAVEL MOTOR (PC300_11-K-C400-042-00-B)

The travel motor converts the fluid energy of hydraulic oil into rotational mechanical energy and travels the ma-
chine.

HB365LC-3 10-339
COMPONENT PARTS OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION

MOTOR PORTION OF TRAVEL MOTOR (PC400_10-K-C400-001-10-B)

OPERATION OF MOTOR PART OF TRAVEL MOTOR (PC300_11-K-C400-044-10-B)

During low-speed travel (motor swash plate angle is maximum)

1. When the solenoid valve is de-energized, no pilot pressure oil flows from the self-pressure reducing valve
to port (P).
2. Regulator valve (19) is pressed to the right by spring (20).
3. The pressurized oil is transmitted to end cover (7) from control valve by pushing check valve (8), but it is
blocked by regulator valve (19).
4. Fulcrum (a) of rocker cam (3) is eccentric to acting point (b) of a resultant force of piston thrust of cylinder
block (5).
5. Resultant force of piston thrust acts as a moment to tilt rocker cam (3) toward the maximum swash plate
angle.
6. The pressurized oil in regulator piston (14) is drained to motor case through orifice (c) of regulator valve
(19).

10-340 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF TRAVEL SYSTEM

7. Rocker cam (3) tilts to the direction of maximum swash plate angle, and motor capacity becomes maximum
and machine travels at low speed.
During high-speed travel (motor swash plate angle is minimum)

1. When the solenoid valve is energized, pilot pressure oil flows from the self-pressure reducing valve to port
(P).
2. It pushes regulator valve (19) to the left.
3. The pressurized oil from the control valve flows to regulator piston (14) through passage (d) of regulator
valve (19).
4. It pushes regulator piston (14) to the right.
5. Rocker cam (3) tilts toward the minimum swash plate angle, and motor capacity becomes minimum and
machine travels at high speed.

HB365LC-3 10-341
COMPONENT PARTS OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION

PARKING BRAKE OF TRAVEL MOTOR (PC400_10-K-G000-001-00-B)

OPERATE PARKING BRAKE OF TRAVEL MOTOR (PC300_11-K-G000-044-00-B)

When machine starts traveling (parking brake is canceled)

1. When the travel lever is operated, the pressurized oil from the pump operates counterbalance valve spool
(25) and opens the parking brake circuit.
2. It flows in chamber (a) of brake piston (10) and compresses spring (9) to push brake piston (10) to the right.
3. Press force to plate (12) and disc (13) is lost, and plate (12) and disc (13) separate from each other to re-
lease the brake.

10-342 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF TRAVEL SYSTEM

When machine stops traveling (parking brake is applied)

1. When the travel lever is set in NEUTRAL, counterbalance valve spool (25) returns to the neutral position,
and the parking brake circuit is closed.
2. The pressurized oil in chamber (a) of brake piston (10) is drained into case through orifice (f) of brake pis-
ton (10).
3. Brake piston (10) is pushed down to the left by spring (9).
4. Plate (12) is pressed to disc (13) and brake is applied.
5. When brake piston (10) returns, the operation of the brake is delayed by throttling the flow of the pressur-
ized with slow return valve (8), and the brake operates after the machine stops.

HB365LC-3 10-343
COMPONENT PARTS OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION

COUNTERBALANCE VALVE AND CHECK VALVE OF TRAVEL MOTOR

(PC400_10-K-C4N0-001-00-B)

FUNCTION OF COUNTERBALANCE VALVE AND CHECK VALVE OF TRAVEL

MOTOR (HB335_3-K-C4N0-042-00-B)
• When the machine travels downhill, it tends to travel faster
than the motor (engine) rotation because of its gravity.
• If the machine travels downhill with the engine at low
speed, the motor runs idle and the machine runs away.
This is very dangerous.
• This valve prevents the motor from running away and
makes it travel in accordance with the engine speed (pump
discharged volume).

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF TRAVEL SYSTEM

OPERATION OF COUNTERBALANCE VALVE AND CHECK VALVE OF TRAVEL

MOTOR (HB335_3-K-C4N0-044-00-B)

During normal travel (flat ground and uphill ground)

1. When travel lever is operated, the pressurized oil flowing
from the control valve is supplied to port (PA).
2. It pushes open the suction valve (15A), and flows from the
motor inlet port (MA) to the motor outlet port (MB).
3. Since the motor outlet side is closed by the suction valve
(15B) and spool (25), the pressure on the supply side in-
creases.

4. The pressurized oil on the supply side flows to chamber

(S1) through orifice (E1) of spool (25) and orifice (E2) of
piston (16).
5. When the pressure in chamber (S1) increases higher than
the reaction force of the spool selector pressure (spring
(21)), spool (25) is pushed to the right.
6. Motor outlet port (MB) and port (PB) are connected to the
outlet passage (B1), and the motor outlet side opens and
the motor turns.

HB365LC-3 10-345
COMPONENT PARTS OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION

During downhill travel

1. If the machine runs away on a downhill, the motor runs idle
and the pressure on the motor inlet side decreases.
2. The pressure in chamber (S1) decreases through orifices
(E1) and (E2).
3. When the pressure in chamber (S1) decreases lower than
the spool selector pressure, spool (25) and piston (16) are
pushed back to the left by the reaction force of spring (21),
and passage (B1) on the outlet side is throttled.
4. The pressure on the motor outlet side increases and rotat-
ing resistance is generated in the motor, thus the machine
is prevented from running away.
5. Spool (25) moves to a position where the force caused by
the machine weight and the hydraulic force on the motor
inlet side are balanced with the pressure of motor outlet
port (MB).
6. The motor outlet circuit is throttled and the machine travels
at speed corresponding to the pump discharged volume.

SAFETY VALVE OF TRAVEL MOTOR (PC400_10-K-C660-001-00-B)

SPECIFICATIONS OF SAFETY VALVE OF TRAVEL MOTOR (PC300_11-K-C660-030-00-B)

High pressure set pressure (when starting travel): 40.2 MPa {410 kg/cm2}
Low pressure set pressure (when stopping travel): 27.5 MPa {280 kg/cm2}

FUNCTION OF SAFETY VALVE OF TRAVEL MOTOR (PC300_11-K-C660-042-00-B)

When the machine stops traveling (or travels downhill), the outlet and inlet circuits of the motor are closed.
Since the motor is turned by inertial force, the pressure on the motor outlet side increases abnormally, and it
damages the motor or piping. The safety valve releases this abnormal pressure into the motor inlet side to pro-
tect the devices from damage.

OPERATION OF SAFETY VALVE OF TRAVEL MOTOR (HB335_3-K-C660-044-00-B)

Both directions (when pressure in chamber (MB) increases during turn to right)
1. When the machine stops traveling (or travels downhill), the
counterbalance valve closes chamber (MB) in the circuit
on the outlet side.
2. Since the motor continues rotation because of inertial
force, the pressure on the outlet (MB) side increases.

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF TRAVEL SYSTEM

3. When this pressure increases above the set pressure, the

force of “Circular area difference between (D1) and (D2) x
Pressure” compresses spring (2).
4. The pressurized oil moves poppet (1) to the left and flows
into chamber (MA) in the circuit on the opposite side.

Both directions (when pressure in chamber (MA) increases during turn to left)
1. When the machine stops traveling (or travels downhill), the
check valve of the counterbalance valve closes chamber
(MB) in the outlet circuit.
2. Since the motor continues rotation because of inertial
force, the pressure on the outlet (MA) side increases.

HB365LC-3 10-347
COMPONENT PARTS OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION

3. When this pressure increases above the set pressure, the

force of “Circular area difference between (D1) and (D3) x
Pressure” compresses spring (2).
4. The pressurized oil moves poppet (1) to the left and flows
into chamber (MB) in the circuit on the opposite side.

Set pressure changing mechanism (when machine starts traveling (setting to

high pressure))
1. When the travel lever is operated, the pressurized oil from
the pump moves spool (4) to the right.
2. It opens the pilot circuit to the safety valve and flows into
chamber (J) through chamber (G) and passage (H).
3. It pushes the piston (3) to the right, compresses the spring
(2), and increases the set load.
4. The safety valve is set to high pressure, and large traction
force is obtained.

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10 STRUCTURE AND FUNCTION COMPONENT PARTS OF TRAVEL SYSTEM

Set pressure changing mechanism (when machine stops traveling (setting to

low pressure))
1. When the travel lever is set to NEUTRAL position, the
pressure in chamber (PA) decreases and spool (4) returns
to the NEUTRAL position.
2. The pressurized oil in chamber (J) continues to flow to
chamber (PA) through passage (H) and chamber (G), until
spool (4) returns to the NEUTRAL position.
3. Piston (3) moves to the left and reduces the set load.
4. The safety valve is set to low pressure, and reduces the
shocks during deceleration.

HB365LC-3 10-349
COMPONENT PARTS OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION

FINAL DRIVE (PC400_10-K-DF10-001-00-B)

STRUCTURE OF FINAL DRIVE (PC300_11-K-DF10-041-00-B)

General view and sectional view

10-350 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF TRAVEL SYSTEM

1: Level plug 8: Cover

2: Drain plug 9: Ring gear (number of teeth: 95)
3: No.1 planetary gear (number of teeth: 42) 10: Hub
4: No. 1 sun gear (number of teeth: 10) 11: Sprocket
5: No. 2 sun gear (number of teeth: 19) 12: Floating seal
6: No. 1 planetary carrier 13: Travel motor
7: No. 2 planetary carrier 14: No.2 planetary gear (number of teeth: 37)

SPECIFICATIONS OF FINAL DRIVE (PC300_11-K-DF10-030-00-B)

Reduction ratio: -((10 + 95) / 10) x ((19 + 95) / 19) + 1 = -62.000

FUNCTION OF FINAL DRIVE (PC300_11-K-DF10-042-00-B)

The travel motor is high in speed but low in driving force. Accordingly, the final drive reduces the speed, increas-
es the driving force, and transmits it to the sprocket.

TRAVEL PPC VALVE (PC400_10-K-C6V0-001-00-B)

PPC
Abbreviation for Proportional Pressure Control

HB365LC-3 10-351
COMPONENT PARTS OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION

STRUCTURE OF TRAVEL PPC VALVE (PC300_11-K-C6V0-041-00-B)

General view

P: From self-pressure reducing valve P3: To control valve (R.H. reverse port)
P1: To control valve (L.H. reverse port) P4: To control valve (R.H. forward port)
P2: To control valve (L.H. forward port) T: To hydraulic tank

10-352 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF TRAVEL SYSTEM

Sectional view

1: Plate 4: Seal
2: Case 5: Spool
3: Piston 6: Damper

HB365LC-3 10-353
COMPONENT PARTS OF TRAVEL SYSTEM 10 STRUCTURE AND FUNCTION

OPERATION OF TRAVEL PPC VALVE (PC400_10-K-C6V0-044-00-B)

When in NEUTRAL
Ports (A) and (B) of the control valve and ports (P1) and P2) of
PPC valve are connected to drain chamber (D) through fine
control hole (f) of spool (1).

In fine control (when fine control is started from neutral state)

1. When piston (4) is pushed by lever (5), retainer (9) is
pushed and spool (1) is also pushed and moved down
through metering spring (2).
2. Almost at the same time when fine control hole (f) is dis-
connected from drain chamber (D), it is connected to pump
pressure chamber (PP).
3. The pilot pressure oil of the control pump flows to port (A)
through fine control hole (f) and port (P1).
4. When the pressure in port (P1) increases, spool (1) is
pushed back. Almost at the same time when fine control
hole (f) is disconnected from pump pressure chamber
(PP), it is connected to drain chamber (D), and the pres-
sure in port (P1) is released.
5. Spool (1) moves up and down so that the force of metering
spring (2) is balanced with the pressure in port (P1).
6. The positional relationship between spool (1) and body
(10) “fine control hole (f) is in an intermediate position be-
tween drain chamber (D) and pump pressure chamber
(PP)” does not change until retainer (9) touches spool (1).
7. Metering spring (2) is compressed in proportion to the trav-
el of control lever.
8. The pressure in port (P1) also increases in proportion to
the travel of control lever.
9. The control valve spool moves to a position where the pressure in port (A) “which is the same as the pres-
sure in port (P1)” is balanced with the reaction force of the control valve spool return spring.

10-354 HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF TRAVEL SYSTEM

In fine control (when control lever is returned)

1. When lever (5) starts being returned, spool (1) is pushed
up by the force of centering spring (3) and the pressure in
port (P1).
2. Fine control hole (f) is connected to drain chamber (D),
and the pressurized oil in port (P1) is released.
3. If the pressure in port (P1) decreases too much, spool (1)
is pushed down by metering spring (2).
4. Almost at the same time when fine control hole (f) is dis-
connected from drain chamber (D), it is connected to pump
pressure chamber (PP).
5. The pump pressure is supplied until the pressure in port
(P1) recovers to the pressure corresponding to the lever
position.
6. When the control valve spool returns, the pressurized oil in
drain chamber (D) flows in through fine control hole (f) of
the valve on the stationary side, and then it flows through
port (P2) to port (B).

When control lever is fully operated

1. Lever (5) pushes down piston (4), and retainer (9) pushes
down spool (1).
2. Fine control hole (f) is disconnected from drain chamber
(D) and connected to pump pressure chamber (PP).
3. The pilot pressure oil from the self-pressure reducing valve
flows to port (A) through fine control hole (f) and port (P1),
and pushes the control valve spool.
4. The return oil from port (B) flows to drain chamber (D)
through port (P2) and fine control hole (f).

HB365LC-3 10-355
COMPONENT PARTS OF TRAVEL SYSTEM
CENTER SWIVEL JOINT
STRUCTURE OF CENTER SWIVEL JOINT
Outline drawing, sectional view
A1: To L.H. reverse travel motor (port PB)
A2: From control valve (port A2)
B1: To L.H. forward travel motor (port PA)
B2: From control valve (port B2)
C1: To R.H. reverse travel motor (port PA)
C2: From control valve (port A5)
1: Cover
2: Rotor
3: Slipper seal
4: Dust seal
10-356
10 STRUCTURE AND FUNCTION
(PC400_10-K-J8E0-001-00-B)
(PC300_11-K-J8E0-041-00-B)
D1: To R.H. forward travel motor (port PB)
D2: From control valve (port B5)
E1: To R.H. and L.H. travel motors (port Pi)
E2: From travel speed increase solenoid valve
DR1: From R.H. and L.H travel motors (port T)
DR2: To hydraulic tank
5: Oil seal
6: Cover
7: Shaft
8: O-ring
HB365LC-3
10 STRUCTURE AND FUNCTION COMPONENT PARTS OF TRAVEL SYSTEM

FUNCTION OF CENTER SWIVEL JOINT (PC400_10-K-J8E0-042-00-B)

Center swivel joint sends the oil from main pump installed to the the upper structure to travel motor installed to
the lower structure while rotating. Center swivel joint would not be twisted unlike hoses or tubes which would be
twisted if they are installed, for the upper structure rotating relative to the lower structure.

HB365LC-3 10-357
LAYOUT DRAWING OF UNDERCARRIAGE 10 STRUCTURE AND FUNCTION

UNDERCARRIAGE AND FRAME (PC400_10-K-DT00-001-00-B)

LAYOUT DRAWING OF UNDERCARRIAGE (HB335_3-K-DT00-04D-00-B)

1: Front guard 6: Track roller

2: Track frame 7: Center guard
3: Track shoe 8: Idler cushion
4: Carrier roller 9: Idler
5: Final drive

SPECIFICATIONS OF UNDERCARRIAGE (HB335_3-K-DT00-030-00-B)

Number of track rollers (one side)

HB335-3, HB365-3: 7 pieces
HB335LC-3, HB365LC-3: 8 pieces
Standard shoe
HB335-3, HB365-3
Shoe width: 600 mm
Link pitch: 216 mm

10-358 HB365LC-3
10 STRUCTURE AND FUNCTION LAYOUT DRAWING OF UNDERCARRIAGE

Number of shoes (one side): 45 pieces

HB335LC-3, HB365LC-3
Shoe width: 600 mm
Link pitch: 216 mm
Number of shoes (one side): 48 pieces

HB365LC-3 10-359
STRUCTURE OF WORK EQUIPMENT 10 STRUCTURE AND FUNCTION

WORK EQUIPMENT (PC400_10-K-L000-001-10-B)

STRUCTURE OF WORK EQUIPMENT (PC300_11-K-L400-041-00-B)

General view

1: Bucket 5: Arm cylinder

2: Bucket link 6: Boom
3: Bucket cylinder 7: Boom cylinder
4: Arm

10-360 HB365LC-3
10 STRUCTURE AND FUNCTION FUNCTION OF WORK EQUIPMENT

FUNCTION OF WORK EQUIPMENT (PC300_11-K-L400-042-00-B)

• The boom is operated by the boom cylinder, and moves the whole work equipment up and down.
• The arm is operated by the arm cylinder, and pulls in or pushes out the bucket.
• The bucket is operated by the bucket cylinder.
• The bucket link increases the moving range of the bucket.

HB365LC-3 10-361
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 10 STRUCTURE AND FUNCTION

WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM (PC300_11-K-L413-001-00-B)

FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM

(PC300_11-K-L413-042-00-B)
There are 2 types of the work equipment clearance adjustment shim; the steel shim and plastic shim. The fol-
lowing is the explanation of the function of each type of the work equipment clearance adjustment shim.
Steel shim
• Mainly inserted in the parts which are greased every 100
hours.
• The purpose of the steel shim is to reduce the clearance in
the right and left direction. There may be some cases that
shim is unnecessary to be inserted on adjusting side if it is
inserted in either on right or left side depending on the
width of the clearance.

Plastic shim
The lubrication interval of 250 hours is attained by combining the long-lubrication-interval bushings, dust seals,
and plastic shims.
• Mainly inserted in the parts which are greased every 250
hours.
• The purpose of the plastic shim is to reduce the clearance
in the right and left direction of the work equipment and to
prevent a creak and scuffing caused by rubbing of the end
faces of steel parts of a joint.
• A creak caused by drying out of grease is prevented and
the lubrication interval is lengthened by combining with
long-lubrication-interval bushings.
• The plastic shims are inserted between every pair of con-
tact faces so that the steel end surfaces of the joint do not
contact with each other.

10-362 HB365LC-3
10 STRUCTURE AND FUNCTION BUCKET CLEARANCE ADJUSTMENT SHIM

BUCKET CLEARANCE ADJUSTMENT SHIM (PC400_11-K-LBKB-001-00-B)

FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM (PC400_10-K-LBKB-042-00-B)

Split-type steel shims are used for the joint of the arm and
bucket.
You can adjust the clearance in the joint by changing the num-
ber of the shims. When the clearance increases, you can re-
duce it by reducing the shims.

HB365LC-3 10-363
ROPS CAB 10 STRUCTURE AND FUNCTION

CAB AND ITS ATTACHMENTS (PC400_10-K-K000-001-20-B)

ROPS CAB (PC400_10-K-K000-001-10-B)

ROPS
Abbreviation for Roll-Over Protective Structure

STRUCTURE OF ROPS CAB (PC300_11-K-K000-041-00-B)

ROPS: Abbreviation for Roll-Over Protective Structure
General view

1: Front window 5: Radio antenna

2: Windshield wiper 6: Door
3: Ceiling window 7: Mirror
4: KOMTRAX GPS antenna

FUNCTION OF ROPS CAB (PC300_11-K-K000-042-00-B)

ROPS cab is to protect the operator wearing seat belt from being crushed when the machine tips over.

10-364 HB365LC-3
10 STRUCTURE AND FUNCTION CAB MOUNT

CAB MOUNT (PC300_11-K-K130-001-00-B)

STRUCTURE OF CAB MOUNT (PC300_11-K-K130-041-00-B)

General view and sectional view

1: Front damper 2: Rear damper

Structure
• The dampers are installed at 2 places in front of the cab and 2 places at the rear of the cab, and they are
fixing the cab and frame to the revolving frame.
• The type of each damper depends on the location as shown in the identification table below.
Location of damper Bent claw Identification seal color
Front left Installed Red
Front right Installed Red
Rear left None Green
Rear right None Green

FUNCTION OF CAB MOUNT (PC300_11-K-K130-042-00-B)

Sealed and lubricated type damper is employed. The damper reduces vibration to be transmitted to operator
when the machine vibrates by absorbing it.

HB365LC-3 10-365
CAB TIPPING STOPPER 10 STRUCTURE AND FUNCTION

CAB TIPPING STOPPER (PC300_11-K-K138-001-00-B)

STRUCTURE OF CAB TIPPING STOPPER (PC300_11-K-K138-041-00-B)

General view and sectional view

1: Bolt 3: Lock plate

2: Lock plate bolt for fixing

FUNCTION OF CAB TIPPING STOPPER (PC300_11-K-K138-042-00-B)

Cab tipping stopper is installed at 1 place in the rear part to secure the cab when the machine tips over.

10-366 HB365LC-3
 20 STANDARD VALUE TABLE

HB365LC-3 20-1
CONTENTS 20 STANDARD VALUE TABLE

CONTENTS (ALL-A-0310-002-00-B)
ABBREVIATION LIST .................................................................................................................................... 20-3
STANDARD VALUE TABLE FOR ENGINE .................................................................................................... 20-9
STANDARD VALUE TABLE FOR ENGINE:HB365LC-3.......................................................................... 20-9
STANDARD VALUE TABLE FOR MACHINE................................................................................................ 20-15
STANDARD VALUE TABLE FOR MACHINE: HB365LC-3 .................................................................... 20-15
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE ................................ 20-32

20-2 HB365LC-3
20 STANDARD VALUE TABLE ABBREVIATION LIST

ABBREVIATION LIST (ALL-A-0360-005-00-B)

• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).

HB365LC-3 20-3
ABBREVIATION LIST 20 STANDARD VALUE TABLE

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
This is an electronic control device that send the
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.

20-4 HB365LC-3
20 STANDARD VALUE TABLE ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.

HB365LC-3 20-5
ABBREVIATION LIST 20 STANDARD VALUE TABLE

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a service that allows transmission and re-
Multimedia Messaging
MMS Communication ception of short messages consisting of charac-
Service
ters or voice or images between cell phones.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NC Normally Closed circuits. Circuit is normally closed if it is not actu-
system
ated, and it opens when it is actuated.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NO Normally Open circuits. Circuit is normally open if it is not actuat-
system
ed, and it closes when it is actuated.
This is a hydraulic system that can operate multi-
Open-center Load
OLSS Hydraulic system ple actuators at the same time regardless of the
Sensing System
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
Steering This is a function that electrically controls the en-
Palm command control gine and transmission in an optimal way with the
PCCS
system (D Series) controller instantly analyzing data from levers,
pedals, and dials.
This is a valve that adjusts the fuel intake amount
PCV Pre-stroke Control Valve Engine at the pump inlet in order to control fuel dis-
charged volume of supply pump.
Proportional Pressure This is a system that operates actuators in pro-
PPC Hydraulic system
Control portion to the oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Work equipment This is a function that performs hydraulic control
Power Tilt and power
PTP of the tilt and pitch of the dozer blade of the bull-
Pitch dozer (D Series) dozer.
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
Roll-Over Protective crushed when the machine rolls over. (Roll-over
ROPS Cab and canopy
Structure protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
Selective Catalytic Re- less nitrogen and water by oxidation-reduction re-
SCR Urea SCR system
duction action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
Le Systeme Internation- Abbreviation for "International System of Units" It
SI al d' Unites (Internation- Unit is the universal unit system and "a single unit for
al unit system) a single quantity" is the basic principle applied.
This is an actuator that consists of a solenoid and
SOL Solenoid Electrical system an iron core that is operated by the magnetic
force when the solenoid is energized.

20-6 HB365LC-3
20 STANDARD VALUE TABLE ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.

*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection

HB365LC-3 20-7
ABBREVIATION LIST 20 STANDARD VALUE TABLE

Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

20-8 HB365LC-3
20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE:HB365LC-3

STANDARD VALUE TABLE FOR ENGINE (PC400_10-K-A000-001-00-B)

STANDARD VALUE TABLE FOR ENGINE:HB365LC-3 (HB335_3-K-A000-033-03-B)

Performance
Machine model HB365LC-3
Engine SAA6D114E-6
Standard value
Item Measurement condition Unit for new ma- Repair limit
chine
• Engine coolant temperature: 60 to Working
100 °C mode: P 1166±70 1166±70
• Hydraulic oil temperature: 45 to (Power Mode)
55 °C
Engine • Auto-deceleration switch: OFF
speed at high Working rpm
idle • Swing lock switch: ON
mode: B Reference
• Fuel control dial: MAX (High idle) (1950)
(Breaker value
position
Mode)
• Work equipment control lever, con-
trol pedal: NEUTRAL position
• Engine coolant temperature: 60 to 100 °C
• Hydraulic oil temperature: 45 to 55 °C
Engine • Working mode: P (Power Mode)
speed at low • Swing lock switch: OFF rpm 700±50 700±50
idle
• Fuel control dial: MIN (Low idle) position
• All control levers and control pedals in NEUTRAL
position

HB365LC-3 20-9
STANDARD VALUE TABLE FOR ENGINE:HB365LC-3 20 STANDARD VALUE TABLE

Air intake and exhaust system

Machine model HB365LC-3
Engine SAA6D114E-6
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine coolant tempera- Gauge pres- 147 120
ture60 to 100 °C sure {1100} {900}
• Hydraulic oil tempera-
ture45 to 55 °C
• Working mode: P (Power
Mode)
• Auto-deceleration switch:
OFF
• Swing lock switch: ON
• Fuel control dial: MAX
(High idle) position
• Operation of work equip- kPa
Boost pressure ment: Relief the pressure
Absolute pres- {mmHg} 248.3 221.3
at arm IN and actuate one-
sure {1860} {2620}
touch power maximizing
REMARK
• The gauge pressure does
not include the atmospheric
pressure.
• The absolute pressure is
obtained by adding
101.3 kPa {760 mmHg} of
ambient pressure at 0 m
above sea level to the
gauge pressure.
• Engine coolant tempera- Engine outlet
ture: 60 to 100 °C (Between VGT Max. 2.0 Max. 2.5
• Auto-deceleration switch: and KDPF in-
OFF let)
• After keeping it at normal
Exhaust gas condition for 5 seconds Bosch in-
color dex
• Swing lock switch: ON SCR outlet
• Fuel control dial: MAX (Exhaust pipe Max. 0.5 Max. 0.5
(High idle) position outlet)
• Work equipment control:
Arm IN relief

Valve clear- Engine coolant temperature: Intake valve 0.22 to 0.38 0.22 to 0.38
mm
ance Normal temperature Exhaust valve 0.48 to 0.64 0.48 to 0.64

20-10 HB365LC-3
20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE:HB365LC-3

Machine model HB365LC-3

Engine SAA6D114E-6
Standard value
Item Measurement condition Unit Repair limit
for new machine
EGR valve oil
Fuel control di- Min. 1.2 Min. 1.2
pressure and
al: MIN (Low
VGT driving oil {Min. 12.2} {Min. 12.2}
• Engine coolant tempera- idle) position
pressure
ture: 60 to 100 °C MPa
Whole speed
• Hydraulic oil temperature: range {kg/cm2}
VGT control oil 45 to 55 °C Min. 1.2 Min. 1.2
pressure Oil pressure
{Min. 12.2} {Min. 12.2}
fluctuation
range

Main body
Machine model HB365LC-3
Engine SAA6D114E-6
Standard value
Item Measurement condition Unit Repair limit
for new machine

Compression • Engine oil temperature: 40 to 60 °C MPa Min. 2.6 Min. 2.1

pressure • Engine Speed: 250 to 280 rpm {kg/cm2} {Min. 26.5} {Min. 21.4}
• Engine coolant temperature: 60 to 100 °C
• Hydraulic oil temperature: 45 to 55 °C
• Working mode: P (Power Mode)
• Auto-deceleration switch: OFF kPa Max. 1.96 Max. 2.94
Blowby pres-
sure • Swing lock switch: ON {mmH2O} {Max. 200} {Max. 300}
• Fuel control dial: MAX (High idle) position
• Operation of work equipment: Relief the
pressure at arm IN and actuate one-touch
power maximizing

HB365LC-3 20-11
STANDARD VALUE TABLE FOR ENGINE:HB365LC-3 20 STANDARD VALUE TABLE

Fuel system
Machine model HB365LC-3
Engine SAA6D114E-6
Standard value
Item Measurement condition Unit Repair limit
for new machine
Fuel control di- Min. 480 Min. 480
Fuel pressure al: MAX (High
idle) position kPa {Min. 4.9} {Min. 4.9}
(Fuel main fil-
ter inlet pres-
Cranking {kg/cm2} Min. 105 Min. 105
sure)
(Min. 150 rpm) {Min. 1.07} {Min. 1.07}
Fuel pressure
(Low-pressure Fuel control di- kPa Min. 80 Min. 80
circuit (pres- al: MAX (High
idle) position {kg/cm2} {Min. 0.82} {Min. 0.82}
sure differ-
ence))
Fuel control di-
al: MAX (High
Fuel pressure idle) position kPa Max. 18.6 Max. 18.6
(Return circuit) • Engine coolant tempera- {kg/cm2} {Max. 0.19} {Max. 0.19}
ture: 60 to 100 °C Cranking

• (Min. 150 rpm)

Hydraulic oil temperature:
Fuel pressure 45 to 55 °C
(Negative kPa -27.1 to 0 -27.1 to 0
pressure cir-
{mmHg} {-203 to 0} {-203 to 0}
cuit (fuel sup-
ply connector))
Fuel pressure
Fuel control di-
(Negative al: MAX (High kPa -33.9 to 0 -33.9 to 0
pressure cir- idle) position {mmHg} {-254 to 0} {-254 to 0}
cuit (supply
pump))
Fuel pressure
(Fuel feed kPa Min. 34 Min. 34
pump outlet {mmHg} {Min. 255} {Min. 255}
pressure)

20-12 HB365LC-3
20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR ENGINE:HB365LC-3

Machine model HB365LC-3

Engine SAA6D114E-6
Standard value
Item Measurement condition Unit Repair limit
for new machine
Supply pump
discharged
volume Cranking
mℓ Min. 75 Min. 75
(Discharged (Min. 150 rpm)
volume for 30
seconds)
Return rate Fuel control di-
from supply al: MIN (Low Max. 350 Max. 350
pump idle) position
mℓ
(Return rate
Cranking
for 30 sec- Max. 320 Max. 320
onds) (Min. 150 rpm)

Return rate
from injector Fuel control di-
(Return rate al: MIN (Low mℓ Max. 300 Max. 300
for 45 sec- idle) position
onds) • Engine coolant tempera-
ture: 60 to 100 °C
Return rate
from injector • Hydraulic oil temperature:
Cranking
(Return rate 45 to 55 °C mℓ Max. 100 Max. 100
(Min. 150 rpm)
for 30 sec-
onds)
Leakage from
pressure limit- Fuel control di-
er valve less than 30 less than 30
al: MIN (Low mℓ
drops drops
(Leakage for idle) position
30 seconds)
Fuel feed
pump dis-
charged vol-
ume When starting
(Discharged switch in ON mℓ Max. 100 Max. 100
volume for 10 position
seconds (Aver-
age of 3 meas-
urements)

HB365LC-3 20-13
STANDARD VALUE TABLE FOR ENGINE:HB365LC-3 20 STANDARD VALUE TABLE

Lubrication system
Machine model HB365LC-3
Engine SAA6D114E-6
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Engine coolant tempera- Fuel control di- MPa 0.34 to 0.59 Min. 0.21
ture: 60 to 100 °C al: MAX (High
idle) position {kg/cm2} {3.5 to 6.0} {Min. 2.1}
• Working equipment mode:
B (Breaker Mode)
• Work equipment control
Engine oil lever, control pedal: NEU-
pressure TRAL position Fuel control di- MPa Min. 0.15 Min. 0.08
• Engine oil (*1) al: MIN (Low
idle) position {kg/cm2} {Min. 1.5} {Min. 0.8}
EO10W30-LA
EO15W40-LA
EOS5W30-LA
EOS5W40-LA
Engine oil tem-
Whole speed range (inside oil pan) °C 80 to 110 120
perature

*1: KES diesel engine oil

Cooling system
Machine model HB365LC-3
Engine SAA6D114E-6
Standard value
Item Measurement condition Unit Repair limit
for new machine
• Between air conditioner compressor pulley
Air conditioner and fan pulley
compressor mm 13 to 15 13 to 15
belt tension • Deflection when pressing with a force of
60 N {6.2 kg} with finger

Cooling fan
Machine model HB365LC-3
Engine SAA6D114E-6
Standard value
Item Measurement condition Unit Repair limit
for new machine

• "Fan 100% Speed Adjust- Fuel control di-

al: MAX (High 1800±100 1800±100
ment" mode
idle) position
• Swing lock switch: ON
Cooling fan Engine Speed:
• Auto-deceleration switch: rpm 1400±100 1400±100
speed 1600 rpm
OFF
Fuel control di-
• Working equipment mode: al: MIN (Low 830±100 830±100
B (Breaker Mode) idle) position

20-14 HB365LC-3
20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: HB365LC-3

STANDARD VALUE TABLE FOR MACHINE (PC400_10-K-0000-001-01-B)

STANDARD VALUE TABLE FOR MACHINE: HB365LC-3 (HB335_3-K-0000-033-03-B)

Engine Speed
Machine model HB365LC-3
Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine
• Engine coolant temperature: 60 to
100 °C
• Hydraulic oil temperature: 45 to 55 °C
• Working mode: P (Power Mode)
Engine speed
• Auto-deceleration switch: OFF rpm 1380±100 1380±100
at 2-pump relief
• Swing lock switch: OFF
• Fuel control dial: MAX (High idle) posi-
tion
• Work equipment control: Arm IN relief
• Engine coolant temperature: 60 to
100 °C
• Hydraulic oil temperature: 45 to 55 °C
Engine speed
when oil pres-
• Working mode: P (Power Mode)
sure of 2 pumps • Auto-deceleration switch: OFF
are relieved + • Swing lock switch: OFF rpm 1528±100 1528±100
One-touch pow-
er maximizing is • Fuel control dial: MAX (High idle) posi-
actuated tion
• Operation of work equipment: Relief
the pressure at arm IN and actuate
one-touch power maximizing
• Engine coolant temperature: 60 to
100 °C
• Hydraulic oil temperature: 45 to 55 °C
• Working mode: P (Power Mode)
Speed when
• Auto-deceleration switch: ON
auto decelera- rpm 700±50 700±50
tion is actuated • Swing lock switch: OFF
• Fuel control dial: MAX (High idle) posi-
tion
• Work equipment control lever, control
pedal: NEUTRAL position

HB365LC-3 20-15
STANDARD VALUE TABLE FOR MACHINE: HB365LC-3 20 STANDARD VALUE TABLE

SCR related items

Machine model HB365LC-3
Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine
AdBlue/DEF
Within approximately 200 seconds after start-
Pump Pressure kPa Min. 800 Min. 800
ing AdBlue/DEF Pump Pressure Up Test
Up Test
AdBlue/DEF in-
jector resist- AdBlue/DEF injector: 20 °C Ω 11.4 to 12.6 11.4 to 12.6
ance
AdBlue/DEF In-
Injection volume when AdBlue/DEF Injection
jection Quantity mℓ 100(+7/-26) 100(+7/-26)
Quantity Test is completed
Test
AdBlue/DEF
Line Heater Re- AdBlue/DEF Line Heater Relay 1 Test V 24.5±1.5 24.5±1.5
lay 1 Test
AdBlue/DEF
Within 900 seconds after starting
Line Heater Re- V 24.5±1.5 24.5±1.5
AdBlue/DEF Line Heater Relay 2 Test
lay 2 Test
AdBlue/DEF
Within 900 seconds after starting
Pump Heater V 24.5±1.5 24.5±1.5
AdBlue/DEF Pump Heater Relay Test
Relay Test
AdBlue/DEF
Within 900 seconds after starting
Tank Heater V 24.5±1.5 24.5±1.5
AdBlue/DEF Tank Heater Valve Test
Valve Test
AdBlue/DEF
Display which appears on Injection Test 1 (Normal) 1 (Normal)
SCR Denitra-
the machine monitor when Result
tion Efficiency -
SCR Denitration Efficiency
Test SCR Efficiency
Test is completed 1 (Normal) 1 (Normal)
Test Result

Control valve spool stroke

Machine model HB365LC-3
Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine
Boom control ℓ a b ℓ a b
valve
• Engine: Stopped
Arm control
valve • Measuring position: See “MACHINE 9.5± 9.5± 9.5± 9.5±
- -
POSTURE AND PROCEDURE FOR mm 0.5 0.5 0.5 0.5
Bucket control
MEASURING PERFORMANCE”, “Fig.
valve
1”.
Travel control 9.5± 9.5± 9.5± 9.5±
- -
valve 0.5 0.5 0.5 0.5

20-16 HB365LC-3
20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: HB365LC-3

Travel of control lever

Machine model HB365LC-3
Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine
Boom control
85±10 85±10
lever
Arm control lev-
85±10 85±10
er
Bucket control
85±10 85±10
lever • Engine: Stopped
Swing control • Center of lever knob
85±10 85±10
lever • Read the maximum value when the mm
Travel control lever is operated to the stroke end (Ex-
clude play in NEUTRAL position) 115±12 115±12
lever
Play of work
equipment con- Max. 15 Max. 20
trol lever
Play of control
Max. 20 Max. 25
lever

Operating effort of control lever and pedal

Machine model HB365LC-3
Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine

Boom control 15.7±3.9 Max. 24.5

lever {1.6±0.4} {Max. 2.5}

Arm control lev- 15.7±3.9 Max. 24.5

er • Hydraulic oil temperature: 45 to 55 °C {1.6±0.4} {Max. 2.5}
• Fuel control dial: MAX (High idle) posi- 12.7±2.9 Max. 21.6
Bucket control
lever
tion
N {1.3±0.3} {Max. 2.2}
• Control lever: At center of grip
Swing control {kg} 12.7±2.9 Max. 21.6
• Pedal: At tip of pedal
lever {1.3±0.3} {Max. 2.2}
• Read the maximum value when the
Travel control lever is operated to the stroke end 24.5±5.9 Max. 39.2
lever {2.5±0.6} {Max. 4.0}

Travel control 74.5±18.6 Max. 107.6

pedal {7.6±1.9} {Max. 11}

HB365LC-3 20-17
STANDARD VALUE TABLE FOR MACHINE: HB365LC-3 20 STANDARD VALUE TABLE

Work equipment and travel oil pressure

Machine model HB365LC-3
Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine
• Hydraulic oil temperature: 45 to 55 °C
• Working mode: P (Power Mode)
• Auto-deceleration switch: OFF

Unload pres- • Swing lock switch: OFF

MPa 3.9±1.0 3.9±1.0
sure • Fuel control dial: MAX (High idle) posi-
tion {kg/cm2} {40±10} {40±10}
(PFC, PRC)
• Work equipment control lever, control
pedal: NEUTRAL position
• Pump discharge pressure with all con-
trol levers in NEUTRAL position
• Hydraulic oil tempera- 34.8(+1.47/-1.18) 33.15 to 36.77
ture: 45 to 55 °C {353(+15/-12)} {338 to 375}
• Working mode: P RAISE (*2) 37.26
(Power Mode) (*2) 35.6 to 39.23
(+1.47/-1.18)
• Auto-deceleration {363 to 400}
{380(+15/-12)}
switch: OFF
LOWER
• Swing lock switch: 18.13+0.98 16.66 to 19.6
OFF At low pres-
{185+10} {170 to 200}
sure set
Boom relief • Fuel control dial: MAX
MPa
pressure (High idle) position
{kg/cm2}
(PFC, PRC) • Pump discharge pres-
sure when the pres-
sure in the circuit to be
measured is being re- LOWER
31.36+1.47 29.4 to 33.32
lieved At high pres-
{320+15} {300 to 340}
• Values marked with sure set
(*2) are oil pressure
when one-touch power
maximizing is actuated
(reference)
• Hydraulic oil temperature: 45 to 55 °C 34.81(+1.47/-1.18) 33.15 to 36.77
• Working mode: P (Power Mode) {355(+15/-12)} {338 to 375}
• Auto-deceleration switch: OFF
• Swing lock switch: OFF
Arm relief pres- • Fuel control dial: MAX (High idle) posi-
MPa
sure tion
(*2) 37.26
{kg/cm2} (*2) 35.6 to 39.23
(PFC, PRC) • Pump discharge pressure when the (+1.47/-1.18)
pressure in the circuit to be measured {363 to 400}
{380(+15/-12)}
is being relieved
• Values marked with (*2) are oil pres-
sure when one-touch power maximiz-
ing is actuated (reference)

20-18 HB365LC-3
20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: HB365LC-3

Machine model HB365LC-3

Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine
• Hydraulic oil temperature: 45 to 55 °C 34.81(+1.47/-1.18) 33.15 to 36.77
• Working mode: P (Power Mode) {355(+15/-12)} {338 to 375}
• Auto-deceleration switch: OFF
• Swing lock switch: OFF
Bucket relief • Fuel control dial: MAX (High idle) posi-
MPa
pressure tion
(*2) 37.26
{kg/cm2} (*2) 35.6 to 39.23
(PFC, PRC) • Pump discharge pressure when the (+1.47/-1.18)
pressure in the circuit to be measured {363 to 400}
{380(+15/-12)}
is being relieved
• Values marked with (*2) are oil pres-
sure when one-touch power maximiz-
ing is actuated (reference)
• Hydraulic oil temperature: 45 to 55 °C
• Working mode: P (Power Mode)
Travel relief
• Auto-deceleration switch: OFF MPa 37.27(+2.94/-0.98) 35.8 to 40.7
pressure
• Fuel control dial: MAX (High idle) posi- {kg/cm2} {380(+30/-10)} {363 to 415}
(PFC, PRC)
tion
• Travel speed: Hi
• Hydraulic oil temperature: 45 to 55 °C
• Working mode: P (Power Mode)
Control circuit • Auto-deceleration switch: OFF MPa 3.23±0.2 2.84 to 3.43
oil pressure
• Fuel control dial: MAX (High idle) posi- {kg/cm2} {33±2} {29 to 35}
(PEPB) tion
• Work equipment control lever, control
pedal: NEUTRAL position
Front
pump 34.81(+1.47/-1.18) 34.81(+1.47/-1.18)
dis-
{355(+15/-12)} {355(+15/-12)}
charged
• pressure
Hydraulic oil temperature:
45 to 55 °C Servo
PC valve outlet • Working mode: P (Power piston in- Above value x ap- Above value x ap-
pressure (servo Mode) let pres- prox. 0.6 prox. 0.6
piston inlet sure MPa
pressure) • Swing lock switch: ON
Rear {kg/cm2}
(PFC-PENF, • Fuel control dial: MAX (High pump
idle) position 34.81(+1.47/-1.18) 34.81(+1.47/-1.18)
PRC-PENR) dis-
• Work equipment control: charged {355(+15/-12)} {355(+15/-12)}
Arm IN relief pressure
Servo
piston in- Above value x ap- Above value x ap-
let pres- prox. 0.6 prox. 0.6
sure

HB365LC-3 20-19
STANDARD VALUE TABLE FOR MACHINE: HB365LC-3 20 STANDARD VALUE TABLE

Machine model HB365LC-3

Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine
• Hydraulic oil temperature: Fuel con-
45 to 55 °C trol dial: Approx. 1.74 Approx. 1.74
MIN (Low {Approx. 17.7} {Approx. 17.7}
• Working mode: P (Power
PC-EPC valve idle)
Mode) MPa
outlet pressure
Fuel con-
• Swing lock switch: OFF {kg/cm2}
(PMF, PMR) trol dial: 0.22 0.22
• Work equipment control lev- MAX
er, control pedal: NEUTRAL (High {2.2} {2.2}
position idle)
• Hydraulic oil temperature: All con-
45 to 55 °C trol lev-
ers and 3.9±1.0 3.9±1.0
• Working mode: P (Power
control
Mode) {40±10} {40±10}
pedals:
• Travel speed: Hi NEU-
LS differential
pressure • Fuel control dial: MAX (High TRAL MPa
idle) position
(PFC-PLSF, {kg/cm2}
PRC-PLSR) • Measuring posture: Run- Travel
ning the track idle off the control 2.45±0.1 2.45±0.1
ground lever:
Half {25±1} {25±1}
• LS differential pressure =
Pump discharge pressure - stroke
LS pressure
All con-
• Hydraulic oil temperature: trol lev-
45 to 55 °C ers and 3.9±1.0 3.9±1.0
LS valve outlet • Working mode: P(Power control
pedals: {40±10} {40±10}
pressure (servo Mode)
piston inlet NEU- MPa
pressure) • Travel speed: Hi TRAL
{kg/cm2}
(PFC-PENF, • Fuel control dial: MAX (High Travel
PRC-PENR) idle) position control Pump discharge Pump discharge
• Travel operation: One-side lever: pressure x Approx. pressure x Approx.
track idle off the ground Half 0.6 0.6
stroke
• Hydraulic oil temperature: Travel Approx. 1.45 Approx. 1.45
45 to 55 °C speed:
Outlet pressure Lo {14.8} {14.8}
• Working mode: P(Power
of LS-EPC MPa
Mode)
valve {kg/cm2}
• Fuel control dial: MAX (High Travel 0 0
(PSIG)
idle) position speed: Hi {0} {0}
• Travel control: Fine control

20-20 HB365LC-3
20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: HB365LC-3

Machine model HB365LC-3

Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine
• Hydraulic oil temperature: Solenoid:
45 to 55 °C OFF (de- 0 0
ener- {0} {0}
• Fuel control dial: MAX (High
gized)
idle) position
Solenoid valve MPa
• For energized/De-energized
outlet pressure conditions of solenoid, see Solenoid: {kg/cm2}
“TESTING AND ADJUST- ON 2.9 2.9
ING, TEST OUTLET PRES- (ener- {30} {30}
SURE OF SOLENOID gized)
VALVE”.
All con-
trol lev-
ers and 0 0
• Hydraulic oil temperature: control
45 to 55 °C pedals: {0} {0}
PPC valve out- • Working mode: P (Power NEU- MPa
let pressure Mode) TRAL
{kg/cm2}
• Fuel control dial: MAX (High Travel
idle) position control 3.24±0.2 2.84 to 3.43
lever:
Stroke {33±2} {29 to 35}
end

Values marked with *2 are oil pressure when one-touch power maximizing is actuated (reference)

Swing
Machine model HB365LC-3
Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine
• Hydraulic oil temperature: 45 to 55 °C
• Fuel control dial: MAX (High idle) posi-
tion
• Working mode: P (Power Mode)
Overrun when
• Overswing of swing circle after 1 swing deg. Max. 125 Max. 150
stopping swing
• Measuring posture: See “MACHINE
POSTURE AND PROCEDURE FOR
MEASURING PERFORMANCE”, “Fig.
2”.

HB365LC-3 20-21
STANDARD VALUE TABLE FOR MACHINE: HB365LC-3 20 STANDARD VALUE TABLE

Machine model HB365LC-3

Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine
• Hydraulic oil temperature: 45 90 ° 3.3±0.4 Max. 4.2
to 55 °C
• Working mode: P (Power
Mode)
• Fuel control dial: MAX (High
Time required idle) position
to start swing- • Time required to pass 90 ° Sec.
ing 180 ° 4.7±0.5 Max. 5.7
and180 ° points after starting
swing
• Measuring posture: See “MA-
CHINE POSTURE AND PRO-
CEDURE FOR MEASURING
PERFORMANCE”, “Fig. 2”.
• Hydraulic oil temperature: 45 to 55 °C
• Working mode: P (Power Mode)
• Fuel control dial: MAX (High idle) posi-
tion
Time required • Time required to complete 5 swings af- Sec. 31.6±0.9 Max. 38
for swinging ter 1 swing
• Measuring posture: See “MACHINE
POSTURE AND PROCEDURE FOR
MEASURING PERFORMANCE”, “Fig.
2”.
• Hydraulic oil temperature: 45 to 55 °C
• Engine: Stopped
• Set the machine on 15 ° slope, and set
the upper structure sideways.
• Put the matchmark on the inner race
Swing drift on a and outer race of the circle. mm 0 0
slope
• Distance that matchmarks move apart
after 5 minutes
• Measuring posture: See “MACHINE
POSTURE AND PROCEDURE FOR
MEASURING PERFORMANCE”, “Fig.
3”.

20-22 HB365LC-3
20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: HB365LC-3

Traveling
Machine model HB365LC-3
Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine
• Hydraulic oil temperature: 45 Lo 58.0±11.5 45.0 to 74.5
to 55 °C
Mi 41.5±6.0 34.0 to 51.5
• Working equipment mode: B
(Breaker Mode)
• Fuel control dial: MAX (High
idle) position
Travel speed
• Time required to complete 5 Sec.
(idle running)
idle turns of track off ground Hi 34.0±2.0 32.0 to 41.5
after 1 idle turn
• Measuring posture: See “MA-
CHINE POSTURE AND PRO-
CEDURE FOR MEASURING
PERFORMANCE”, “Fig. 4”.
• Hydraulic oil temperature: 45 Lo 22.5±4.2 18.1 to 30.2
to 55 °C
Mi 16.0±2.1 13.7 to 20.3
• Working mode: P (Power
Mode)
• Fuel control dial: MAX (High
idle) position
Travel speed
• Time required to travel 20 m Sec.
(actual running)
after running up 10 m on a lev- Hi 13.1±0.7 12.1 to 15.1
el ground
• Measuring posture: See “MA-
CHINE POSTURE AND PRO-
CEDURE FOR MEASURING
PERFORMANCE”, “Fig. 5”.
• Hydraulic oil temperature: 45 to 55 °C
• Fuel control dial: MAX (High idle) posi-
tion
• Working mode: P (Power Mode)
• Travel speed: Lo
Travel deviation • Travel deviation (x) in travel of 20 m mm Max. 200 Max. 300
after running up 10 m on a firm and
level ground
• Measurement posture: See “MA-
CHINE POSTURE AND PROCE-
DURE FOR MEASURING PERFORM-
ANCE”, “Fig. 5” and “Fig. 6”.

HB365LC-3 20-23
STANDARD VALUE TABLE FOR MACHINE: HB365LC-3 20 STANDARD VALUE TABLE

Machine model HB365LC-3

Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine
• Hydraulic oil temperature: 45 to 55 °C
• Engine: Stopped
• Place the machine on a slope of 12 °
with sprocket toward uphill side.
Machine drift on • Travel distance by machine drift on a mm 0 0
a slope slope for 5 minutes
• Measuring posture: See “MACHINE
POSTURE AND PROCEDURE FOR
MEASURING PERFORMANCE”, “Fig.
7”.
• Hydraulic oil temperature: 45 to 55 °C
• Fuel control dial: MAX (High idle) posi-
Leakage from tion
ℓ/min Max. 15 Max. 30
travel motor • Lock the sprocket with pin, etc.
• Leakage for 1 minute during travel re-
lief

Hydraulic drift of work equipment

Machine model HB365LC-3
Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine
Whole work
equipment
• Hydraulic oil temperature: 45 to 55 °C
(Hydraulic drift Max. 550 Max. 825
measured at • Level and flat ground
tooth tip) • Bucket filled up with dirt and sand, or
Boom cylinder at the rated load (21170 N {2160 kg} )
(Retraction • Engine: Stopped
Max. 30 Max. 45
amount of cylin- • Work equipment control lever, control
der) pedal: NEUTRAL position mm
Arm cylinder • Hydraulic drift for 15 minutes, measure
(Extension it every 5 minutes from immediately af-
ter initial setting Max. 165 Max. 248
amount of cylin-
der) • Measuring posture: See “MACHINE
Bucket cylinder POSTURE AND PROCEDURE FOR
MEASURING PERFORMANCE”, “Fig.
(Retraction 8”. Max. 25 Max. 38
amount of cylin-
der)

20-24 HB365LC-3
20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: HB365LC-3

Work equipment speed

Machine model HB365LC-3
Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine
• Hydraulic oil tempera- RAISE 3.7±0.4 Max. 4.5
ture: 45 to 55 °C
• Working mode: P
(Power Mode)
• Fuel control dial: MAX
(High idle) position
• Time required for the
boom to be raised from
the point the bucket is
Boom speed at the ground to the Sec.
LOWER 3.1±0.3 Max. 4.0
boom RAISE stroke
end (just before cush-
ion)
• Measuring posture:
See “MACHINE POS-
TURE AND PROCE-
DURE FOR MEASUR-
ING PERFORM-
ANCE”, “Fig. 9”.
• Hydraulic oil tempera- Dig (working
ture: 45 to 55 °C mode: P (Pow- 3.8±0.4 Max. 4.4
er Mode))
• Working mode: P
(Power Mode) IN (Working
• Fuel control dial: MAX mode: E
3.9±0.4 Max. 4.5
(Economy
(High idle) position
Mode))
• Time required for the
arm to be operated IN (Working
from the arm OUT mode: L (Fine
Arm speed Sec. 4.9±0.5 Max. 5.7
Operation
stroke end (just before
Mode))
cushion) to the arm IN
stroke end
• Measuring posture:
See “MACHINE POS- Dump (work-
TURE AND PROCE- ing mode: P 3.1±0.3 Max. 3.5
DURE FOR MEASUR- (Power Mode))
ING PERFORM-
ANCE”, “Fig. 10”.

HB365LC-3 20-25
STANDARD VALUE TABLE FOR MACHINE: HB365LC-3 20 STANDARD VALUE TABLE

Machine model HB365LC-3

Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine
• Hydraulic oil tempera- CURL 3.2±0.3 Max. 3.8
ture: 45 to 55 °C
• Working mode: P
(Power Mode)
• Fuel control dial: MAX
(High idle) position
• Time required to oper-
Bucket speed ate the bucket from the Sec.
DUMP stroke end to DUMP 2.3±0.3 Max. 2.9
the CURL stroke end
• Measuring posture:
See “MACHINE POS-
TURE AND PROCE-
DURE FOR MEASUR-
ING PERFORM-
ANCE”, “Fig. 11”.

Operation time lag

Machine model HB365LC-3
Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine
• Hydraulic oil temperature: 45 to 55 °C
• Working mode: P (Power Mode)
• Fuel control dial: MIN (Low idle) posi-
tion
• Set the arm and the bucket to the
DUMP stroke end. Lower the work
Boom time lag equipment to the ground, and measure Sec. Max. 3.0 Max. 3.6
how long it takes for the machine to be
raised off the ground from the point
that the bucket is on the ground.
• Measuring posture: See “MACHINE
POSTURE AND PROCEDURE FOR
MEASURING PERFORMANCE”, “Fig.
12”.

20-26 HB365LC-3
20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: HB365LC-3

Machine model HB365LC-3

Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine
• Hydraulic oil temperature: 45 to 55 °C
• Working mode: P (Power Mode)
• Fuel control dial: MIN (Low idle) posi-
tion
• Set the boom top face horizontally and
the bucket to the DUMP stroke end.
Operate the arm IN operation from the
Arm time lag arm DUMP stroke end, and from this Sec. Max. 3.0 Max. 3.6
position, measure how long it takes for
the arm to be moved off again since it
stopped.
• Measuring posture: See “MACHINE
POSTURE AND PROCEDURE FOR
MEASURING PERFORMANCE”, “Fig.
13”.
• Hydraulic oil temperature: 45 to 55 °C
• Working mode: P (Power Mode)
• Fuel control dial: MIN (Low idle) posi-
tion
• Set the boom top face horizontally and
the arm to the arm OUT stroke end.
Operate the bucket CURL operation
Bucket time lag from the bucket DUMP stroke end, Sec. Max. 3.0 Max. 5.0
and from this position, measure how
long it takes for the bucket to be
moved off again since it stopped.
• Measuring posture: See “MACHINE
POSTURE AND PROCEDURE FOR
MEASURING PERFORMANCE”, “Fig.
14”.

Oil leakage
Machine model HB365LC-3
Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine
Oil leakage • Hydraulic oil temperature: 45 to 55 °C
4.5 20
from cylinder
• Fuel control dial: MAX (High idle) posi-
tion
mℓ/min
Center swivel • Measure the leakage for 1 minute 10 50
joint while relieving the travel motor or cyl-
inder to be measured

HB365LC-3 20-27
STANDARD VALUE TABLE FOR MACHINE: HB365LC-3 20 STANDARD VALUE TABLE

Pump performance
Machine model HB365LC-3
Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine
• Hydraulic oil temperature: 45 to 55 °C
• Working mode: P (Power Mode)
Combined oper- • Fuel control dial: MAX (High idle) posi-
ation perform- tion
ance • Travel speed: Lo
(Travel devia- • Travel deviation (x) in travel of 20 m mm Max. 400 Max. 440
tion at simulta- after running up 10 m on a firm and
neous operation
level ground
of work equip-
ment + travel) • Measurement posture: See “MA-
CHINE POSTURE AND PROCE-
DURE FOR MEASURING PERFORM-
ANCE”, “Fig. 5” and “Fig. 6”.
• Hydraulic oil tempera- All control lev-
ture: 45 to 55 °C ers and control
1.560±0.20 1.560±0.63
pedals: NEU-
• Working mode: P
TRAL
(Power Mode)
• Swing lock switch:
Output voltage OFF
of pump swash At running V
plate sensor • Fuel control dial: MAX track idle off
(High idle) position ground 3.632±0.20 3.632±0.63
• Travel speed: Hi (Control pedal:
• Measuring posture: Stroke end)
Running the track idle
off the ground
• Pump speed (rpm): 1800 rpm
• PC-EPC current value (mA): 440 mA
• Test pump discharge pressure (MPa
Main pump per- {kg/cm2}): PFC Q Q
ℓ/min
formance • Other pump discharge pressure (MPa (See the graph) (See the graph)
{kg/cm2}): PRC
• Average discharge pressure (MPa
{kg/cm2}): Pp = (PFC+PRC)/2

20-28 HB365LC-3
20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: HB365LC-3

REMARK
• Adjust the pump discharge pressure PFC and PRC as close as possible to the average pressure when
measuring.
• Avoid performing the test where the lines of the flow lower limit and the flow upper limit begin to drop sharp-
ly, as the margin of error increases.
• When measuring with the pump mounted on the machine, if it is impossible to set the engine speed to the
specified speed by using the fuel control dial, take the pump discharged volume and the engine speed at the
time of measurement, and use them as a base for figuring out the pump discharged volume at the specified
speed.

HB365LC-3 20-29
STANDARD VALUE TABLE FOR MACHINE: HB365LC-3 20 STANDARD VALUE TABLE

Hybrid system
Machine model HB365LC-3
Engine SAA6D114E-6
Standard value for
Item Measurement condition Unit Repair limit
new machine

Lubrication oil • Fuel control dial: MAX (High idle) posi-

pressure of tion MPa 0.3 0.3
electric swing • Work equipment control lever, control {kg/cm2} {Mx. 3.1} {Mx. 3.1}
motor case pedal: NEUTRAL position

Lubrication oil • Fuel control dial: MAX (High idle) posi-

pressure of tion MPa 0.6 0.6
generator oil • Work equipment control lever, control {kg/cm2} {Less than 6.1} {Less than 6.1}
case pedal: NEUTRAL position
• Fuel control dial: MAX (High idle) posi-
Swing motor tion
N 0.00 Other than 0.00
torque • Work equipment control lever, control
pedal: NEUTRAL position
• Engine coolant temperature: 60 to
100 °C
• Engine: Running
• Battery voltage (Monitoring code
(03203)): Min. 20 V
Performance of MPa P P
hybrid water • Fuel control dial: MAX (High idle) posi-
pump tion or MIN (Low idle) position {kg/cm2} (See graph) (*3) (See graph) (*3)
• Read the value (a) in the column of the
monitoring code 01142Service Press
(HYB Water Pump), and convert it by
the formula shown below.
Water pressure (P) = a/500 (MPa)

*3: If the pressure of the hybrid water pump changes when the connector of a hybrid water pump is disconnect-
ed, the hybrid water pump is working properly. If the pressure of the water pump does not change, there is a
problem with the hybrid water pump.

20-30 HB365LC-3
20 STANDARD VALUE TABLE STANDARD VALUE TABLE FOR MACHINE: HB365LC-3

a: Both hybrid water pumps operate normally c: Neither of hybrid water pumps work
b: Either one of the hybrid water pumps operates nor-
mally

HB365LC-3 20-31
MACHINE POSTURE AND PROCEDURE FOR MEASURING PER-
FORMANCE 20 STANDARD VALUE TABLE

MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORM-

ANCE (HB335_3-K-0000-321-00-B)

Fig. 1

Fig. 2

Fig. 3

Fig. 4

20-32 HB365LC-3
 MACHINE POSTURE AND PROCEDURE FOR MEASURING PER-
20 STANDARD VALUE TABLE FORMANCE

Fig. 5

Fig. 6

Fig. 7

Fig. 8

HB365LC-3 20-33
MACHINE POSTURE AND PROCEDURE FOR MEASURING PER-
FORMANCE 20 STANDARD VALUE TABLE

Fig. 9

Fig. 10

Fig. 11

Fig. 12

20-34 HB365LC-3
 MACHINE POSTURE AND PROCEDURE FOR MEASURING PER-
20 STANDARD VALUE TABLE FORMANCE

Fig. 13

Fig. 14

HB365LC-3 20-35
 30 TESTING AND ADJUSTING

HB365LC-3 30-1
CONTENTS 30 TESTING AND ADJUSTING

CONTENTS (ALL-A-0310-002-00-B)
ABBREVIATION LIST .................................................................................................................................... 30-5
RELATED INFORMATION ON TESTING AND ADJUSTING ........................................................................30-11
TOOLS FOR TESTING AND ADJUSTING.............................................................................................30-11
SKETCH OF TOOLS FOR TESTING AND ADJUSTING ...................................................................... 30-18
ENGINE AND COOLING SYSTEM.............................................................................................................. 30-20
TEST ENGINE SPEED ......................................................................................................................... 30-20
METHOD FOR TESTING ENGINE SPEED ................................................................................... 30-20
TEST BOOST PRESSURE................................................................................................................... 30-23
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR.................................... 30-23
METHOD FOR TESTING BOOST PRESSURE............................................................................. 30-24
TEST EXHAUST GAS COLOR ............................................................................................................. 30-25
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER .................... 30-25
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER ...................................... 30-26
TEST AND ADJUST VALVE CLEARANCE ........................................................................................... 30-28
METHOD FOR TESTING VALVE CLEARANCE ............................................................................ 30-28
METHOD FOR ADJUSTING VALVE CLEARANCE ....................................................................... 30-30
TEST COMPRESSION PRESSURE..................................................................................................... 30-31
METHOD FOR TESTING COMPRESSION PRESSURE............................................................... 30-31
TEST BLOWBY PRESSURE ................................................................................................................ 30-34
METHOD FOR TESTING BLOWBY PRESSURE .......................................................................... 30-34
TEST ENGINE OIL PRESSURE ........................................................................................................... 30-36
METHOD FOR TESTING ENGINE OIL PRESSURE ..................................................................... 30-36
TEST EGR VALVE AND VGT OIL PRESSURE .................................................................................... 30-38
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE .............................................. 30-38
TEST FUEL PRESSURE ...................................................................................................................... 30-40
METHOD FOR TESTING FUEL PRESSURE ................................................................................ 30-41
TEST FUEL DISCHARGE, RETURN AND LEAKAGE .......................................................................... 30-48
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE .................................... 30-49
BLEED AIR FROM FUEL SYSTEM ...................................................................................................... 30-56
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM ................................................................ 30-56
TEST FUEL CIRCUIT FOR LEAKAGE ................................................................................................. 30-57
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE ........................................................... 30-57
HANDLE CYLINDER CUT-OUT MODE OPERATION........................................................................... 30-59
HANDLE NO-INJECTION CRANKING OPERATION ............................................................................ 30-60
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION ........................................ 30-61
METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT....................................... 30-61
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT ..................................... 30-61
TEST COOLING FAN SPEED ............................................................................................................. 30-63
METHOD FOR TESTING COOLING FAN SPEED ........................................................................ 30-63
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER ....................... 30-64
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROL-
LER ............................................................................................................................................ 30-64
TEST SCR RELATED FUNCTIONS...................................................................................................... 30-65
TEST AdBlue/DEF PUMP RAISED PRESSURE ........................................................................... 30-68
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR ....................................................... 30-71
TEST AdBlue/DEF LINE HEATER RELAY 1 ................................................................................. 30-75
TEST AdBlue/DEF LINE HEATER RELAY 2 ................................................................................. 30-77
TEST AdBlue/DEF PUMP HEATER RELAY................................................................................... 30-80
TEST AdBlue/DEF TANK HEATER VALVE .................................................................................... 30-83
TEST DENITRATION EFFICIENCY OF SCR................................................................................. 30-86
CLEAN AdBlue/DEF TANK ................................................................................................................... 30-90
METHOD FOR CLEANING AdBlue/DEF TANK ............................................................................. 30-90
HYBRID SYSTEM........................................................................................................................................ 30-95
PRECAUTIONS FOR USING HYBRID SYSTEMS ............................................................................... 30-95
DRAIN, REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT .............................................. 30-96
METHOD FOR DRAINING THE HYBRID SYSTEM COOLANT..................................................... 30-97

30-2 HB365LC-3
30 TESTING AND ADJUSTING CONTENTS

REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT ...................................................30-100

WATER PRESSURE TEST OF THE HYBRID SYSTEM COOLANT ....................................................30-102
METHOD FOR TESTING THE WATER PRESSURE OF THE HYBRID SYSTEM COOLANT ......30-102
TEST LUBRICATION CIRCUIT OIL PRESSURE OF HYBRID SYSTEM .............................................30-104
TEST LUBRICATION CIRCUIT OIL PRESSURE OF ELECTRIC SWING MOTOR CASE............30-104
TEST LUBRICATION CIRCUIT OIL PRESSURE OF MOTOR-GENERATOR OIL CASE .............30-104
TEST SWING PARKING BRAKE PRESSURE.....................................................................................30-106
METHOD FOR TESTING THE SWING PARKING BRAKE PRESSURE.......................................30-106
TEST AND CLEAN DELIVERY FILTER OF SWING MOTOR ..............................................................30-108
METHOD FOR CHECKING AND CLEANING ELECTRIC SWING MOTOR COOLING OIL DELIVERY
FILTER ......................................................................................................................................30-108
POWER TRAIN...........................................................................................................................................30-109
TEST SWING CIRCLE BEARING CLEARANCE .................................................................................30-109
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE ...........................................30-109
UNDERCARRIAGE AND FRAME...............................................................................................................30-110
TEST AND ADJUST TRACK TENSION...............................................................................................30-110
METHOD FOR TESTING TRACK TENSION ................................................................................30-110
METHOD FOR ADJUSTING TRACK TENSION ...........................................................................30-110
HYDRAULIC SYSTEM................................................................................................................................30-112
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM...................................................30-112
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK ....................30-112
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT ...30-112
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT ........30-115
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT AND TRAVEL CIRCUITS ..................30-116
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, AND TRAVEL CIRCUITS ...30-117
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,AND TRAVEL CIRCUITS ..........
..................................................................................................................................................30-122
TEST OIL PRESSURE OF CONTROL CIRCUIT .................................................................................30-125
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT ...........................................30-125
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT ..........................................30-127
METHOD FOR TESTING PC VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) ......
..................................................................................................................................................30-127
METHOD FOR TESTING PC-EPC VALVE OUTLET PRESSURE ................................................30-128
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT.......................30-129
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT...........................................30-131
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE WITH MACHINE MONITOR .............30-131
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE..........................................................30-132
METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET PRESSURE) .......
..................................................................................................................................................30-134
METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE.................................................30-136
METHOD FOR ADJUSTING LS VALVE........................................................................................30-136
TEST OUTLET PRESSURE OF SOLENOID VALVE ...........................................................................30-138
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE .....................................30-138
OPERATING CONDITION OF SOLENOID VALVE .......................................................................30-139
TEST PPC VALVE OUTPUT PRESSURE............................................................................................30-142
METHOD FOR TESTING PPC VALVE OUTLET PRESSURE ......................................................30-142
ADJUST WORK EQUIPMENT AND SWING PPC VALVES .................................................................30-144
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES............30-144
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE..........30-145
TEST PUMP SWASH PLATE SENSOR...............................................................................................30-147
METHOD FOR TESTING PUMP SWASH PLATE SENSOR.........................................................30-147
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT.......................................30-148
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND
BUCKET CYLINDER.................................................................................................................30-148
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER......30-148
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE .............30-149
TEST OIL LEAKAGE ...........................................................................................................................30-150
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER ...........................................30-150

HB365LC-3 30-3
CONTENTS 30 TESTING AND ADJUSTING

METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER ..............................................30-151

METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER ........................................30-151
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR..............................................30-152
BLEED AIR FROM HYDRAULIC CIRCUIT ..........................................................................................30-153
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT ....................................................30-153
CAB AND ITS ATTACHMENTS ..................................................................................................................30-156
TEST CAB TIPPING STOPPER ..........................................................................................................30-156
METHOD FOR TESTING CAB TIPPING STOPPER ....................................................................30-156
METHOD FOR ADJUSTING MIRRORS ..............................................................................................30-157
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A).....................................30-157
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A)......
..................................................................................................................................................30-158
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) ..................................30-159
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B)....
..................................................................................................................................................30-160
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) ......................................30-161
ELECTRICAL SYSTEM ..............................................................................................................................30-163
SET AND OPERATE MACHINE MONITOR.........................................................................................30-163
OPERATOR MODE .....................................................................................................................30-166
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN ............................30-167
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN .................................30-167
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) ..................................................30-168
CHECKING FUNCTION OF SERVICE METER ............................................................................30-168
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD ..........................30-168
SERVICE MODE...........................................................................................................................30-171
METHOD FOR OPERATING SERVICE MODE ............................................................................30-171
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION ................................30-173
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION .................................30-182
ABNORMALITY RECORD MENU.................................................................................................30-195
METHOD FOR CONFIRMING MAINTENANCE RECORD ...........................................................30-199
METHOD FOR OPERATING MAINTENANCE MODE SETTING..................................................30-200
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING .............................................30-204
DEFAULT MENU...........................................................................................................................30-205
DIAGNOSTIC TESTS MENU........................................................................................................30-213
ADJUSTMENT MENU ..................................................................................................................30-227
METHOD FOR PERFORMING NO-INJECTION CRANKING .......................................................30-247
KOMTRAX SETTINGS MENU ......................................................................................................30-248
METHOD FOR DISPLAYING SERVICE MESSAGE .....................................................................30-251
METHOD FOR STARTING UP KOMTRAX TERMINAL .......................................................................30-253
ADJUST REARVIEW CAMERA ANGLE ..............................................................................................30-258
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE .......................................................30-258
ADJUST KomVision CAMERA ANGLE ................................................................................................30-261
METHOD FOR ADJUSTING KomVision CAMERA ANGLE ..........................................................30-262
ADJUST KomVision RELATED ITEMS ................................................................................................30-266
SETTING OF KomVision (MAIN SETTING) ..................................................................................30-266
SETTING OF KomVision (CAMERA SETTING) ............................................................................30-268
SETTING OF KomVision (CAMERA CALIBRATION) ....................................................................30-270
KomVision screen - Check 12 m visibility ......................................................................................30-283
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER ................................................................30-286
HANDLE BATTERY DISCONNECT SWITCH ......................................................................................30-287
TEST DIODES .....................................................................................................................................30-288
METHOD FOR TESTING DIODE USING DIGITAL TESTER ........................................................30-288
METHOD FOR TESTING DIODE USING ANALOG TESTER.......................................................30-288
Pm CLINIC..................................................................................................................................................30-289
Pm CLINIC SERVICE ..........................................................................................................................30-289
Pm CLINIC CHECK SHEET:HB365LC-3.......................................................................................30-290

30-4 HB365LC-3
30 TESTING AND ADJUSTING ABBREVIATION LIST

ABBREVIATION LIST (ALL-A-0360-005-00-B)

• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).

HB365LC-3 30-5
ABBREVIATION LIST 30 TESTING AND ADJUSTING

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
This is an electronic control device that send the
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.

30-6 HB365LC-3
30 TESTING AND ADJUSTING ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.

HB365LC-3 30-7
ABBREVIATION LIST 30 TESTING AND ADJUSTING

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a service that allows transmission and re-
Multimedia Messaging
MMS Communication ception of short messages consisting of charac-
Service
ters or voice or images between cell phones.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NC Normally Closed circuits. Circuit is normally closed if it is not actu-
system
ated, and it opens when it is actuated.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NO Normally Open circuits. Circuit is normally open if it is not actuat-
system
ed, and it closes when it is actuated.
This is a hydraulic system that can operate multi-
Open-center Load
OLSS Hydraulic system ple actuators at the same time regardless of the
Sensing System
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
Steering This is a function that electrically controls the en-
Palm command control gine and transmission in an optimal way with the
PCCS
system (D Series) controller instantly analyzing data from levers,
pedals, and dials.
This is a valve that adjusts the fuel intake amount
PCV Pre-stroke Control Valve Engine at the pump inlet in order to control fuel dis-
charged volume of supply pump.
Proportional Pressure This is a system that operates actuators in pro-
PPC Hydraulic system
Control portion to the oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Work equipment This is a function that performs hydraulic control
Power Tilt and power
PTP of the tilt and pitch of the dozer blade of the bull-
Pitch dozer (D Series) dozer.
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
Roll-Over Protective crushed when the machine rolls over. (Roll-over
ROPS Cab and canopy
Structure protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
Selective Catalytic Re- less nitrogen and water by oxidation-reduction re-
SCR Urea SCR system
duction action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
Le Systeme Internation- Abbreviation for "International System of Units" It
SI al d' Unites (Internation- Unit is the universal unit system and "a single unit for
al unit system) a single quantity" is the basic principle applied.
This is an actuator that consists of a solenoid and
SOL Solenoid Electrical system an iron core that is operated by the magnetic
force when the solenoid is energized.

30-8 HB365LC-3
30 TESTING AND ADJUSTING ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.

*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection

HB365LC-3 30-9
ABBREVIATION LIST 30 TESTING AND ADJUSTING

Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

30-10 HB365LC-3
30 TESTING AND ADJUSTING TOOLS FOR TESTING AND ADJUSTING

RELATED INFORMATION ON TESTING AND ADJUSTING

(PC400_10-A-3831-001-00-B)

TOOLS FOR TESTING AND ADJUSTING (HB335_3-A-5320-304-00-B)

Tools for testing the boost pressure

Symbol Part No. Part name Q'ty Remarks
- 799-201-2002 Boost gauge kit 1
A 1 799-401-2311 Gauge 1 -101 to 200 kPa {-760 to 1500 mmHg}
2 799-101-5160 Nipple 1 Size: R1/8
B - 799-401-2301 Pm kit 1
1 790-261-1130 Coupling 1

Tools for testing the exhaust gas color

Symbol Part No. Part name Q'ty Remarks
A 799-201-9002 Handy smoke checker 1
- Commercially
Smoke meter 1
available
B
1 Commercially
Probe 1
available

Tools for testing and adjusting the valve clearance

Symbol Part No. Part name Q'ty Remarks
A 795-799-1131 Gear 1
B Commercially
Feeler gauge 1
available

Tools for testing the compression pressure

Symbol Part No. Part name Q'ty Remarks
A 795-502-1590 Gauge assembly 1 Pressure range: 0 to 7 MPa
B 795-799-6700 Puller 1
C 795-790-6111 Adapter 1
D 6754-11-3130 Gasket 1
E 795-799-8150 Remover 1

HB365LC-3 30-11
TOOLS FOR TESTING AND ADJUSTING 30 TESTING AND ADJUSTING

Tools for testing the blowby pressure

Symbol Part No. Part name Q'ty Remarks
- 799-201-1506 Blowby checker 1
1 799-201-1541 Gauge 1 Pressure range: 10 kPa
A
2 799-201-1511 Tool 1
3 799-201-1450 Adapter 1
B Commercially Hose inside diameter: 24 mm
Plug 1
available
C Commercially Tube inside diameter: 25.4 mm
Cap 2
available

Tools for testing the engine oil pressure

Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A
1 799-101-5160 Nipple 1 Size: R1/8
B 799-401-2320 Gauge 1 Pressure range: 1 MPa
C 6732-81-3170 Adapter 1 Size: M10 x 1.0 mm
D 6215-81-9710 O-ring 1

Tools for testing EGR valve and VGT oil pressure

Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A 1 799-101-5140 Gauge 1 Pressure range: 2.5 MPa
2 799-101-5160 Nipple 1 Size: R1/8
B 799-401-3100 Adapter 1 Size: 02
C 799-401-3200 Adapter 1 Size: 03

Testing tools for fuel pressure

Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A
1 799-101-5160 Nipple 2 Size: R1/8
B 799-401-2320 Gauge 2 Pressure range: 1 MPa
C 6732-81-3170 Adapter 2 Size: M10 × 1.0 mm → R1/8
D 6215-81-9710 O-ring 2
E 795-790-5100 Screw 2 Size: M12x1.5 mm
F 9745-71-1130 Seal washer 1
795-790-1500
G or Vacuum gauge 1
799-201-1201
H 795-790-5200 Adapter kit 1
J 795-790-5010 Screw 1
K 795-790-1150 Pressure gauge 1

30-12 HB365LC-3
30 TESTING AND ADJUSTING TOOLS FOR TESTING AND ADJUSTING

Tools for testing fuel discharge, return and leakage

Symbol Part No. Part name Q'ty Remarks
A 795-790-4800 Tester kit 1
B 6164-81-5790 Joint 1
C 07206-30812 Joint bolt 1
D 6745-71-1130 Seal washer 3
E Commercially
Stopwatch 1
available

Commercially • Length: Approx. 2 m

F Hose 1
available • Inside diameter: Approx. 14 mm
Commercially Capacity: 200 to 500 mℓ
G Measuring cylinder 1
available

Commercially • Length: Approx. 2 m

H Hose 1
available • Inside diameter: Approx. 8 mm
J 795-790-6210 Fitting 1
K 795-790-5600 Hose 1
L 795-790-6500 Adapter 1
M Commercially Capacity: Approx. 20 ℓ
Oil container 1
available

Tools for testing the leakage in fuel system

Symbol Part No. Part name Q'ty Remarks
Commercially Developer for dye penetrant (color
A 1
available checker)

Tools for testing the injection amount from the AdBlue/DEF injector
Symbol Part No. Part name Q'ty Remarks
A 799-601-4340 Socket 1
Commercially
B Multimeter 1
available
Commercially Container made of polyethylene or poly-
C Resin container 1
available propylene: Approx. 200 mℓ
Commercially Capacity: 200 to 500 mℓ
D Measuring cylinder 1
available
E Commercially
Rubber gloves 1
available

Testing tools for AdBlue/DEF line heater relay 1

Symbol Part No. Part name Q'ty Remarks
A 799-601-9020 T-adapter 1
B 799-601-2600 T-box 1
C Commercially
Multimeter 1
available

HB365LC-3 30-13
TOOLS FOR TESTING AND ADJUSTING 30 TESTING AND ADJUSTING

Testing tools for AdBlue/DEF line heater relay 2

Symbol Part No. Part name Q'ty Remarks
A 799-601-9020 T-adapter 1
B 799-601-2600 T-box 1
C Commercially
Multimeter 1
available

Testing tools for AdBlue/DEF pump heater relay

Symbol Part No. Part name Q'ty Remarks
A 799-601-9130 T-adapter 1
B 799-601-2600 T-box 1
C Commercially
Multimeter 1
available

Testing tools for AdBlue/DEF tank heater valve

Symbol Part No. Part name Q'ty Remarks
A 799-601-9020 T-adapter 1
B 799-601-2600 T-box 1
C Commercially
Multimeter 1
available

Tools for testing cleaning of AdBlue/DEF tank

Symbol Part No. Part name Q'ty Remarks
Commercially
A Oil container 4 Made of plastic (for drained AdBlue/DEF)
available
- Commercially
Remote breather hose 1
available
1 Commercially (ASOH Co., LTD ASOH CICCOLO:
Valve 1
available Equivalent to CY-2208)
B
2 Commercially Approximately 2 m, TOYOX TOYOSILI-
Hose 1
available CONE, TSI-8 or equivalent
3 Commercially Made of stainless steel
Joint 1
available
C Commercially For cleaning: 30 ℓ
AdBlue/DEF 1
available
D Commercially
Rubber gloves 1
available

30-14 HB365LC-3
30 TESTING AND ADJUSTING TOOLS FOR TESTING AND ADJUSTING

Tools for draining, refilling, air bleeding of hybrid system coolant

Symbol Part No. Part name Q'ty Remarks
Commercially
A Oil container 2 Capacity: Approx. 20 ℓ
available
SYCG-AF-
B Super Coolant 1 Undiluted solution: 3.5 to 6.8 ℓ
NACCNK
C 207-03-22480 Clip 1

Commercially • Length: Approx. 2 m

D Hose 1
available • Inside diameter: Approx. 25 mm

Tools for water pressure test of hybrid system coolant

Symbol Part No. Part name Q'ty Remarks
- 796-403-1100 Pressure checker 1
1 796-403-1110 Pressure sensor 1
A 2 195-40-31670 Plug 1
3 07002-11823 O-ring 1
4 796-403-1120 Tool box 1

Testing tools for lubrication circuit oil pressure of hybrid system

Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A
1 799-101-5140 Gauge 1 Pressure range: 2.5 MPa
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-101-5220 Nipple 1 Size: M10x1.25
D 07002-11023 O-ring 1

Testing tools for delivery filter of swing motor

Symbol Part No. Part name Q'ty Remarks
A 7875-13-3421 Oil filter 1
B 07002-11623 O-ring 1
C 07000-11010 O-ring 1

Tools for testing the swing circle bearing clearance

Symbol Part No. Part name Q'ty Remarks
Commercially
A Dial gauge 1
available

Tools for testing the track tension

Symbol Part No. Part name Q'ty Remarks
Commercially
A Wooden block 1
available

HB365LC-3 30-15
TOOLS FOR TESTING AND ADJUSTING 30 TESTING AND ADJUSTING

Tools for testing and adjusting the oil pressure in work equipment circuit and travel circuit
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A 1 799-101-5110 Gauge 1 Pressure range: 60 MPa
2 799-101-5130 Gauge 1 Pressure range: 6 MPa
B - 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-101-5220 Nipple 2 Size: M10 x 1.25 mm
D 07002-11023 O-ring 2
• MaterialSS400
Commercially
E Pin 1 • Diameter: 80 mm
available
• Length: 200 mm

Commercially • MaterialSS400
F Plate 1
available • Size250 × 260 × 32 (mm)

Testing and adjusting tools for oil pressure in the control circuit
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A
1 799-101-5130 Gauge 1 Pressure range: 6 MPa
B - 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-101-5220 Nipple 1 Size: M10 x 1.25 mm
D 07002-11023 O-ring 1

Testing and adjusting tools for the oil pressure in the pump PC control circuit
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A 1 799-101-5110 Gauge 1 Pressure range: 60 MPa
2 799-101-5130 Gauge 1 Pressure range: 6 MPa
B - 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-101-5220 Nipple 4 Size: M10 x 1.25 mm
D 07002-11023 O-ring 4

Testing and adjusting tools for the oil pressure in the pump LS control circuit
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A 1 799-101-5110 Gauge 1 Pressure range: 60 MPa
2 799-101-5130 Gauge 1 Pressure range: 6 MPa
B - 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-101-5220 Nipple 4 Size: M10 x 1.25 mm
D 07002-11023 O-ring 4
E 799-401-2701 Differential pressure gauge 1 Pressure range: 50 MPa
F 796T-440-1101 Sensor adapter 1 Pressure range: 50 MPa

30-16 HB365LC-3
30 TESTING AND ADJUSTING TOOLS FOR TESTING AND ADJUSTING

Tools for testing the outlet pressure of the solenoid valve

Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A 1 799-101-5130 Gauge 1 Pressure range: 6 MPa
2 799-101-5160 Nipple 1 Size: R1/8
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-401-3100 Adapter 1 Size: 02
D 02896-11008 O-ring 1
E 799-401-3200 Adapter 1 Size: 03
F 02896-11009 O-ring 1

Tools for testing the PPC valve outlet pressure

Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A 1 799-101-5130 Gauge 1 Pressure range: 6 MPa
2 799-101-5160 Nipple 1 Size: R1/8
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 790-301-1730 Joint 1 PF1/4 × Rc1/8
D 07000-12011 O-ring 1

Tools for testing the oil leakage

Symbol Part No. Part name Q'ty Remarks
Commercially
A Measuring cylinder 1
available
B 07379-01044 Flange 2 Size: 10
C 07379-00640 Flange 1 Size: 06
D 07376-70522 Plug 1 Size: 04
• MaterialSS400
Commercially
E Pin 1 • Diameter: 80 mm
available
• Length: 200 mm

Commercially • MaterialSS400
F Plate 1
available • Size250 × 260 × 32 (mm)

HB365LC-3 30-17
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 30 TESTING AND ADJUSTING

SKETCH OF TOOLS FOR TESTING AND ADJUSTING (PC400_10-A-5320-050-00-B)

Note: Komatsu does not take any responsibility for special tools manufactured according to these sketches.
Sensor adapter

Nipple

30-18 HB365LC-3
30 TESTING AND ADJUSTING SKETCH OF TOOLS FOR TESTING AND ADJUSTING

Socket

Plug

HB365LC-3 30-19
TEST ENGINE SPEED 30 TESTING AND ADJUSTING

ENGINE AND COOLING SYSTEM (ALL-K-A000-001-30-B)

TEST ENGINE SPEED (HB335_3-K-A000-304-00-B)

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
Check this item under the following conditions.
• Engine coolant temperature: 60 to 100 °C
• Hydraulic oil temperature: 45 to 55 °C
For testing of engine speed to perform troubleshooting, refer to this section.

METHOD FOR TESTING ENGINE SPEED (HB335_3_E-K-A000-388-00-B)

Check this item with Pre-defined Monitoring or Monitoring function of the machine monitor.

Testing the engine speed at high idle

1. Start the engine.
2. Select “Pre-defined Monitoring” (01/28) or “Monitoring Se-
lection Menu” and display the following monitoring items
by referring to “SET AND OPERATE MACHINE MONI-
TOR”.
Monitoring code: 01002 “Engine Speed”
Monitoring code: 04107 “Coolant Temperature”
Monitoring code: 04401 “Hydraulic Oil Temperature”
3. Keep the engine coolant temperature and the hydraulic oil
temperature in the testing condition range.
4. Set the working mode to B (“Breaker Mode”).
5. Turn off the auto-deceleration.
6. Turn the swing lock switch to ON position.
7. Turn the fuel control dial to MAX (High idle) position.
8. Check the engine speed when all control levers and control pedals are in NEUTRAL position.
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”.

Testing the engine speed at low idle

The engine speed at low idle becomes higher during the aftertreatment devices regeneration, and the engine
speed cannot be tested correctly. If the aftertreatment devices regeneration pilot lamp is still lit, perform the test
after the aftertreatment devices regeneration is done.
REMARK
When the aftertreatment devices regeneration is finished, the
aftertreatment devices regeneration pilot lamp goes out.

1. Start the engine.

30-20 HB365LC-3
30 TESTING AND ADJUSTING TEST ENGINE SPEED

2. Select “Pre-defined Monitoring” (01/28) or “Monitoring Se-

lection Menu” and display the following monitoring items
by referring to “SET AND OPERATE MACHINE MONI-
TOR”.
Monitoring code: 01002 “Engine Speed”
Monitoring code: 04107 “Coolant Temperature”
Monitoring code: 04401 “Hydraulic Oil Temperature”
3. Keep the engine coolant temperature and the hydraulic oil
temperature in the testing condition range.
4. Set the working mode to P (“Power Mode”).
5. Set the fuel control dial to MIN (Low idle) position.
6. Check the engine speed when all control levers and control pedals are in NEUTRAL position.
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”.

Test the engine speed at 2-pump relief

1. Start the engine.
2. Select “Pre-defined Monitoring” (01/28) or “Monitoring Se-
lection Menu” and display the following monitoring items
by referring to “SET AND OPERATE MACHINE MONI-
TOR”.
Monitoring code: 01002 “Engine Speed”
Monitoring code: 04107 “Coolant Temperature”
Monitoring code: 04401 “Hydraulic Oil Temperature”
3. Keep the engine coolant temperature and the hydraulic oil
temperature in the testing condition range.
4. Set the working mode to P (“Power Mode”).
5. Turn off the auto-deceleration.
6. Turn the fuel control dial to MAX (High idle) position.
7. Operate the L.H. work equipment control lever to check the engine speed at arm IN relief.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.

Testing the engine speed (Engine rated speed) at 2-pump relief + one-touch
power maximizing function
1. Start the engine.
2. Select “Pre-defined Monitoring” (01/28) or “Monitoring Se-
lection Menu” and display the following monitoring items
by referring to “SET AND OPERATE MACHINE MONI-
TOR”.
Monitoring code: 01002 “Engine Speed”
Monitoring code: 04107 “Coolant Temperature”
Monitoring code: 04401 “Hydraulic Oil Temperature”
3. Keep the engine coolant temperature and the hydraulic oil
temperature in the testing condition range.
4. Set the working mode to P (“Power Mode”).
5. Turn off the auto-deceleration.
6. Turn the fuel control dial to MAX (High idle) position.
7. While operating L.H. work equipment control lever to arm IN relief and keeping pressing the one-touch pow-
er maximizing switch (Max. 8.5 seconds), check the engine speed.

HB365LC-3 30-21
TEST ENGINE SPEED 30 TESTING AND ADJUSTING

REMARK
One-touch power maximizing function is automatically released after approximately 8.5 seconds even if the
One-touch power maximizing switch is kept pressed. Test the engine speed before the function is released.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.

Test the engine speed during auto-deceleration

1. Start the engine.
2. Select “Pre-defined Monitoring” (01/28) or “Monitoring Se-
lection Menu” and display the following monitoring items
by referring to “SET AND OPERATE MACHINE MONI-
TOR”.
Monitoring code: 01002 “Engine Speed”
Monitoring code: 04107 “Coolant Temperature”
Monitoring code: 04401 “Hydraulic Oil Temperature”
3. Keep the engine coolant temperature and the hydraulic oil
temperature in the testing condition range.
4. Set the working mode to P (“Power Mode”).
5. Turn on the auto-deceleration.
6. Turn the fuel control dial to MAX (High idle) position.
7. Check the engine speed when auto-decelerator is operated after double checking that all control levers and
control pedals are in NEUTRAL position.
REMARK
If all control levers and control pedals remain NEUTRAL for more than 4 seconds, the engine speed de-
creases to the auto deceleration activation speed. Check the engine speed at this time. (For details, see
STRUCTURE AND FUNCTION, “ENGINE SYSTEM”.)
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.

30-22 HB365LC-3
30 TESTING AND ADJUSTING TEST BOOST PRESSURE

TEST BOOST PRESSURE (HB335_3-K-A900-304-00-B)

Tools for testing the boost pressure

Symbol Part No. Part name Q'ty Remarks
- 799-201-2202 Boost gauge kit 1
Pressure range: -101 to 200 kPa {-760 to
A 1 799-401-2311 Gauge 1
1500 mmHg}
2 799-101-5160 Nipple 1 Size: R1/8
- 799-401-2301 Pm kit 1
B
1 790-261-1130 Coupling 1

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
Check this item under the following conditions.
• Engine coolant temperature: 60 to 100 °C
• Hydraulic oil temperature: 45 to 55 °C
For testing of boost pressure to perform troubleshooting, refer to this section.

METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR

(HB335_3_E-K-A900-362-00-B)
1. Start the engine.
2. Select and display “SET AND OPERATE MACHINE MONITOR” (01/28). See “SET AND OPERATE MA-
CHINE MONITOR”.
3. Keep the engine coolant temperature and the hydraulic oil temperature in the testing condition range.
4. Select and display the following monitoring items on “Pre-
defined Monitoring” (05/28) or “Monitoring Selection
Menu”.
Monitoring code: 37400 “Ambient Pressure”
Monitoring code: 36500 “Charge Pressure”
5. Set the working mode to P (“Power Mode”).
6. Turn off the auto-deceleration.
7. Turn the swing lock switch to ON position.
REMARK
If the swing lock switch is turned on, the main relief valve
is set for high-pressure relief.
8. Turn the fuel control dial to MAX (High idle) position.
9. Operate the work equipment control lever, and test the boost pressure with arm IN relief + one-touch power
maximizing ON.
For standard values, see the absolute pressure in STANDARD VALUE TABLE, “STANDARD VALUE TA-
BLE FOR ENGINE”.
REMARK
• The absolute pressure includes the atmospheric pressure. Check the atmospheric pressure because
the pressure changes with altitude.
• The relationship between the absolute pressure and the gauge pressure.
Absolute pressure = Gauge pressure + Atmospheric pressure

HB365LC-3 30-23
TEST BOOST PRESSURE 30 TESTING AND ADJUSTING

METHOD FOR TESTING BOOST PRESSURE (HB335_3-K-A900-362-01-B)

1. Open the engine hood.
2. Remove the boost pressure pickup plug (1).

3. Install the nipple A2 of the boost gauge kit A, and connect

them to the gauge A1.
4. Start the engine.
5. Keep the engine speed at medium or higher by adjusting
the fuel control dial.
6. Insert the gauge half-way into the connecting part of gauge
and hose to drain the oil.
REMARK
• If Pm kit B is available, you can use the air bleeding
coupling B1 in the kit.
• If any oil remains in the hose, the gauge does not work
normally. Be sure to drain the oil remaining in the hose.
7. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
8. Keep the engine coolant temperature and the hydraulic oil
temperature in the testing condition range.
9. Set the working mode to P (“Power Mode”).
10. Turn off the auto-deceleration.
11. Turn the swing lock switch to ON position.
REMARK
If the swing lock switch is turned on, the main relief valve is set for high-pressure relief.
12. Turn the fuel control dial to MAX (High idle) position.
13. Operate the work equipment control lever, and test the boost pressure with arm IN relief + one-touch power
maximizing ON.
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”.
REMARK
• The absolute pressure includes the atmospheric pressure. Check the atmospheric pressure because
the pressure changes with altitude.
• The relationship between the absolute pressure and the gauge pressure.
Gauge pressure = Absolute pressure - Atmospheric pressure
After finishing the test, remove the testing tools and restore the machine.
3 Boost pressure pickup plug (1):
15±2 Nm {1.5±0.2 kgm}

30-24 HB365LC-3
30 TESTING AND ADJUSTING TEST EXHAUST GAS COLOR

TEST EXHAUST GAS COLOR (HB335_3-K-A900-304-01-B)

Tools for testing the exhaust gas color

Symbol Part No. Part name Q'ty Remarks
A 799-201-9002 Handy smoke checker 1
- Commercially
Smoke meter 1
available
B
1 Commercially
Probe 1
available

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
Check this item under the following conditions.
Engine coolant temperature: 60 to 100 °C
If an air source and an electric power source are not available in the field, use the handy smoke checker A. Use
the smoke meter B when recording the official data, etc.
For testing of exhaust gas color to perform troubleshooting, refer to this section.

METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER

(HB335_3-K-A900-385-00-B)
1. Open the engine hood.
2. Remove the plug (1).

HB365LC-3 30-25
TEST EXHAUST GAS COLOR 30 TESTING AND ADJUSTING

3. Fit a sheet of filter paper to the handy smoke checker A.

Insert the exhaust gas intake pipe of handy smoke checker
A into port (a) or tail pipe (b) for removed plug (1).
REMARK
Insert the handy smoke checker A so that its tip is at the
center of the piping, and it is in parallel with the piping.
4. Start the engine.
5. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
6. Raise the coolant temperature to the specified range.
7. Turn off the auto-deceleration.
8. Turn the swing lock switch to ON position.
9. Turn the fuel control dial to MAX (High idle) position.
10. Operate the work equipment control lever and collect the
exhaust gas to the filter paper by operating the handle of
smoke checker A at arm IN relief.
REMARK
• When collecting the exhaust gas with fuel control dial
at MAX (High idle) position, hold the dial in place for 5
seconds.
• Collecting time: 1.4±0.2 seconds
11. Remove the filter paper and compare it with the attached scale for judgment.
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”.
After finishing the test, remove the testing tools and restore the machine.
2 Plug (1):
Seizure prevention compound (LC-G)
3 Plug (1):
51.0 to 85.3 Nm {5.2 to 8.7 kgm}

METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER

(HB335_3-K-A900-385-01-B)
1. Open the engine hood.
2. Remove the plug (1).

30-26 HB365LC-3
30 TESTING AND ADJUSTING TEST EXHAUST GAS COLOR

3. Insert the probe B1 of smoke meter B into the port (a) for
removed plug (1) or tail pipe (b).
REMARK
Insert the probe B1 so that its tip is at the center of the pip-
ing, and it is in parallel with the piping.
4. Set the smoke meter B for inspection.
REMARK
For the operation method of the smoke meter B, see Oper-
ation and Maintenance Manual for the smoke meter B.
5. Start the engine.
6. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
7. Raise the coolant temperature to the specified range.
8. Turn off the auto-deceleration.
9. Turn the swing lock switch to ON position.
10. Turn the fuel control dial to MAX (High idle) position.
11. Operate the work equipment control lever and collect the
exhaust gas to the filter paper by operating the smoke me-
ter B at arm IN relief.
REMARK
• When collecting the exhaust gas with fuel control dial
at MAX (High idle) position, hold the dial in place for 5
seconds.
• For the operation method of smoke meter B, see Oper-
ation and Maintenance Manual for the smoke meter.
12. Place the contaminated filter paper on the clean filter pa-
per (at least 10 sheets) in the filter paper holder and read
the indicated value.
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”.
After finishing the test, remove the testing tools and restore the machine.
2 Plug (1):
Seizure prevention compound (LC-G)
3 Plug (1):
51.0 to 85.3 Nm {5.2 to 8.7 kgm}

HB365LC-3 30-27
TEST AND ADJUST VALVE CLEARANCE 30 TESTING AND ADJUSTING

TEST AND ADJUST VALVE CLEARANCE (HB335_3-K-A700-304-00-B)

Tools for testing and adjusting the valve clearance

Symbol Part No. Part name Q'ty Remarks
A 795-799-1131 Gear 1
Commercially
B Feeler gauge 1
available

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Check that the system operating lamp is not lit, turn the battery disconnect switch to OFF position.
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
Check and adjust this item under the following conditions.
Engine coolant temperature: Normal temperature
For testing of valve clearance to perform troubleshooting, refer to this section.

METHOD FOR TESTING VALVE CLEARANCE (HB335_3-K-A700-361-00-B)

1. Open the engine hood.
2. Remove the cylinder head cover (2). See DISASSEMBLY
AND ASSEMBLY, “REMOVE AND INSTALL INJECTOR
ASSEMBLY”.
3. Remove the cover (3).
REMARK
The cover (3) needs to be removed to check the timing
mark.

4. Use a filter wrench, etc., and remove the cap (4) of the
front gear cover.

5. Remove the undercover (5).

30-28 HB365LC-3
30 TESTING AND ADJUSTING TEST AND ADJUST VALVE CLEARANCE

6. Remove the plate (6) of the engine flywheel housing, and

then insert the gear A to rotate the crankshaft to normal di-
rection.

7. Align the TDC stamp line (a) of the front gear cover with
the supply pump gear (b), and set the No.1 cylinder to
compression top dead center.
REMARK
At the compression top dead center, the rocker arm of No.
1 cylinder can be moved by the valve clearance with
hands. If the intake and the exhaust rocker arms cannot be
moved, No. 1 cylinder is not at its compression top dead
center. In that case, rotate the crankshaft one more turn.

8. While No. 1 cylinder is at the compression top dead center,

check the valve clearance marked with ● in the figure.
9. Rotate the crankshaft clockwise by 1 turn and check the
valve clearance of the remaining valves marked with ○.
REMARK
You may check the valve clearance of No. 1 cylinder while
No. 1 cylinder is at the compression top dead center, and
then turn the crankshaft in the normal direction by 120 ° at
a time and check the valve clearance of each cylinder in
the firing order.
Firing order: 1-5-3-6-2-4
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”.
After finishing the test, remove the testing tools and restore the machine.
NOTICE
Be sure to remove the gear A.

HB365LC-3 30-29
TEST AND ADJUST VALVE CLEARANCE 30 TESTING AND ADJUSTING

REMARK
Replace the gasket with a new one, and install the plate (6) to
the flywheel housing.

METHOD FOR ADJUSTING VALVE CLEARANCE (HB335_3-K-A700-27D-00-B)

After testing, adjust the valve clearance according to the following procedure, if necessary.
After setting No. 1 cylinder at the compression top dead center, adjust valve clearance of No. 1 cylinder.
1. While fixing the adjustment screw (7), loosen the lock nut
(8).
2. Insert the feeler gauge B in the clearance between rocker
arm (9) and crosshead (10) and then adjust the valve
clearance with the adjustment screw (7).
Turn the adjustment screw (7) with the feeler gauge B in-
serted, and then adjust it with the adjustment screw (7) un-
til the feeler gauge B can move lightly.
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR ENGINE”.
3. With adjustment screw (7) fixed, tighten the lock nut (8).
3 Lock nut (8):
20.0 to 28.0 Nm {2.01 to 2.86 kgm}
Tighten the lock nut (8), and check the valve clearance again.
After finishing the adjustment, restore the machine.

30-30 HB365LC-3
30 TESTING AND ADJUSTING TEST COMPRESSION PRESSURE

TEST COMPRESSION PRESSURE (HB335_3-K-A000-304-01-B)

Tools for testing the compression pressure

Symbol Part No. Part name Q'ty Remarks
A 795-502-1590 Gauge assembly 1 Pressure range: 0 to 7 MPa
B 795-799-6700 Puller 1
C 795-790-6111 Adapter 1
D 6754-11-3130 Gasket 1
E 795-799-8150 Remover 1

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Check that the system operating lamp is not lit, turn the battery disconnect switch to OFF position.
k When testing the compression pressure, be careful not to burn yourself by touching the exhaust
manifold, KDPF, SCR, or AdBlue/DEF mixing piping, or get caught in a rotating part.
Check this item under the following conditions.
Engine coolant temperature: 40 to 60 °C
For testing of compression pressure to perform troubleshooting, refer to this section.

METHOD FOR TESTING COMPRESSION PRESSURE (HB335_3_E-K-A000-36B-00-B)

1. Remove the cylinder head cover (1). See DISASSEMBLY
AND ASSEMBLY, “REMOVE AND INSTALL INJECTOR
ASSEMBLY”.
2. Set the cylinders to be checked to the compression top
dead center. For details, see “TEST AND ADJUST VALVE
CLEARANCE”.
REMARK
Check that both of the intake rocker arm and exhaust rock-
er arm at the compression top dead center are movable by
hand as much as the valve clearance.
3. After removing the fuel spray prevention cap (2), remove
the sleeve nut and disconnect the high-pressure pipe (3).

HB365LC-3 30-31
TEST COMPRESSION PRESSURE 30 TESTING AND ADJUSTING

4. Loosen the injector terminal nuts (4) and remove the termi-
nals from injector (5).
5. Remove the mounting bolts (7) of rocker arm assembly (6)
on exhaust side, and remove the rocker arm assembly (6).

6. Remove the retaining nut (8), and remove the inlet con-
nector (9).
7. Remove the injector mounting bolt (10), and remove the
injector holder (11).

8. Remove the injector (5) by using puller B.

REMARK
• Remove the injector (5) by utilizing the impacts of the
slide hammer of puller B.
• Do not pry the top of injector (5) to remove.
9. Fix adapter C to the portion from which injector (5) was re-
moved with injector holder (11).
REMARK
• Be sure to fit the gasket D to the end of adapter C.
• Tighten the injector holder mounting bolts (10) alter-
nately.
3 Injector holder mounting bolt (10):
9.8±2.0 Nm {1.0±0.2 kgm}
10. Install the rocker arm assembly (7).
3 Rocker arm assembly mounting bolt (7):
64.7±4.9 Nm {6.6±0.5 kgm}
11. Adjust the valve clearance by referring to “TEST AND AD-
JUST VALVE CLEARANCE”.
12. Connect the hoses (12) and (13), connectors (14) and
(15), and sensor (16).
REMARK
• Hose (12): VGT drive hydraulic circuit
• Hose (13): VGT control hydraulic circuit
• Connector (14): VGT speed sensor

30-32 HB365LC-3
30 TESTING AND ADJUSTING TEST COMPRESSION PRESSURE

13. Connect the gauge assembly A to adapter C.

REMARK
If a small amount of oil is applied to the connecting parts of
the gauge assembly A and the adapter C, the air will not
escape easily.

14. Set to “No-Injection Cranking” by referring to “SET AND

OPERATE MACHINE MONITOR”.
k Set the “No-Injection Cranking”mode, otherwise
the engine starts and it is dangerous. Be sure to
set the engine in this mode.
15. Test the compression pressure when the engine is cranked
by the starting motor.
NOTICE
Do not crank the engine for 20 seconds or longer to
protect the starting motor.
REMARK
• Read the compression pressure when the pointer of
gauge is stabilized.
• For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR ENGINE”.
After finishing the test, remove the testing tools, and restore the machine. For details, see DISASSEMBLY AND
ASSEMBLY, “REMOVE AND INSTALL INJECTOR ASSEMBLY”.

HB365LC-3 30-33
TEST BLOWBY PRESSURE 30 TESTING AND ADJUSTING

TEST BLOWBY PRESSURE (HB335_3-K-A000-304-02-B)

Tools for testing the blowby pressure

Symbol Part No. Part name Q'ty Remarks
- 799-201-1506 Blowby checker 1
1 799-201-1591 Gauge 1 Pressure range: 0 to 10 kPa
A
2 799-201-1511 Tool 1
3 799-201-1450 Adapter 1
Commercially
B Plug 1 Hose inside diameter: 24 mm
available
Commercially
C Cap 2 Tube inside diameter: 25.4 mm
available

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Be careful not to burn yourself when KDPF regeneration is performed since high temperature ex-
haust gas is spouted from the inspection port. Be sure to disable KDPF regeneration operation with
machine monitor before testing.
(For the detail of disable KDPF regeneration operation, see Operation and Maintenance Manual.)
Check this item under the following conditions.
• Engine coolant temperature: 60 to 100 °C
• Hydraulic oil temperature: 45 to 55 °C
For testing of compression pressure to perform troubleshooting, refer to this section.

METHOD FOR TESTING BLOWBY PRESSURE (HB335_3-K-A000-36C-00-B)

1. Open the engine hood.
2. Loosen the clamp (1) of KCCV (2), and disconnect the
blowby gas inlet side hose (3) and the outlet side hose (4).

3. Put the caps C to the blowby gas inlet side and the outlet
side of KCCV (2).
4. Install the plug B to KCCV gas outlet side hose (4) and fix
it with clamp (1).
3 Clamp (1):
4.4±0.5 Nm {0.45±0.05 kgm}

30-34 HB365LC-3
30 TESTING AND ADJUSTING TEST BLOWBY PRESSURE

5. Install the tool A2 and the adapter A3 of the blowby check-

er A to the KCCV inlet side hose (3), and connect the
gauge A1 and fix it with clamp (1).
3 Clamp (1):
4.4±0.5 Nm {0.45±0.05 kgm}
6. Start the engine.
7. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
8. Keep the engine coolant temperature and the hydraulic oil
temperature in the testing condition range.
9. Set the working mode to P (“Power Mode”).
10. Turn off the auto-deceleration.
11. Turn the swing lock switch to ON position.
REMARK
If the swing lock switch is turned on, the main relief valve is set for high-pressure relief.
12. Turn the fuel control dial to MAX (High idle) position.
13. Operate the work equipment control lever, and test the blowby pressure with arm IN relief + one-touch pow-
er maximizing ON.
REMARK
• Read the blowby pressure when the pointer of gauge is stabilized.
• One-touch power maximizing function is automatically released after approximately 8.5 seconds even if
the One-touch power maximizing switch is kept pressed. Test the engine speed before the function is
released.
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”.
After finishing the test, remove the testing tools and restore the machine.

HB365LC-3 30-35
TEST ENGINE OIL PRESSURE 30 TESTING AND ADJUSTING

TEST ENGINE OIL PRESSURE (HB335_3-K-AB00-304-00-B)

Tools for testing the engine oil pressure

Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A
1 799-101-5160 Nipple 1 Size: R1/8
B 799-401-2320 Gauge 1 Pressure range: 1 MPa
C 6732-81-3170 Adapter 1 Size: M10x1.0 mm
D 6215-81-9710 O-ring 1

k Place the machine on a level ground, lower the work equipment to the ground, stop the engine, and
set the parking brake lever and work equipment lock lever to LOCK position.
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
Check this item under the following conditions.
Engine coolant temperature: 60 to 100 °C
For testing of engine oil pressure to perform troubleshooting, refer to this section.

METHOD FOR TESTING ENGINE OIL PRESSURE (HB335_3-K-AB00-362-00-B)

1. Remove the undercover (1).

2. Remove the oil pressure pickup plug (2) of the cylinder

block.

30-36 HB365LC-3
30 TESTING AND ADJUSTING TEST ENGINE OIL PRESSURE

3. Install the nipple A1 of the hydraulic tester A to the adapter

C, and connect the gauge B.
REMARK
When installing the adapter C, be sure to fit the O-ring D.
4. Start the engine.
5. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
6. Raise the coolant temperature to the specified range.
7. Set the working mode to B (“Breaker Mode”).
8. Turn off the auto-deceleration.
9. Set all of the control levers and control pedals in NEU-
TRAL position, and test the engine oil pressure when the
fuel control dial is at MAX (High idle) and MIN (Low idle)
positions.
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR ENGINE”.

After finishing the test, remove the testing tools and restore the machine.
3 Oil pressure pickup plug (2):
8±1 Nm {0.8±0.1 kgm}

HB365LC-3 30-37
TEST EGR VALVE AND VGT OIL PRESSURE 30 TESTING AND ADJUSTING

TEST EGR VALVE AND VGT OIL PRESSURE (HB335_3-K-A9K1-304-00-B)

Tools for testing EGR valve and VGT oil pressure

Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A 1 799-101-5140 Gauge 2 Pressure range: 2.5 MPa
2 799-101-5160 Nipple 2 Size: R1/8
B 799-401-3100 Adapter 1 Size: 02
C 799-401-3200 Adapter 1 Size: 03

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
Check this item under the following conditions.
• Engine coolant temperature: 60 to 100 °C
• Hydraulic oil temperature: 45 to 55 °C
For testing of EGR valve and VGT oil pressure to perform troubleshooting, refer to this section.

METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE (HB335_3-K-A9K1-362-00-B)
1. Open the engine hood.
2. Remove the step (1).

3. Disconnect the hoses (2) and (3).

Hose (2): EGR valve and VGT drive oil pressure circuit
Hose (3): VGT control hydraulic circuit

30-38 HB365LC-3
30 TESTING AND ADJUSTING TEST EGR VALVE AND VGT OIL PRESSURE

4. Install the adapter B to hose (2) and install the adapter C

to hose (3), then connect the disconnected hoses again.
3 Adapter B:
15±1.0 Nm {1.53±0.10 kgm}
3 Adapter C:
25±1.0 Nm {2.55±0.10 kgm}
5. Install the nipples A2 of the hydraulic tester A to the re-
spective adapters, and connect them to gauge A1.
6. Start the engine.
7. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
8. Keep the engine coolant temperature and the hydraulic oil
temperature in the testing condition range.
9. Turn the fuel control dial to MIN (Low idle) position, and
measure EGR valve and VGT driving oil pressure and
VGT control oil pressure.

After finishing the test, remove the testing tools and restore the machine.
3 Hose (2):
15±1.0 Nm {1.53±0.10 kgm}
3 Hose (3):
25±1.0 Nm {2.55±0.10 kgm}

HB365LC-3 30-39
TEST FUEL PRESSURE 30 TESTING AND ADJUSTING

TEST FUEL PRESSURE (HB335_3-K-AE20-304-00-B)

Testing tools for fuel pressure

Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A
1 799-101-5160 Nipple 2 Size: R1/8
B 799-401-2320 Gauge 2 Pressure range: 1 MPa
C 6732-81-3170 Adapter 2 Size: M10×1.0 mm → R1/8
D 6215-81-9710 O-ring 2
E 795-790-5110 Screw 1 Size: M12x1.5 mm
F 9745-71-1130 Seal washer 1
795-790-1500
G or Vacuum gauge 1
799-201-1201
H 795-790-5200 Adapter kit 1
J 795-790-5010 Screw 1
K 795-790-1150 Pressure gauge 1

k Place the machine on a level ground, lower the work equipment to the ground, stop the engine, and
set the parking brake lever and work equipment lock lever to LOCK position.
k Wait for the remaining pressure in the fuel circuit to be released for at least 30 seconds after stop-
ping the engine. Then, perform removing or installing the testing tools. (Do not start the work imme-
diately after the engine is stopped since remaining pressure is still in the circuit.)
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
NOTICE
Check the fuel pressure of low pressure circuit between feed pump, fuel main filter, and supply pump,
and the negative pressure circuit between supply pump, common rail, injector, and fuel tank.

30-40 HB365LC-3
30 TESTING AND ADJUSTING TEST FUEL PRESSURE

A: Low-pressure circuit measuring position (fuel main D: Negative pressure circuit measuring position (fuel
filter inlet side) supply connector)
B: Low-pressure circuit measuring position (fuel main E: Negative pressure circuit measuring position (sup-
filter outlet side) ply pump inlet)
C: Return circuit measuring position (supply pump F: Fuel feed pump outlet pressure measuring position
drain port) (supply pump inlet)
k Since the pressure in the high-pressure circuit from the supply pump through the common rail to the
injector is very high and dangerous, do not measure it.
Check this item under the following conditions.
• Engine coolant temperature: 60 to 100 °C
• Hydraulic oil temperature: 45 to 55 °C
For testing of fuel pressure to perform troubleshooting, refer to this section.

METHOD FOR TESTING FUEL PRESSURE (HB335_3-K-AE20-362-00-B)

Testing of low-pressure circuit (fuel main filter inlet side)

1. Open the cover on the right side of the machine.
2. Remove the fuel pressure pickup plug (1) on the inlet side
of the fuel main filter.
3. Install the adapter C, install the nipple A1 of the hydraulic
tester A.

HB365LC-3 30-41
TEST FUEL PRESSURE 30 TESTING AND ADJUSTING

4. Connect the gauge B to the nipple A1.

REMARK
When installing the adapter C, be sure to fit the O-ring D.
3 Adapter C:
20 to 22 Nm {2.0 to 2.2 kgm}
5. Start the engine.
6. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
7. Keep the engine coolant temperature and the hydraulic oil
temperature in the testing condition range.
8. Turn the fuel control dial in MAX (High idle) position, and
measure the oil pressure in the low-pressure circuit.
NOTICE
If the engine cannot be started, you may perform the
measurement while rotating the engine by using the
starting motor. But do not crank the engine for more
than 20 seconds continuously to protect the starting
motor.
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE FOR ENGINE”.
After finishing the test, remove the testing tools and restore the machine.
3 Fuel pressure pickup plug (1):
20 to 22 Nm {2.0 to 2.2 kgm}

Testing of low-pressure circuit (pressure difference)

1. Open the cover on the right side of the machine.
2. Remove the fuel pressure pickup plug (1) on the inlet side
of fuel main filter and the fuel pressure pickup plug (2) on
the outlet side.

3. Install the adapters C to the measuring hole on the inlet

side and the outlet side, install the nipple A1 of the hy-
draulic tester A.

30-42 HB365LC-3
30 TESTING AND ADJUSTING TEST FUEL PRESSURE

4. Connect the gauge B to the nipple A1.

REMARK
When installing the adapter C, be sure to fit the O-ring D.
3 Adapter C:
20 to 22 Nm {2.0 to 2.2 kgm}
5. Start the engine.
6. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
7. Keep the engine coolant temperature and the hydraulic oil temperature in the testing condition range.
8. Test the pressure of the inlet and the outlet of the low-pressure circuit with fuel control dial at MAX (High
idle) position.
NOTICE
If the engine cannot be started, you may perform the measurement while rotating the engine by us-
ing the starting motor. But do not crank the engine for more than 20 seconds continuously to pro-
tect the starting motor.
9. Calculate the pressure difference of the low-pressure circuit.
Pressure difference in low-pressure circuit = Pressure on fuel main filter inlet side - Pressure on fuel main
filter outlet side
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”.
REMARK
If it exceeds the standard value, the fuel main filter may be clogged. Replace the fuel main filter, and test it
again.
After finishing the test, remove the testing tools and restore the machine.
3 Fuel pressure pickup plug (1) and (2):
20 to 22 Nm {2.0 to 2.2 kgm}

Testing of return circuit

1. Open the engine hood.
2. Remove the piping (3) between the air cleaner and VGT.

3. Remove the bracket (4).

HB365LC-3 30-43
TEST FUEL PRESSURE 30 TESTING AND ADJUSTING

4. Remove the joint bolt (5) of the fuel return hose of the sup-
ply pump.

5. Install the screw E and the nipple A1 of the hydraulic tester

A instead of the joint bolt (5).

6. Connect the gauge B to the nipple A1.

REMARK
When installing the screw E, be sure to install the seal
washer F.
3 Screw E:
36±5 Nm {3.67±0.5 kgm}
7. Install the piping (3) between the air cleaner and VGT.
8. Start the engine.
9. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE MONITOR”.
10. Keep the engine coolant temperature and the hydraulic oil temperature in the testing condition range.
11. Turn the fuel control dial in MAX (High idle) position, and measure the oil pressure in the return circuit.
NOTICE
If the engine cannot be started, you may perform the measurement while rotating the engine by us-
ing the starting motor, but do not crank the engine for more than 20 seconds continuously to pro-
tect the starting motor.
After finishing the test, remove the testing tools and restore the machine.
3 Joint bolt (3) of fuel return hose:
24±4 Nm {2.45±0.41 kgm}

30-44 HB365LC-3
30 TESTING AND ADJUSTING TEST FUEL PRESSURE

Testing of negative pressure circuit

Testing the pressure of fuel negative pressure circuit (fuel supply connector)
1. Remove the pressure pickup plug (1) of the fuel supply
connector.

2. Connect the adapter C and the fuel vacuum gauge G.

REMARK
When installing the adapter C, be sure to install the O-ring
D.
3 Adapter C:
20 to 22 Nm {2.0 to 2.2 kgm}
3. Start the engine.
4. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
5. Keep the engine coolant temperature and the hydraulic oil temperature in the testing condition range.
6. Test the pressure in the fuel negative pressure circuit when the fuel control dial is turned to MAX (High idle)
position.
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”.
REMARK
If the standard value is exceeded, the fuel main filter may be clogged, so replace the fuel main filter and
test it again.
7. After finishing the test, remove the testing tools and restore the machine.
3 Fuel pressure pickup plug:
20 to 22 Nm {2.0 to 2.2 kgm}

HB365LC-3 30-45
TEST FUEL PRESSURE 30 TESTING AND ADJUSTING

Testing the negative pressure circuit (supply pump inlet)

8. Disconnect the fuel tube (1) on the supply pump (2) side.
9. Remove the screw (3) installed to the supply pump (2).

10. Install the hose assembly of the adapter kit H to the screw
J, and install them to the supply pump (2).
3 Screw J:
24±4 Nm {2.4±0.4 kgm}
11. Connect the fuel tube (1) again.
12. Connect the vacuum gauge G to the hose assembly of
adapter kit H.
13. Start the engine.
14. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
15. Keep the engine coolant temperature and the hydraulic oil temperature in the testing condition range.
16. Test the pressure in the fuel negative pressure circuit when the fuel control dial is turned to MAX (High idle)
position.
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE TABLE FOR ENGINE”.
After finishing the test, remove the testing tools and restore the machine.
3 Screw (1):
24±4 Nm {2.4±0.4 kgm}
REMARK
Replace the fuel tube (1) with a new one at reassembly.
3 Intake hose clamp:
10.5±0.5 Nm {107±5 kgcm}

Testing the fuel feed pump outlet pressure (supply pump)

1. The measuring position is same as fuel negative pressure
circuit pressure test (supply pump section) however, only a
different gauge K is used in the measurement tool.
2. Turn the starting switch to ON position.
3. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
4. Keep the engine coolant temperature and the hydraulic oil
temperature in the testing condition range.

30-46 HB365LC-3
30 TESTING AND ADJUSTING TEST FUEL PRESSURE

5. Operate the fuel feed pump (4) and test the fuel feed pump
outlet pressure.
REMARK
• Since the fuel feed pump (4) operates for 60 seconds
after turning the starting switch to ON position and then
stops, test the pressure during the operation.
• Fuel feed pump (4) is installed to the cooling plate (6)
on the back side of the engine controller (5).
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR ENGINE”.
• When the fuel feed pump outlet pressure is out of the
standard value range, test the following items.
• Check that the fuel is fed to feed pump (4).
• If the fuel has not been sent to the fuel feed pump
(4) after the fuel filter is replaced or the fuel sys-
tem parts are removed or installed, turn the start-
ing switch to ON position and then operate the
fuel feed pump (4) 3 to 4 times to bleed the air
from the fuel circuit. At last, measure the value
while sending the fuel to the pump.
• If the fuel feed pump outlet pressure is not within
the standard value range even though the fuel has sent to the fuel feed pump (4), remove the
check valve (7) of the engine controller cooling plate (6) and check that the check valve (7) is not
locked.
After finishing the test, remove the testing tools and restore the
machine.
3 Screw (3):
24±4 Nm {2.4±0.4 kgm}
REMARK
Replace the fuel tube (1) with a new one at reassembly.
3 Intake hose clamp:
10.5±0.5 Nm {107±5 kgcm}

HB365LC-3 30-47
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 30 TESTING AND ADJUSTING

TEST FUEL DISCHARGE, RETURN AND LEAKAGE (HB335_3-K-AE20-304-01-B)

Tools for testing fuel discharge, return and leakage

Symbol Part No. Part name Q'ty Remarks
A 795-790-4800 Tester kit 1
B 6164-81-5790 Joint 1
C 07206-30812 Joint bolt 1
D 6745-71-1130 Seal washer 3
Commercially
E Stopwatch 1
available

Commercially • Length: Approx. 2 m

F Hose 1
available • Inside diameter: Approx. 14 mm
Commercially
G Measuring cylinder 1 Capacity: 200 to 500 mℓ
available

Commercially • Length: Approx. 2 m

H Hose 1
available • Inside diameter: Approx. 8 mm
J 795-790-6210 Fitting 1
K 795-790-5600 Hose 1
L 795-790-6500 Adapter 1
Commercially
M Oil container 1 Capacity: Approx. 20 ℓ
available

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
k Wait for the remaining pressure in the fuel circuit to be released for at least 30 seconds after stop-
ping the engine. Then, perform removing or installing the testing tools. (Do not start the work imme-
diately after the engine is stopped since remaining pressure is still in the circuit.)

30-48 HB365LC-3
30 TESTING AND ADJUSTING TEST FUEL DISCHARGE, RETURN AND LEAKAGE

A: Measuring position of supply pump discharged vol- D: Measuring position of leakage from pressure limiter
ume E: Fuel feed pump discharged volume measuring po-
B: Measuring position of supply pump return rate sition
C: Measuring position of injector return rate
Check this item under the following conditions.
• Engine coolant temperature: 60 to 100 °C
• Hydraulic oil temperature: 45 to 55 °C
For testing of fuel discharged volume, return rate and leakage to perform troubleshooting, refer to this section.

METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE

(HB335_3-K-AE20-363-00-B)

Testing supply pump discharged volume

1. Remove the fuel feed pump fuse.
REMARK
Stop the operation of fuel feed pump which starts when the starting switch is turned to ON position.
2. Remove the piping (1) between the air cleaner and VGT.

HB365LC-3 30-49
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 30 TESTING AND ADJUSTING

3. Remove the bracket (2).

4. Remove fuel spray prevention cap (3), and remove the

high-pressure pipe (4).

5. Install the hose F to the connector on the discharge side of

the supply pump.
REMARK
• Clamp the hose F with a hose band to prevent it from
coming off.
• Adjust the route of hose F so that it does not slack, and
put its end in the oil container M.
6. Install the piping (1) between the air cleaner and VGT.
7. Crank the engine for 30 seconds and measure the dis-
charged volume by using the measuring cylinder G.
NOTICE
In order to protect the starting motor, do not crank
continuously for more than 20 seconds. “Crank the en-
gine for 15 seconds, stop for 15 seconds and then
crank it again for 15 seconds.” Perform the measure-
ment according to this procedure.
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE FOR ENGINE”.

30-50 HB365LC-3
30 TESTING AND ADJUSTING TEST FUEL DISCHARGE, RETURN AND LEAKAGE

After finishing the test, remove the testing tools and restore the machine.
3 High-pressure pipe (4) sleeve nut:
37±4 Nm {3.7±0.4 kgm}

Testing supply pump return rate

1. Remove the piping (1) between the air cleaner and VGT.

2. Remove the bracket (2).

3. Remove the joint bolt (3) of the fuel return tube of the sup-
ply pump.

4. Install the cap nut (5) of the tester kit A to the fuel return
hose (4) side to block the fuel flow.
REMARK
When installing the cap nut (5), be sure to install the seal
washer D.
5. Install the piping (1) between the air cleaner and VGT.
6. Start the engine.
7. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
8. Keep the engine coolant temperature and the hydraulic oil
temperature in the testing condition range.

HB365LC-3 30-51
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 30 TESTING AND ADJUSTING

9. Set the fuel control dial to MIN (Low idle) position, and
measure the fuel return rate for 30 seconds.
NOTICE
In order to protect the starting motor, do not crank
continuously for more than 20 seconds. “Crank the en-
gine for 15 seconds, stop for 15 seconds and then
crank it again for 15 seconds.” Perform the measure-
ment according to this procedure.
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE FOR ENGINE”.

After finishing the test, remove the testing tools and restore the machine.
3 Joint bolt (3) of fuel return hose (4):
24±4 Nm {2.45±0.41 kgm}

Testing of leakage from pressure limiter

If failure code [CA559] or [CA2249] is displayed, perform troubleshooting for it first.
1. Remove the joint bolt (6) of the pressure limiter and dis-
connect the spill tube (7).

2. Install the cap nut (5) of the tester kit A to the spill tube (7)
side to block the fuel flow.
REMARK
When installing the cap nut (5), be sure to install the seal
washer D.
3. Install the joint B to the pressure limiter side with the joint
bolt C.
REMARK
When installing the joint B and the joint bolt C, be sure to
install the seal washer D.
3 Joint bolt C:
24±4 Nm {2.45±0.41 kgm}
4. Start the engine.
5. Select and display “SET AND OPERATE MACHINE MONITOR” (01/28). See “SET AND OPERATE MA-
CHINE MONITOR”.
6. Keep the engine coolant temperature and the hydraulic oil temperature in the testing condition range.
7. Set the fuel control dial set to MIN (Low idle) position, and measure the amount of fuel leakage for 60 sec-
onds with measuring cylinder G.
For standard values, see STANDARD VALUE TABLE, “STANDARD VALUE FOR ENGINE”.
After finishing the test, remove the testing tools and restore the machine.

30-52 HB365LC-3
30 TESTING AND ADJUSTING TEST FUEL DISCHARGE, RETURN AND LEAKAGE

3 Spill tube (7) mounting joint bolt (6):

24±4 Nm {2.45±0.41 kgm}

Testing the fuel return rate from injector

1. Make a space for work by separating the sensor on the
right side of SCR.
2. Remove the joint bolt (1) on the cylinder head, and discon-
nect the spill tube (2).

3. Install the cap nut (5) of the tester kit A to the spill tube (2)
side to block the fuel flow.
REMARK
When installing the cap nut (5), be sure to install the seal
washer D.
4. Install the joint B to the cylinder head side with the joint
bolt C.
REMARK
When installing the joint B and the joint bolt C, be sure to
install the seal washer D.
3 Joint bolt C:
24±4 Nm {2.45±0.41 kgm}
5. Install the hose (H) to the joint B.
6. Start the engine.
7. Select and display “SET AND OPERATE MACHINE MONITOR” (01/28). See “SET AND OPERATE MA-
CHINE MONITOR”.
8. Keep the engine coolant temperature and the hydraulic oil temperature in the testing condition range.

HB365LC-3 30-53
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 30 TESTING AND ADJUSTING

9. Set the fuel control dial set to MIN (Low idle) position, and
measure the fuel return rate for 60 seconds with measur-
ing cylinder G.
NOTICE
When the engine cannot be started, you may perform
the measurement while cranking the engine by the
starting motor. However, to protect the starting motor,
do not crank the engine for more than 20 seconds con-
tinuously. “Crank the engine for 15 seconds, stop for
15 seconds and then crank it again for 15 seconds.”
Perform the measurement according to this proce-
dure.
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR ENGINE”.

After finishing the test, remove the testing tools and restore the machine.

Testing the fuel feed pump discharged volume

Since the fuel feed pump operates for 60 seconds after turning the starting switch to ON position and then
stops, measure the discharged volume in the 60 seconds.
1. Remove the piping (1) between the air cleaner and VGT.

2. Remove the bracket (2).

30-54 HB365LC-3
30 TESTING AND ADJUSTING TEST FUEL DISCHARGE, RETURN AND LEAKAGE

3. Disconnect the fuel tube (4) from the supply pump (3).
4. Remove the connector (5) of the supply pump (3), and in-
stall the fitting J.

5. Connect the portion (a) hose K to the fitting J.

6. Connect the portion (b) of the hose K to the fuel tube (4).
7. Disconnect the hose K at portion (c), install the adapter L,
and connect the disconnected hose.

8. Insert the portion (d) of the hose K into the measuring cyl-
inder G.
9. Turn the starting switch to ON position and operate the fuel
feed pump.
10. When the fuel flows out continuously, measure the dis-
charged volume for 10 seconds with measuring cylinder G.
11. Perform the measurement described in Step 10 for 3
times, and calculate the measurement values to obtain the
average value.
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR ENGINE”.
After finishing the test, remove the testing tools and restore the machine.
REMARK
Replace the fuel tube with a new one at reassembly.
3 Intake hose clamp:
10.5±0.5 Nm {107±5 kgcm}

HB365LC-3 30-55
BLEED AIR FROM FUEL SYSTEM 30 TESTING AND ADJUSTING

BLEED AIR FROM FUEL SYSTEM (PC300_11-K-AD00-304-10-B)

k Place the machine on a level ground, lower the work equipment to the ground in a stable posture, set
the lock lever to LOCK position, and stop the engine.
For bleeding air from fuel system to perform troubleshooting or Pm Clinic, refer to this section.

METHOD FOR BLEEDING AIR FROM FUEL SYSTEM (HB335_3-K-AD00-231-00-B)

In the following cases, bleed air according to this procedure.
• When the fuel filter has been replaced
• When the fuel has run out
• When starting the engine for the first time after replacing the fuel piping or the supply pump
1. Refill the fuel tank with the fuel until the fuel level monitor reaches blue range.
2. Turn the starting switch to OFF position.
3. Loosen and pull out the hand primer (1), and move it back
and forth until resistance increases.
REMARK
The plug on the upper part of fuel main filter need not be
removed.
4. After bleeding air, push the hand primer (1) in, and tight-
en it.

30-56 HB365LC-3
30 TESTING AND ADJUSTING TEST FUEL CIRCUIT FOR LEAKAGE

TEST FUEL CIRCUIT FOR LEAKAGE (PC400_10-K-AD00-304-01-B)

Tools for testing fuel circuit for leakage

Symbol Part No. Part name Q'ty Remarks
Commercially Developer for dye penetrant (color
A 1
available checker)

k Very high pressure is generated in the high-pressure circuit of the fuel system. If fuel leaks while the
engine is running, it presents a serious danger that could result in a fire. When the fuel circuit is test-
ed or any component is removed from or installed to it, check for fuel leakage according to the fol-
lowing procedure.
k Place the machine on a level ground, and then lower the work equipment completely to the ground in
a stable posture. Set the lock lever to LOCK position, and then stop the engine.
k Parts and oil are still very hot immediately after the engine is stopped. It may cause burn injury. Wait
for the temperature to go down, and then start the work.
Clean the engine and the parts around it, and degrease them in advance so that you can easily find the leakage
if any.
For testing the fuel system for leakage to perform troubleshooting, refer to this section.

METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE (PC400_10-K-AD00-364-01-B)

Testing method of fuel circuit for leakage at engine stopped

1. Start the engine.
2. Run the engine with fuel control dial at MIN (Low idle), and stop it after the engine automatic warm-up func-
tion is canceled automatically and engine speed is stabilized.
REMARK
• Turn the fuel control dial to MAX (High idle), the engine automatic warm-up function is canceled.
• For the condition of canceling the engine automatic warm-up function, see “ENGINE AUTOMATIC
WARM-UP SYSTEM”.
3. Spray color checker A to the supply pump, common rail, injectors, and joints of the high-pressure piping.
4. Check the fuel piping and component for fuel leakage.
• Check the high-pressure circuit for fuel leakage focusing on the area where the color checker A is
sprayed.
• If any fuel leakage is detected, repair it and perform the checks from step 1 again.

Testing method of fuel circuit for leakage at engine low idle

1. Start the engine.
2. Run the engine with fuel control dial at MIN (Low idle), and stop it after the engine automatic warm-up func-
tion is canceled automatically and engine speed is stabilized.
REMARK
• Turn the fuel control dial to MAX (High idle), the engine automatic warm-up function is canceled.
• For the condition of canceling the engine automatic warm-up function, see “ENGINE AUTOMATIC
WARM-UP SYSTEM”.
3. Spray color checker A to the supply pump, common rail, injectors, and joints of the high-pressure piping.
4. Start the engine, and set the fuel control dial to MIN (Low idle).
5. Stop the engine and check the fuel piping and component for fuel leakage.
• Check the high-pressure circuit for fuel leakage focusing on the area where the color checker A is
sprayed.
• If any fuel leakage is detected, repair it and perform the checks from step 1 again.

HB365LC-3 30-57
TEST FUEL CIRCUIT FOR LEAKAGE 30 TESTING AND ADJUSTING

Testing method of fuel circuit for leakage at engine high idle

1. Start the engine.
2. Run the engine with fuel control dial at MIN (Low idle), and stop it after the engine automatic warm-up func-
tion is canceled automatically and engine speed is stabilized.
REMARK
• Turn the fuel control dial to MAX (High idle), the engine automatic warm-up function is canceled.
• For the condition of canceling the engine automatic warm-up function, see “ENGINE AUTOMATIC
WARM-UP SYSTEM”.
3. Spray color checker A to the supply pump, common rail, injectors, and joints of the high-pressure piping.
4. Start the engine, and set the fuel control dial to MAX (High idle).
5. Stop the engine and check the fuel piping and component for fuel leakage.
• Check the high-pressure circuit for fuel leakage focusing on the area where the color checker A is
sprayed.
• If any fuel leakage is detected, repair it and perform the checks from step 1 again.

Testing method of fuel circuit for leakage at engine rated speed

1. Start the engine.
2. Run the engine with fuel control dial at MIN (Low idle), and stop it after the engine automatic warm-up func-
tion is canceled automatically and engine speed is stabilized.
REMARK
• Turn the fuel control dial to MAX (High idle), the engine automatic warm-up function is canceled.
• For the condition of canceling the engine automatic warm-up function, see “ENGINE AUTOMATIC
WARM-UP SYSTEM”.
3. Spray color checker A to the supply pump, common rail, injectors, and joints of the high-pressure piping.
4. Start the engine.
5. Run the engine with “2 pumps relief + One-touch power maximizing” state. For details, see “TEST ENGINE
SPEED”.
6. Stop the engine and check the fuel piping and component for fuel leakage.
• Check the high-pressure circuit for fuel leakage focusing on the area where the color checker A is
sprayed.
• If any fuel leakage is detected, repair it and perform the checks from step 1 again.

30-58 HB365LC-3
30 TESTING AND ADJUSTING HANDLE CYLINDER CUT-OUT MODE OPERATION

HANDLE CYLINDER CUT-OUT MODE OPERATION (PC400_10-K-AD00-34F-00-B)

The cylinder cutout mode operation means to run the engine with the fuel injectors of one or more cylinders
disabled electrically to reduce the number of active cylinders. The purposes and effects of cylinder cutout mode
operation are as follows.
• Cylinder cutout mode operation is used to find out a cylinder which does not output power normally (or,
combustion in it is abnormal).
• If the engine speed and output do not change from the normal operation (all-cylinder operation) when a cyl-
inder is cutout with the cylinder cutout mode operation, that cylinder has a failure.
The possible failures are as follows.
• Compression gas leakage from cylinder head gasket area
• Defective injection
• Defective piston, piston ring or cylinder liner
• Defective valve mechanism (valve operating system)
• Defective electrical system
• Common rail fuel injection system individually controls the injector of each cylinder electronically , so the
cylinder cutout test can be performed easily by the simple operations of the switches compared with the
mechanical fuel injection system. So, the defective cylinder can be found out easily.

HB365LC-3 30-59
HANDLE NO-INJECTION CRANKING OPERATION 30 TESTING AND ADJUSTING

HANDLE NO-INJECTION CRANKING OPERATION (PC400_10-K-A000-25L-00-B)

No-injection cranking operation means to crank the engine by using the starting motor while disabling injection
in all cylinders electrically. The purpose and effect of this operation are as follows.
No-injection cranking is performed to lubricate the engine parts and to protect them from seizure. It is performed
before the engine is started after the machine or engine has been stored for a long period.

30-60 HB365LC-3
 TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TEN-
30 TESTING AND ADJUSTING SION

TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION

(PC400_10-K-K5A0-304-00-B)

k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, and
set the lock lever to LOCK position, and then stop the engine.
For testing and adjusting the tension of air conditioner compressor belt to perform troubleshooting, refer to this
section.

METHOD FOR CHECKING AIR CONDITIONER COMPRESSOR BELT

(HB335_1-K-K5A0-92C-00-B)
1. Open the engine hood (1).

2. Remove the guard (2).

3. Press the midpoint between compressor pulley (A) and fan

pulley (B) with a finger (approximately 58.8 N {6.0 kg} ).
If deflection (C) is 13 to 15 mm the belt tension is normal.
If the deflection is out of the standard, adjust it to the
standard value.

METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT

(PC300_11-K-K5A0-92C-01-B)
1. Loosen bolt (2) and nut (3).
REMARK
Loosening bolts (2) and (3) allows compressor (4) to move
around the mounting position of bolt (2).
2. Adjust by moving compressor (4).
3. When the compressor is positioned, fix it by tightening
bolts (2) and (3).

HB365LC-3 30-61
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TEN-
SION 30 TESTING AND ADJUSTING

NOTICE
• Check each pulley for damage, wear of the V-groove, and the wear of the V-belt. In particular, be sure
to check that the V-belt is not touching the bottom of the V-groove.
• Replace the belt with a new one if the belt is stretched and has no allowance for adjustment, or has
slipping sound or squeak because of cuts or cracks of the belt.
• When the new V-belt is installed, readjust it after operating for 1 hour.

30-62 HB365LC-3
30 TESTING AND ADJUSTING TEST COOLING FAN SPEED

TEST COOLING FAN SPEED (PC210_11-K-ACN3-304-00-B)

k Place the machine on a level ground, and then lower the work equipment completely to the ground in
a stable posture. Set the lock lever to LOCK position, and then stop the engine.
For testing the cooling fan speed to perform troubleshooting, refer to this section.

METHOD FOR TESTING COOLING FAN SPEED (HB335_3_E-K-ACN3-388-00-B)

1. Start the engine, select “Fan Speed Mode Select”, and select 100 % mode. See “SET AND OPERATE MA-
CHINE MONITOR”.
REMARK
If 100 % mode is not selected in “Fan Speed Mode Select”, the cooling fan speed is set to 500±100 rpm
when the engine coolant temperature is below 73 °C and hydraulic oil temperature is below 76 °C. When
the engine coolant temperature and hydraulic oil temperature exceed the above level, the cooling fan speed
varies with the temperature.
2. Select “Pre-defined Monitoring” (15/28) or “Monitoring Se-
lection Menu” and display the following monitoring items
by referring to “SET AND OPERATE MACHINE MONI-
TOR”.
Monitoring code: 10007 “Fan Speed”
3. Turn off the auto-deceleration.
4. Turn the swing lock switch to ON position.
5. Check the “Fan Speed” when the fuel control dial is in MIN
(Low idle) position, partial (Engine speed 1600 rpm) posi-
tion, and MAX (High idle) position.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
See the section of “SET AND OPERATE MACHINE MONITOR”. Select the mode to “Fan Speed Mode Select”
and select normal control mode.
REMARK
Even if the starting switch is turned to OFF position, the cooling fan speed is set in the normal control mode
when the engine is started again.

HB365LC-3 30-63
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE
CONTROLLER 30 TESTING AND ADJUSTING

WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CON-

TROLLER (PC400_11-K-AP70-304-00-B)

k Check that there is no person or combustible material around the machine (particularly in the direc-
tion of the exhaust gas flows).
• When starting the engine, ash contained in engine oil accumulates in KCSF and increases filter differential
pressure.
• Since filter differential pressure is used for calculation of soot accumulation in the engine controller, in-
crease amount of differential pressure by ash needs to be corrected.
• Correction amount of filter differential pressure increased by ash is calculated in the engine controller as
“Soot Correction by Ash Influence”.
• When engine controller is replaced with the new one, “Soot Correction by Ash Influence” becomes default
value, 0 g/ ℓ.
• When engine controller is replaced with the new one, perform applicable operation to obtain correct “Soot
Correction by Ash Influence”.

METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO EN-

GINE CONTROLLER (PC400_11-K-AP70-270-00-B)
Perform the applicable operation according to the following procedure.
• When only the engine controller is replaced.
Perform “Ash in Soot Accumulation Correction”. For detail, see “SETTING AND OPERATION OF MA-
CHINE MONITOR”.
• When both of engine controller and KCSF are replaced,
the value of “Soot Correction by Ash Influence” and Ash Accumulationaccumulated in KCSF become 0 g/ ℓ,
“Ash in Soot Accumulation Correction” needs not to be performed.
Perform applicable operation. For details, see TROUBLESHOOTING, “Precautions for KDPF (KCSF,
KDOC) cleaning and change”.

30-64 HB365LC-3
30 TESTING AND ADJUSTING TEST SCR RELATED FUNCTIONS

TEST SCR RELATED FUNCTIONS (HB335_3_E-K-AF00-362-00-B)

For testing of SCR related function to perform troubleshooting, refer to this section.

Types of SCR Service Test

Code Item Purpose Reference page
AdBlue/DEF AdBlue/DEF pump is actuated singly. Damage of
AdBlue/DEF Pump Pressure Up
01 Pump Pressure AdBlue/DEF hose and failure in AdBlue/DEF pump
Test
Up Test can be detected.
AdBlue/DEF injector for failure can be detected by
AdBlue/DEF Injec- AdBlue/DEF Injection Quantity
02 increasing the AdBlue/DEF pump pressure and in-
tion Quantity Test Test
jecting a certain amount of AdBlue/DEF.
AdBlue/DEF Line
AdBlue/DEF line heater 1 can be actuated at any AdBlue/DEF Line Heater Relay
03 Heater Relay 1
timing, and electrical action can also be checked. 1 Test
Test
AdBlue/DEF Line
AdBlue/DEF line heater 2 can be actuated at any AdBlue/DEF Line Heater Relay
04 Heater Relay 2
timing, and electrical action can also be checked. 2 Test
Test
AdBlue/DEF
AdBlue/DEF pump heater can be actuated at any AdBlue/DEF Pump Heater Re-
05 Pump Heater Re-
timing, and electrical action can also be checked. lay Test
lay Test
AdBlue/DEF tank heater valve can be actuated at
AdBlue/DEF Tank AdBlue/DEF Tank Heater Valve
06 any timing, and electrical action can also be
Heater Valve Test Test
checked.
SCR Denitration Performance of AdBlue/DEF injection and catalyzer
07 SCR Denitration Efficiency Test
Efficiency Test can be checked if necessary.

Test State Category

Test State (a) Content
0 Waiting for execution of test (Test can be started by pressing start test switch)
1 Test is in preparation
When nor-
5 Abnormalities have been reported after performing the test
mal
10 Test is being executed
20 Test is completed successfully
11 to 18 Test is being performed but it is paused by external factor
When it is
30 to 41 Test cannot be performed or cannot be continued
abnormal
100 Key OFF/ECU shut down is necessary

(a): Test State

HB365LC-3 30-65
TEST SCR RELATED FUNCTIONS 30 TESTING AND ADJUSTING

Parameter list of test state

Test
Content Details Required action
State
Regeneration disable state of af-
Wait for the start (de-
0 tertreatment devices by machine Press the start test switch to start the test.
fault)
monitor
AdBlue/DEF pump pres- System is moving to “Test State”
1 Wait “Test State” changes to “10”.
sure is being increased. “10”
It is on the following state de-
pending on the contents.
• Being pressure-fed by
AdBlue/DEF pump
• AdBlue/DEF is being inject-
ed. • Check the items to be performed dur-
ing the test.
• The operation of energiza-
10 Being tested • In case of “SCR Denitration Efficiency
tion cycle at a fixed time af-
ter specific time passes. Test” or “Ash in Soot Accumulation
Correction”, wait until test is finished.
• “SCR Denitration Efficiency
Test” is being performed
• “Ash in Soot Accumulation
Correction” is being per-
formed
Pressure drop of AdBl- Pressure drops (only when AdBl-
Perform the troubleshooting for the failure
ue/DEF pump is detect- ue/DEF pump is pressure-fed)
5 code [CA3574]. For details, see “TROUBLE-
ed (failure code while the display of “Test State” is
SHOOTING”.
[CA3574] is displayed) “10”.
• If “Please turn the key off.” is dis-
played, turn the starting switch to OFF
position and shut down the engine
• AdBlue/DEF is being controller. (*1)
purged.
20 Test has been finished. • If “STOP” is displayed, press the cor-
• Heater energizing has responding switch to return the test to
been completed. initial state.
Other than the above, the state automatically
returns to initial state.
• Turn the starting switch to OFF posi-
tion, and perform the test again after
Purging (energizing • AdBlue/DEF is being shutting down the engine controller.
temporarily stops) or purged. (*1)
11
test cannot be per- • A particular error message • If a specific error message is dis-
formed. is displayed. played, see “TROUBLESHOOT-
ING”and perform troubleshooting for
the failure code.
Wait for AdBlue/DEF tank temperature or
AdBlue/DEF tank or AdBlue/DEF tank temperature ex-
AdBlue/DEF pump temperature to be low-
AdBlue/DEF pump is at ceeds 70 °C or AdBlue/DEF
12 ered. After the display of “Test State”
high temperature (ener- pump temperature exceeds upper
changes to “10”, the test restarts automatical-
gizing temporarily stops) limit.
ly.

30-66 HB365LC-3
30 TESTING AND ADJUSTING TEST SCR RELATED FUNCTIONS

Test
Content Details Required action
State
The test state is displayed when step is
SCR temperature is 450 °C or
switched during “SCR Denitration Efficiency
SCR temperature is out above or 250 °C or below (tem-
14 Test”. Wait for several minutes. After “Test
of specified range perature range is set by each test
State” becomes “10”, test restarts automati-
level)
cally.
Under the condition described on the left,
“SCR Denitration Efficiency Test” does not
Mass air flow is out of Mass air flow is above 0.49g/sec
15 finish successfully. Perform the troubleshoot-
specified range or below 0.04kg/sec.
ing for the failure code. See “TROUBLE-
SHOOTING”.

• Turbo outlet NOX concen- Under the condition described on the left,
NOX value at turbo- tration: Max. 100 ppm “SCR Denitration Efficiency Test” does not
16 charger outlet is out of finish successfully. Perform the troubleshoot-
specified range • NOX sensor at turbocharg- ing for the failure code. See “TROUBLE-
er outlet is unmeasurable SHOOTING”.
Injection of AdBlue/DEF Perform the troubleshooting for the failure
17 The failure code is displayed.
is prohibited code. See “TROUBLESHOOTING”.
• Ambient temperature is Under the condition described on the left,
Ambient temperature -30 °C or below “SCR Denitration Efficiency Test” does not
and ambient pressure
18 • Ambient pressure is 60 kPa finish successfully. Perform the troubleshoot-
are out of specified
or below, or 160 kPa or ing for the failure code. See “TROUBLE-
range
above SHOOTING”.

• Operate the work equipment lock lever

to LOCK position.
30 Machine state is unsafe Safety of machine is not secured
• Turn the fuel control dial to MIN (Low
idle) position.
Fuel low level caution is dis-
31 Fuel level has dropped Refill with fuel.
played
The error message is displayed
Test cannot be per- Perform the troubleshooting for the failure
32 to prohibit the regeneration of af-
formed (1) code. See “TROUBLESHOOTING”.
tertreatment devices
Within 20 seconds after Within 20 seconds after starting Start the engine, wait for 20 seconds or more,
33
starting the engine the engine and then restart the test.
The engine is stopped. Start the engine, and then restart the test.
Test cannot be per-
34 Perform the troubleshooting for the failure
formed (2) Specified error is being displayed
code. See “TROUBLESHOOTING”.
Fuel control dial is not in MIN po- Lower the engine speed, and then restart the
Test cannot be per- sition test.
35
formed (3) AdBlue/DEF tank temperature is Start the engine, thaw AdBlue/DEF, and then
below -1 °C restart the test.
A particular error is being dis- Perform the troubleshooting for the failure
Test cannot be per- played code. See “TROUBLESHOOTING”.
36
formed (4) The AdBlue/DEF level is below Refill with AdBlue/DEF, and then restart the
10 %. test.

HB365LC-3 30-67
TEST SCR RELATED FUNCTIONS 30 TESTING AND ADJUSTING

Test
Content Details Required action
State
• Engine operation is unsta-
ble Set the engine at low idle, and then restart
Test cannot be per- • Immediately after the en- the test.
37
formed (5) gine has started, etc.
AdBlue/DEF pump pressure does Perform the troubleshooting for the failure
not increase code. See “TROUBLESHOOTING”.
Test cannot be per- A particular error is being dis- Perform the troubleshooting for the failure
39
formed (6) played code. See “TROUBLESHOOTING”.
Engine control governor Set the engine at low idle, and then restart
40 Engine control is unstable
state is not conformable the test
Test cannot be per- Overheat or oil pressure low error Perform the troubleshooting for the failure
41
formed (7) is displayed code. See “TROUBLESHOOTING”.
• Shut down the engine controller for re-
setting. (*1)
Key OFF/ECU shut • Engine is running
100 down is necessary or • SCR Denitration Efficiency Test does
• Elapsed time exceeds
exceed specified time not finish successfully. Perform the
specified time
troubleshooting for the failure code.
See “TROUBLESHOOTING”.

*1: Shut down of engine controller will be completed when the system operating lamp goes out 1 to 6 minutes
after the starting switch is turned to OFF position.

TEST AdBlue/DEF PUMP RAISED PRESSURE (PC400_11-K-AFH0-304-00-B)

k Place the machine on a level ground, lower the work equipment with a stable posture to the ground,
set the lock lever in LOCK position, and stop the engine.
NOTICE
• If KOMNET communication error remains less than 1 second, engine controller is unable to detect it,
and the test may be continued while the machine monitor does not continue (standard screen). In
that case, turn the starting switch to OFF position once, and then system operating lamp goes out,
and the engine controller shuts down to reset the test.
• AdBlue/DEF may freeze when the outside air temperature is low. AdBlue/DEF should be thawed com-
pletely before performing the test. Devices will get damaged if the calibration is performed when the
AdBlue/DEF is still frozen.
AdBlue/DEF Pump Pressure UP Test function can actuate AdBlue/DEF pump alone, and can check damaged
AdBlue/DEF or failed AdBlue/DEF pump.
For testing of AdBlue/DEF hose or AdBlue/DEF pump to perform troubleshooting or Pm Clinic, etc. refer to this
section.

METHOD FOR TESTING AdBlue/DEF PUMP RAISED PRESSURE (PC400_11_E-K-AFH0-362-01-B)

1. Start the engine.
2. Check the AdBlue/DEF conditions.

30-68 HB365LC-3
30 TESTING AND ADJUSTING TEST SCR RELATED FUNCTIONS

1) Select the following monitoring items on “Monitoring

Selection Menu”. See “SET AND OPERATE MA-
CHINE MONITOR”.
Monitoring code 19305: “AdBlue/DEF Tank Heating
State”
Monitoring code 19309: “AdBlue/DEF Pump Heater
State”
Monitoring code 19306: “AdBlue/DEF Line Heater 1
State”
Monitoring code 19307: “AdBlue/DEF Line Heater 2
State”
2) Check the monitoring information of (a) to (d) on
“Monitoring” screen.
Details of monitoring information are as follows.
1: Being thawed
2: Being kept warm
3: OFF
• When the status of the monitoring information (a) to
(d) is “1”
AdBlue/DEF is being thawed because it is still frozen.
Keep the engine speed at low idle and wait until the
status of the monitoring information becomes “2” or
“3”, and then proceed to step 3.
• The status of the monitoring information (a) to (b) is
“2” or “3”:
AdBlue/DEF is not frozen. Proceed to step 3.
3. Stop the engine.
4. Turn the starting switch to ON position.
k Do not perform this test while engine is running for
the safety reasons.
5. Check that AdBlue/DEF level is higher than (a) with the
sight gauge.
REMARK
When AdBlue/DEF level is below level (a), the
AdBlue/DEF level is low. Add AdBlue/DEF.

6. See “METHOD FOR OPERATING TESTING MENU (SCR

SERVICE TEST)” of “SET AND OPERATE MACHINE
MONITOR” and select “AdBlue/DEF Pump Pressure Up
Test”.

HB365LC-3 30-69
TEST SCR RELATED FUNCTIONS 30 TESTING AND ADJUSTING

7. Check that “0” of “Test State” is flashing.

REMARK
Flashing of “0” indicates “Waiting for the start (default)”,
and test can be performed. Display other than “0” appears,
follow instructions according to “Parameter list of test
state”.
8. Press F1 to start “AdBlue/DEF Pump Pressure Up Test”.
F1: Starts “AdBlue/DEF Pump Pressure Up Test”.
F2: Stops “AdBlue/DEF Pump Pressure Up Test”. (When
“STOP” is displayed.)
F5: Returns the screen to “SCR Service Test” screen.
NOTICE
“Test State” does not change to “10” and test does not
start even if F1 is pressed, turn starting switch to OFF
position once, and repeat the testing procedure from
step 1.
REMARK
• Display of “Test State” changes to flashing of “10”, and
value of “AdBlue/DEF Pump Pressure” increases.
While the pressure is increasing, display of “Remaining
Permitted Test Time” is counted down from “1800 to 0
sec”, and when it reaches to “0 sec”, the test will be fin-
ished automatically.
• When the display of “Test State” is “11” to “41”, follow
“Parameter list of Test State”.
• When the value of “AdBlue/DEF Pump Pressure” ex-
ceeds “900 kPa” within 1800 seconds of “Remaining
Permitted Test Time”, AdBlue/DEF pump and
AdBlue/DEF pressure line are normal. Press F2 to
complete the test.
• If the value of “AdBlue/DEF Pump Pressure” does not increase, check each part of AdBlue/DEF pres-
sure line for leakage, or check by sound and vibration that AdBlue/DEF pump operates. However, per-
form the checking of each part of AdBlue/DEF pressure line for leakage, and AdBlue/DEF pump for
operation, before “Remaining Permitted Test Time” becomes “0sec”.
• If the value of “AdBlue/DEF Pump Pressure” does not exceeds 800 kPa after approximately 200 sec-
onds are elapsed, AdBlue/DEF stops operation automatically and failure code [CA1682] is displayed. If
the failure code is displayed, perform troubleshooting.
9. When the display of “Test State” changes from flashing of
“20” to flashing of “0”, press F5.
REMARK
• The display of “20” of “Test State” indicates that AdBl-
ue/DEF purge is in progress, and it starts automatically
and stops in 5 minutes at maximum.
• The display of “0” of “Test State” indicates “Wait for the
start (default)”, and is ready for test again.

30-70 HB365LC-3
30 TESTING AND ADJUSTING TEST SCR RELATED FUNCTIONS

TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR (PC300_11-K-AFJ0-304-00-B)

Tools for testing injection amount from AdBlue/DEF injector

Symbol Part No. Part name Q'ty Remarks
A 799-601-4340 Socket 1
Commercially
B Multimeter 1
available
Commercially
C Resin container 1 Capacity: Approximately 200 mℓ
available
Commercially
D Measuring cylinder 1 Capacity: 200 to 500 mℓ
available
Commercially
E Rubber gloves 1
available

k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, set
the lock lever to LOCK position, and stop the engine.
k For handling of AdBlue/DEF, see Operation and Maintenance Manual, “PRECAUTIONS FOR DEF”.
k When handling AdBlue/DEF injector, always wear the protective eyeglasses and rubber gloves.
NOTICE
• When KOMNET communication error within 1 second which the engine controller can not detect oc-
curs, the test may be continued although the machine monitor does not continue the test (standard
screen). In that case, turn the starting switch to OFF position once, and system operating lamp goes
out, and the engine controller shuts down to reset the test.
• If the testing of this item is performed without removing AdBlue/DEF injector, it may cause a failure.
Be sure to remove AdBlue/DEF injector before starting the testing.
• AdBlue/DEF may freeze when the outside air temperature is low. AdBlue/DEF should be thawed com-
pletely before performing the test. Devices will get damaged if the calibration is performed when the
AdBlue/DEF is still frozen.
AdBlue/DEF injection quantity test is the function that checks if AdBlue/DEF injector has any failure by increas-
ing AdBlue/DEF pump pressure and injecting a certain amount of AdBlue/DEF.
For testing of AdBlue/DEF injector to perform troubleshooting or others, refer to this section.

METHOD FOR TESTING INJECTION AMOUNT FROM AdBlue/DEF INJECTOR

(HB335_3_E-K-AFJ0-362-00-B)
1. Start the engine.
2. Check the AdBlue/DEF conditions.
1) Select the following monitoring items on “Monitoring
Selection Menu”. See “SET AND OPERATE MA-
CHINE MONITOR”.
Monitoring code 19305: “AdBlue/DEF Tank Heating
State”
Monitoring code 19309: “AdBlue/DEF Pump Heater
State”
Monitoring code 19306: “AdBlue/DEF Line Heater 1
State”
Monitoring code 19307: “AdBlue/DEF Line Heater 2
State”

HB365LC-3 30-71
TEST SCR RELATED FUNCTIONS 30 TESTING AND ADJUSTING

2) Check the monitoring information of (a) to (d) on

“Monitoring” screen.
Details of monitoring information are as follows.
1: Being thawed
2: Being kept warm
3: OFF
• When the status of the monitoring information (a) to
(d) is “1”
AdBlue/DEF is being thawed because it is still frozen.
Keep the engine speed at low idle and wait until the
status of the monitoring information to become “2” or
“3”, and then proceed to step 3.
• The status of the monitoring information (a) to (b) is
“2” or “3”:
AdBlue/DEF is not frozen. Proceed to step 3.
3. Stop the engine.
k Immediately after the engine is stopped, its parts
and oil are still very hot and it may cause burn in-
jury. Wait for the temperature to go down, and then
start the work.
4. Check that the system operating lamp is not lit, turn the battery disconnect switch to OFF position, and re-
move the key.
5. Open the engine hood.
6. Check that there are not any cracks or dissolution on AdBl-
ue/DEF injector (1).

7. Disconnect the connector (MB03) and connect the socket

A to AdBlue/DEF injector (1) side, and then measure the
resistance value.
REMARK
• The resistance value becomes high when it is at high
temperature. Cool it down completely, and perform the
measurement.
• Measure the resistance between pin 1 and pin 2.
For standard values, see STANDARD VALUE TABLE,
“STANDARD VALUE TABLE FOR ELECTRICITY”.
8. After the measurement is completed, remove the measuring instrument, and connect the connector
(MB03).
9. Turn the battery disconnect switch to ON position.
10. Remove the AdBlue/DEF injector (1).

30-72 HB365LC-3
30 TESTING AND ADJUSTING TEST SCR RELATED FUNCTIONS

REMARK
• If the crystal of AdBlue/DEF is adhered at the tip of AdBlue/DEF injector (1), wipe it off with clean cloth.
• If the crystal of AdBlue/DEF is stuck and it is difficult to wipe it off, soak new AdBlue/DEF to clean cloth
and wipe the crystal off with it. Or, wipe crystal off by using distilled water or deionized water instead of
AdBlue/DEF.
11. Set AdBlue/DEF injector (1) so that resin container C can
receive AdBlue/DEF injected from AdBlue/DEF injector (1).

12. Check that AdBlue/DEF level is higher than level (a) of the
sight gauge of AdBlue/DEF tank.
REMARK
If the level of AdBlue/DEF is below level (a), AdBlue/DEF
amount is insufficient for test, so refill with AdBlue/DEF.
13. Turn the starting switch to ON position.
k For the safety reasons, this test cannot be per-
formed while the engine is running.

14. See “METHOD FOR SETTING WITH TESTING MENU

(SCR SERVICE TEST)” of “SETTING AND OPERATION
OF MACHINE MONITOR”, and select “AdBlue/DEF Injec-
tion Quantity Test”.

HB365LC-3 30-73
TEST SCR RELATED FUNCTIONS 30 TESTING AND ADJUSTING

15. Check that “0” in the “Test State” column is flashing.

REMARK
Flashing of “0” indicates “Ready for the start (default)”, and
the test can be performed. When the display is not “0”,
perform the required action according to “Parameter list of
test state”.
16. Press F1 to start “AdBlue/DEF Injection Quantity Test”.
F1: Starts “AdBlue/DEF Injection Quantity Test”.
(AdBlue/DEF is injected from AdBlue/DEF injector.)
F2: Stops “AdBlue/DEF Injection Quantity Test”. (When
“STOP” is displayed.)
F5: Returns to the “SCR Service Test” screen.
NOTICE
• If “Test State” does not change to “10” after press-
ing F1 and the test does not start, turn the starting
switch to OFF position. Then, repeat the testing
procedure from step 10.
• To cancel AdBlue/DEF injection halfway, press F2.
(If F2 is pressed, the display of “Test State”
changes to flashing of “20”.)
• Do not return the starting switch to ON position
soon even if you turn the starting switch to OFF
position by mistake during the test. Check that the
system operating lamp is not lit. When the engine
controller shuts down completely, turn the starting
switch to ON position.
• The engine controller cannot detect a KOMNET
communication error which does not remain for
one second, and the test may continue even when
the machine monitor does not continue the test
(standard screen). In such a case, turn the starting
switch to OFF position to shut down the engine
controller, and the system operating lamp goes
out, and then the test is reset.
REMARK
• Display of “Test State” changes to flashing of “10” and AdBlue/DEF pump pressure increases, and then
“AdBlue/DEF Pump Pressure” increases.
• When the display of “Test State” is “11” to “41”, perform the required action according to the “Parameter
list of test state”.
• When display of Remaining Permitted Test Time becomes “0:00 min:sec”, the injection is finished. AdBl-
ue/DEF purge action starts automatically, and the display of “Test State” changes to the flashing of “20”.
• AdBlue/DEF purge action is finished in 5 minutes, display of “Test State” changes to the flashing of “0”,
and AdBlue/DEF injector finishes injection.
• Since “Final Accumulated Quantity” is the target value, it does not change from “100.0 mℓ”.
• If the value of “AdBlue/DEF Pump Pressure” does not increase, check each part of AdBlue/DEF supply
line for leakage, or check by sound and vibration that AdBlue/DEF pump operates.
• If the value of “AdBlue/DEF Pump Pressure” does not increase to 800 or above kPa in approximately
200 seconds, AdBlue/DEF stops operation automatically and failure code [CA1682] is displayed. If the
failure code appears, perform troubleshooting for it.
17. When the display of Remaining Permitted Test Time becomes “0:00 min: sec” and injection is finished,
measure the amount of AdBlue/DEF collected in resin container C with measuring cylinder D.

30-74 HB365LC-3
30 TESTING AND ADJUSTING TEST SCR RELATED FUNCTIONS

REMARK
If the measurement result is out of the standard value, replace the AdBlue/DEF injector. For the replace-
ment procedure of AdBlue/DEF injector, see “DISASSEMBLY AND ASSEMBLY”, “REMOVE AND INSTALL
AdBlue/DEF INJECTOR”.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.
NOTICE
• Replace the gasket on the mounting face of the AdBlue/DEF injector with new one.
• For the installation procedure of AdBlue/DEF injector, see DISASSEMBLY AND ASSEMBLY, “RE-
MOVE AND INSTALL AdBlue/DEF INJECTOR”.

TEST AdBlue/DEF LINE HEATER RELAY 1 (PC400_11-K-AFK4-304-00-B)

Tools for testing AdBlue/DEF line heater relay 1

Symbol Part No. Part name Q'ty Remarks
A 799-601-9020 T-adapter 1
B 799-601-2600 T-box 1
Commercially
C Multimeter 1
available

k Place the machine on a level ground, lower the work equipment with a stable posture to the ground,
set the lock lever in LOCK position, and stop the engine.
NOTICE
If KOMNET communication error remains less than 1 second, engine controller is unable to detect it,
and the test may be continued while the machine monitor does not continue (standard screen). In that
case, turn the starting switch to OFF position once, and then system operating lamp goes out, and the
engine controller shuts down to reset the test.
“AdBlue/DEF Line Heater 1 Relay Test” function can actuate AdBlue/DEF line heater 1 at any timing, and can
check electrical action.
For testing of AdBlue/DEF suction circuit, or purge circuit or to perform troubleshooting or others, refer to this
section.

METHOD FOR TESTING AdBlue/DEF LINE HEATER RELAY 1 (HB335_3_E-K-AFK4-362-01-B)

1. Check that the system operating lamp is not lit, turn the battery disconnect switch to OFF position, and re-
move the key.
2. Open the cover on the right side of the machine.
3. Disconnect the connector to be tested.
When testing the low temperature pressure line heater re-
lay of AdBlue/DEF: Connector (MB07)
When testing the return line heater relay of AdBlue/DEF:
Connector (MB05)
When testing the suction line heater relay of AdBlue/DEF:
Connector (MB04)

HB365LC-3 30-75
TEST SCR RELATED FUNCTIONS 30 TESTING AND ADJUSTING

4. Connect the T-adapter A and T-adapter box B, and pre-

pare the multimeter C.
REMARK
Measure the voltage between pin 1 and pin 2.
5. Turn the battery disconnect switch to ON position.
6. Turn the starting switch to ON position.
k For the safety reasons, this test cannot be per-
formed while the engine is running.

7. See “METHOD FOR SETTING WITH TESTING MENU

(SCR SERVICE TEST)” of “SETTING AND OPERATION
OF MACHINE MONITOR”, and select “AdBlue/DEF Line
Heater Relay 1 Test”.

8. Check that “0” in the “Test State” column is flashing.

REMARK
Flashing of “0” indicates “Ready for the start (default)”, and
the test can be performed. When the display is not “0”,
perform the required action according to “Parameter list of
test state”.
9. Press F1 to start “AdBlue/DEF Line Heater Relay 1 Test”.
F1: Starts “AdBlue/DEF Line Heater Relay 1 Test”.
F2: Stops “AdBlue/DEF Line Heater Relay 1 Test”. (When
“STOP” is displayed.)
F5: Returns to the “SCR Service Test” screen.

30-76 HB365LC-3
30 TESTING AND ADJUSTING TEST SCR RELATED FUNCTIONS

NOTICE
• When F1 is pressed, if the display of “Test State” does not change to “10” and the test does not
start, turn the starting switch to OFF position, and repeat the testing procedure from step 5.
• Do not return the starting switch to ON position soon even if you turn the starting switch to OFF
position by mistake during the test. Check that the system operating lamp is not lit. When the
engine controller shuts down completely, turn the starting switch to ON position.
• The engine controller cannot detect a KOMNET communication error which does not remain for
one second, and the test may continue even when the machine monitor does not continue the
test (standard screen). In such a case, turn the starting switch to OFF position to shut down the
engine controller, and the system operating lamp goes out, and then the test is reset.
REMARK
• Display of “Test State” changes to flashing of “10”, and display of “Remaining Time to Start Test” is
counted down from “60 sec” to “0 sec”. When the time reaches to “0 sec”, the test finishes automatically.
• When the display of “Test State” is “11” to “41”, perform the required action according to the “Parameter
list of test state”.
• When the display of “Remaining Time to Start Test” becomes “0 sec”, “AdBlue/DEF Line Heater 1 Com-
mand” becomes “ON”, and voltage is outputted to the heater relay.
• The heater relay operates 900 seconds at maximum, and its remaining operable time is displayed as
“Remaining Permitted Test Time”.
• When the sum of “Remaining Time to Start Test” (1 min) + Heater relay operating time exceeds 16 mi-
nutes after F1 is pressed, the test stops automatically.
10. Measure the voltage between pin 1 and pin 2.
REMARK
• If an abnormality occurs during measurement, failure codes [CA3713], [CA5115], [CA3562], and
[CA3563] are displayed. If these failure codes appear, perform troubleshooting for them.
• If 24.5±1.5 V is measured within 900 seconds of “Remaining Permitted Test Time”, you can finish the
measurement by pressing F2.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
11. When the voltage of 24.5±1.5 V is measured, press F2.
REMARK
The display of “Test State” changes to flashing of “20”.
After finishing the test, remove the testing tools and restore the machine.
REMARK
Always turn the battery disconnect switch to OFF position when disconnecting connector.

TEST AdBlue/DEF LINE HEATER RELAY 2 (PC400_11-K-AFK4-304-01-B)

Testing tools for AdBlue/DEF line heater relay 2

Symbol Part No. Part name Q'ty Remarks
A 799-601-9020 T-adapter 1
B 799-601-2600 T-box 1
Commercially
C Multimeter 1
available

k Place the machine on a level ground, lower the work equipment with a stable posture to the ground,
set the lock lever in LOCK position, and stop the engine.

HB365LC-3 30-77
TEST SCR RELATED FUNCTIONS 30 TESTING AND ADJUSTING

NOTICE
If KOMNET communication error remains less than 1 second, engine controller is unable to detect it,
and the test may be continued while the machine monitor does not continue (standard screen). In that
case, turn the starting switch to OFF position once, and then system operating lamp goes out, and the
engine controller shuts down to reset the test.
“AdBlue/DEF Line Heater 2 Relay Test” function can actuate AdBlue/DEF line heater 2 at any timing, and can
check electrical action.
For testing of AdBlue/DEF pressure circuit relay to perform troubleshooting or others, refer to this section.

METHOD FOR TESTING AdBlue/DEF LINE HEATER RELAY 2 (HB335_3_E-K-AFK4-362-02-B)

1. Check that the system operating lamp is not lit, turn the battery disconnect switch to OFF position, and re-
move the key.
2. Open the engine hood.
3. Disconnect the connector (MB06).

4. Connect the T-adapter A and T-adapter box B, and pre-

pare the multimeter C.
REMARK
Measure the voltage between pin 1 and pin 2.
5. Turn the battery disconnect switch to ON position.
6. Turn the starting switch to ON position.
k For the safety reasons, this test cannot be per-
formed while the engine is running.

30-78 HB365LC-3
30 TESTING AND ADJUSTING TEST SCR RELATED FUNCTIONS

7. See “METHOD FOR SETTING WITH TESTING MENU

(SCR SERVICE TEST)” of “SETTING AND OPERATION
OF MACHINE MONITOR”, and select “AdBlue/DEF Line
Heater Relay 2 Test”.

8. Check that “0” in the “Test State” column is flashing.

REMARK
Flashing of “0” indicates “Ready for the start (default)”, and
the test can be performed. When the display is not “0”,
perform the required action according to “Parameter list of
test state”.
9. Press F1 to start “AdBlue/DEF Line Heater Relay 2 Test”.
F1: Starts “AdBlue/DEF Line Heater Relay 2 Test”.
F2: Stops “AdBlue/DEF Line Heater Relay 2 Test”. (When
“STOP” is displayed.)
F5: Returns to the “SCR Service Test” screen.
NOTICE
• If “Test State” does not change to “10” after press-
ing F1 and the test does not start, turn the starting
switch to OFF position. Then, repeat the testing
procedure from step 6.
• Do not return the starting switch to ON position
soon even if you turn the starting switch to OFF
position by mistake during the test. Check that the
system operating lamp is not lit. When the engine
controller shuts down completely, turn the starting
switch to ON position.
• The engine controller cannot detect a KOMNET
communication error which does not remain for
one second, and the test may continue even when
the machine monitor does not continue the test
(standard screen). In such a case, turn the starting
switch to OFF position to shut down the engine
controller, and the system operating lamp goes
out, and then the test is reset.
REMARK
• Display of “Test State” changes to flashing of “10”, and display of “Remaining Time to Start Test” is
counted down from “60 sec” to “0 sec”. When the time reaches to “0 sec”, the test finishes automatically.
• When the display of “Test State” is “11” to “41”, perform the required action according to the “Parameter
list of test state”.
• When the display of “Remaining Time to Start Test” becomes “0 sec”, “AdBlue/DEF Line Heater 2 Com-
mand” becomes “ON”, and voltage is outputted.
• The heater relay operates 900 seconds at maximum, and its remaining operable time is displayed as
“Remaining Permitted Test Time”.
• When the sum of “Remaining Time to Start Test” (1 min) + Heater relay operating time exceeds 16 mi-
nutes after F1 is pressed, the test stops automatically.

HB365LC-3 30-79
TEST SCR RELATED FUNCTIONS 30 TESTING AND ADJUSTING

10. Measure the voltage between pin 1 and pin 2.

REMARK
• If an abnormality occurs during measurement, failure codes [CA3713], [CA5115], [CA3562], and
[CA3563] are displayed. If these failure codes appear, perform troubleshooting for them.
• If 24.5±1.5 V is measured within 900 seconds of “Remaining Permitted Test Time”, you can finish the
measurement by pressing F2.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
11. When the voltage of 24.5±1.5 V is measured, press F2.
REMARK
The display of “Test State” changes to flashing of “20”.
After finishing the test, remove the testing tools and restore the machine.
REMARK
Always turn the battery disconnect switch to OFF position when disconnecting connector.

TEST AdBlue/DEF PUMP HEATER RELAY (PC400_11-K-AFK4-304-02-B)

Tools for testing AdBlue/DEF pump heater relay

Symbol Part No. Part name Q'ty Remarks
A 799-601-9130 T-adapter 1
B 799-601-2600 T-box 1
Commercially
C Multimeter 1
available

k Place the machine on a level ground, lower the work equipment to the ground in a stable posture, set
the lock lever to LOCK position, and stop the engine.
NOTICE
• If KOMNET communication error remains less than 1 second, engine controller is unable to detect it,
and the test may be continued while the machine monitor does not continue (standard screen). In
that case, turn the starting switch to OFF position once, and then system operating lamp goes out,
and the engine controller shuts down to reset the test.
• In this pump heater relay test, when the starting switch is turned to OFF position while testing (ener-
gizing), and turned to ON position again before system operating lamp goes out, then energizing re-
starts. If, by mistake, the starting switch is turned to ON position while testing (energizing) without
waiting that system lamp goes out, immediately turn the starting switch to OFF position regardless
of the display of machine monitor, and wait the system operating lamp goes out.
“AdBlue/DEF Pump Heater Relay Test” function can actuate AdBlue/DEF pump heater at any timing, and can
check electrical action.
For testing of AdBlue/DEF pump heater relay to perform troubleshooting or others, refer to this section.

METHOD FOR TESTING AdBlue/DEF PUMP HEATER RELAY (HB335_3_E-K-AFK4-362-03-B)

1. Check that the system operating lamp is not lit, turn the battery disconnect switch to OFF position, and re-
move the key.
2. Open the cover on the right side of the machine.

30-80 HB365LC-3
30 TESTING AND ADJUSTING TEST SCR RELATED FUNCTIONS

3. Disconnect the connector (R53A).

4. Connect the T-adapter A and T-adapter box B, and pre-

pare the multimeter C.
REMARK
Measure the voltage between pin 2 and pin 12.
5. Turn the battery disconnect switch to ON position.
6. Turn the starting switch to ON position.
k For the safety reasons, this test cannot be per-
formed while the engine is running.

7. See “METHOD FOR SETTING WITH TESTING MENU

(SCR SERVICE TEST)” of “SETTING AND OPERATION
OF MACHINE MONITOR”, and select “AdBlue/DEF Pump
Heater Relay Test”.

HB365LC-3 30-81
TEST SCR RELATED FUNCTIONS 30 TESTING AND ADJUSTING

8. Check that “0” in the “Test State” column is flashing.

REMARK
Flashing of “0” indicates “Ready for the start (default)”, and
the test can be performed. When the display is not “0”,
perform the required action according to “Parameter list of
test state”.
9. Press F1 to start “AdBlue/DEF Pump Heater Relay Test”.
F1: Starts “AdBlue/DEF Pump Heater Relay Test”.
F2: Stops “AdBlue/DEF Pump Heater Relay Test”. (When
“STOP” is displayed.)
F5: Returns to the “SCR Service Test” screen.
NOTICE
• If “Test State” does not change to “10” after press-
ing F1 and the test does not start, turn the starting
switch to OFF position. Then, repeat the testing
procedure from step 5.
• Do not return the starting switch to ON position
soon even if you turn the starting switch to OFF
position by mistake during the test. Check that the
system operating lamp is not lit. When the engine
controller shuts down completely, turn the starting
switch to ON position.
• The engine controller cannot detect a KOMNET
communication error which does not remain for
one second, and the test may continue even when
the machine monitor does not continue the test
(standard screen). In such a case, turn the starting
switch to OFF position to shut down the engine
controller, and the system operating lamp goes
out, and then the test is reset.
REMARK
• The result of “Test State” will be “10” and the number starts flashing, and the “Remaining Time to Start
Test” countdown starts “60” to “0 sec”.
• When the display of “Test State” is “11” to “41”, perform the required action according to the “Parameter
list of test state”.
• When the display of “Remaining Time to Start Test” becomes “0 sec”, the voltage is outputted.
• The heater relay operates 900 seconds at maximum, and its remaining operable time is displayed as
“Remaining Permitted Test Time”. Pump stops operation automatically if the temperature of the pump
reaches 55 °C to protect pump heater. Wait for the temperature to drop before restarting the relay oper-
ation.
• Do not measure the voltage when the AdBlue/DEF pump heater is energized or de-energized repeated-
ly because it is unable to measure the stable voltage.
• When the AdBlue/DEF pump heater is energized or de-energized repeatedly, press F2 to stop the test,
and wait for the pump temperature to drop.
• When the sum of “Remaining Time to Start Test” (1 min) + Heater relay operating time exceeds 16 mi-
nutes after F1 is pressed, the test stops automatically.
• The pump heater relay test can be judged by the AdBlue/DEF pump temperature on the machine moni-
tor. If the temperature rises 5 °C or more by starting “AdBlue/DEF Pump Heater Relay Test” when
“AdBlue/DEF Pump Temperature” is 45 °C or below.
10. Measure the voltage between pin 2 and pin 12.

30-82 HB365LC-3
30 TESTING AND ADJUSTING TEST SCR RELATED FUNCTIONS

REMARK
• If an abnormality occurs during measurement, failure codes [CA4115] , [CA4156], and [CA4169] are dis-
played. If these failure codes appear, perform troubleshooting for them.
• If 24.5±1.5 V is measured within 900 seconds of “Remaining Permitted Test Time”, you can finish the
measurement by pressing F2.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
11. When the voltage of 24.5±1.5 V is measured, press F2.
REMARK
The display of “Test State” changes to flashing of “20”.
After finishing the test, remove the testing tools and restore the machine.
REMARK
Always turn the battery disconnect switch to OFF position when disconnecting connector.

TEST AdBlue/DEF TANK HEATER VALVE (PC400_11-K-AFK2-304-00-B)

Tools for testing AdBlue/DEF tank heater valve

Symbol Part No. Part name Q'ty Remarks
A 799-601-9020 T-adapter 1
B 799-601-2600 T-box 1
Commercially
C Multimeter 1
available

k Place the machine on a level ground, lower the work equipment with a stable posture to the ground,
set the lock lever in LOCK position, and stop the engine.
NOTICE
If KOMNET communication error remains less than 1 second, engine controller is unable to detect it,
and the test may be continued while the machine monitor does not continue the test (standard screen).
In that case, once the starting switch is turned to OFF position, system operating lamp goes out, and
the engine controller shuts down to reset the test.
“AdBlue/DEF Tank Heater Valve Test” is a function to actuate AdBlue/DEF tank heater valve at any timing, and
to check electrical action.
For testing of AdBlue/DEF tank heater valve to perform troubleshooting or others, refer to this section.

METHOD FOR TESTING AdBlue/DEF HEATER VALVE (HB335_3_E-K-AFK2-362-00-B)

1. Check that the system operating lamp is not lit, turn the battery disconnect switch to OFF position, and re-
move the key.
2. Remove the undercover (1).

HB365LC-3 30-83
TEST SCR RELATED FUNCTIONS 30 TESTING AND ADJUSTING

3. Disconnect the connector (V41).

4. Connect the T-adapter A and T-adapter box B, and pre-

pare the multimeter C.
REMARK
Measure the voltage between pin 1 and pin 2.
5. Turn the battery disconnect switch to ON position.
6. Turn the starting switch to ON position.
k For the safety reasons, this test cannot be per-
formed while the engine is running.

7. See “METHOD FOR SETTING WITH TESTING MENU

(SCR SERVICE TEST)” of “SETTING AND OPERATION
OF MACHINE MONITOR”, and select “AdBlue/DEF Tank
Heater Valve Test”.

30-84 HB365LC-3
30 TESTING AND ADJUSTING TEST SCR RELATED FUNCTIONS

8. Check that “0” in the “Test State” column is flashing.

REMARK
Flashing of “0” indicates “Ready for the start (default)”, and
the test can be performed. When the display is not “0”,
perform the required action according to “Parameter list of
test state”.
9. Press F1 to start “AdBlue/DEF Tank Heater Valve Test”.
F1: Starts “AdBlue/DEF Tank Heater Valve Test”.
F2: Stops “AdBlue/DEF Tank Heater Valve Test”. (When
“STOP” is displayed.)
F5: Returns to the “SCR Service Test” screen.
NOTICE
• If “Test State” does not change to “10” after press-
ing F1 and the test does not start, turn the starting
switch to OFF position. Then, repeat the testing
procedure from step 5.
• Do not return the starting switch to ON position
soon even if you turn the starting switch to OFF
position by mistake during the test. Check that the
system operating lamp is not lit. When the engine
controller shuts down completely, turn the starting
switch to ON position.
• The engine controller cannot detect a KOMNET
communication error which does not remain for
one second, and the test may continue even when
the machine monitor does not continue the test
(standard screen). In such a case, turn the starting
switch to OFF position to shut down the engine
controller, and the system operating lamp goes
out, and then the test is reset.
REMARK
• The result of “Test State” will be “10” and the number starts flashing, and the “Remaining Time to Start
Test” countdown starts “60” to “0 sec”.
• When the display of “Test State” is “11” to “41”, perform the required action according to the “Parameter
list of test state”.
• When the display of “Remaining Time to Start Test” becomes “0 sec”, the voltage is outputted.
• The heater relay operates 900 seconds at maximum, and its remaining operable time is displayed as
“Remaining Permitted Test Time”.
• When the sum of “Remaining Time to Start Test” (1 min) + Heater valve operating time exceeds 16 mi-
nutes after F1 is pressed, the test stops automatically. Check the time of Remaining Time to Start Test
and Remaining Permitted Test Time displayed on the machine monitor since the heater valve does not
always operate continuously.
10. Measure the voltage between pin 1 and pin 2.

HB365LC-3 30-85
TEST SCR RELATED FUNCTIONS 30 TESTING AND ADJUSTING

REMARK
• If an abnormality occurs during measurement, failure codes [CA1683] and [CA1684] are displayed. If
these failure codes appear, perform troubleshooting for them.
• If 24.5±1.5 V is measured within 900 seconds of “Remaining Permitted Test Time”, you can finish the
test by pressing F2.
• If AdBlue/DEF tank temperature rises too high, AdBlue/DEF may be deteriorated or toxic ammonia
(NH3) odor is generated at refilling port. Observe the description in “Operation and Maintenance Man-
ual”, “Precautions for AdBlue/DEF”.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
11. When the voltage of 24.5±1.5 V is measured, press F2.
REMARK
The display of “Test State” changes to flashing of “20”.
After finishing the test, remove the testing tools and restore the machine.
REMARK
Always turn the battery disconnect switch to OFF position when disconnecting connector.

TEST DENITRATION EFFICIENCY OF SCR (PC400_11-K-AF00-304-10-B)

k Place the machine on a level ground, lower the work equipment with a stable posture to the ground,
set the lock lever in LOCK position, and stop the engine.
k Check that there is no person or combustibles around the machine (especially the outlet of exhaust
pipe from where the exhaust gas spout out).
NOTICE
If KOMNET communication error remains less than 1 second, engine controller is unable to detect it,
and the test may be continued while the machine monitor does not continue (standard screen). In that
case, turn the starting switch to OFF position once, and then system operating lamp goes out, and the
engine controller shuts down to reset the test.
For testing of AdBlue/DEF injection performance and catalyst efficiency to perform troubleshooting or others, re-
fer to this section.

METHOD FOR TESTING DENITRATION EFFICIENCY OF SCR (PC400_11_E-K-AF00-362-11-B)

1. Check that AdBlue/DEF level is higher than (a') with the

sight gauge.
2. Check that the system operating lamp is off, turn the start-
ing switch to ON position, and check fuel gauge for the re-
maining fuel.
REMARK
• “SCR Denitration Efficiency Test” uses fuel and AdBl-
ue/DEF, and it takes approximately 90 minutes at maxi-
mum. Make sure that the remaining amount of these
are at least the minimum amount.
• If the fuel and AdBlue/DEF are less than minimum
amount shown below, be sure to refill with them.
Gauge Minimum amount (gauge position)
Fuel gauge Position (a) and above
Sight gauge of AdBlue/DEF level Position (a') and above
3. Start the engine, and set the fuel control dial to MIN (Low idle) position.

30-86 HB365LC-3
30 TESTING AND ADJUSTING TEST SCR RELATED FUNCTIONS

4. See “METHOD FOR OPERATING TESTING MENU (SCR

SERVICE TEST)” of “SET AND OPERATE MACHINE
MONITOR” and select “SCR Denitration Efficiency Test”.

5. Check that “0” of “Test State” is flashing.

REMARK
Flashing of “0” indicates “Waiting for the start (default)”,
and test can be performed. Screen other than “0” is dis-
played, follow instructions according to “Parameter list of
test state”.
6. Press F1 to start “SCR Denitration Efficiency Test”.
F1: Starts “SCR Denitration Efficiency Test”.
F2: Stops “SCR Denitration Efficiency Test”. (When
“STOP” is displayed)
F5: Returns the screen to “SCR Service Test” screen.
NOTICE
• “Test State” does not change to “10” and test does
not start even if F1 is pressed, turn starting switch
to OFF position once, and repeat the procedure
from step 1.
• When the test is stopped by pressing F2, “0” of
“Test State” flashes, but you can not restart the
test by pressing F1. To restart the test, turn the
starting switch to OFF position once. System oper-
ating lamp goes out, and engine controller shuts
down, and test is reset.
• If you turn starting switch to OFF position by mis-
take during test, do not turn starting switch to ON
position immediately. Check that system operating
lamp is off, and turn starting switch to ON position
again after engine controller shuts down.
• If KOMNET communication error remains less than
1 second, engine controller is unable to detect it,
and the test may be continued while the machine
monitor does not continue the test(standard
screen). In that case, once the starting switch is
turned to OFF position, system operating lamp
goes out, and the engine controller shuts down to
reset the test.

HB365LC-3 30-87
TEST SCR RELATED FUNCTIONS 30 TESTING AND ADJUSTING

REMARK
• The display of “Test State” changes to the flashing of “10”, and “SCR Denitration Efficiency Test” starts.
• “SCR Denitration Efficiency Test” will be normally completed in approximately 30 minutes, however it
may take approximately 90 minutes at maximum depending on the test state.
• When the display of “Test State” is “11” to “41” or “100”, follow “Parameter list of test state”.
• The test results of “AdBlue/DEF Injection Test Result” and “SCR Efficiency Test Result” are displayed as
“3” during test.
• When the display of “Test State” changes from flashing of “10” to flashing of “20”, the test is completed.
• “Test State” becomes “14” temporarily at the half way of the test, this state means the temperature is in
transition and it is not abnormal, so continue the test. (The display changes to “10” in a few minutes.)
• If you want to stop the test at halfway, press F2 to return the screen to the standard screen. (When F2 is
pressed, the display of “Test State” changes to the flashing of “20”.)
• If F2 is pressed and the operation stops halfway through the test, “AdBlue/DEF Injection Test Result”
and “SCR Efficiency Test Result” are displayed as “3”.
• The test results of “AdBlue/DEF Injection Test Result” and “SCR Efficiency Test Result” are displayed as
“0”, “1” or “4” after the test.
7. When “20” of “Test State” flashes, check the state of “AdBl-
ue/DEF Injection Test Result” and “SCR Efficiency Test
Result”.
REMARK
• “1” indicates a normal state, “0” indicates an abnormal
state, and “4” indicates that the test ends halfway due
to a failure.
• If “0” or “4” are displayed, perform procedure 8 and fail-
ure code is displayed.
After finishing the test, remove the testing tools and re-
store the machine. If failure code [CA3751] or [CA3755]
are displayed, perform troubleshooting.

Test Test result (indication on monitor)

AdBlue/DEF injection
1 0 1 0 4 4
performance
SCR catalyst perform-
1 1 0 0 4 4
ance
Failure code to be
- [CA3755] [CA3751] [CA3755] [CA1694] (*1)
displayed

*1: Failure codes other than [CA3751], [CA3755] and [CA1694] may be displayed. Take measures to trou-
bleshoot ongoing problem of failure code first.
8. Turn the starting switch to OFF position once, and then turn it to ON position.

30-88 HB365LC-3
30 TESTING AND ADJUSTING TEST SCR RELATED FUNCTIONS

REMARK
• If failure codes [CA3751], [CA3755], [CA1694] appear, troubleshoot them.
• If the test result is “4” but the failure code [CA1694] does not appear, continue to troubleshoot ongoing
problem.

HB365LC-3 30-89
CLEAN AdBlue/DEF TANK 30 TESTING AND ADJUSTING

CLEAN AdBlue/DEF TANK (PC400_11-K-AFF0-304-00-B)

Testing tools for cleaning of AdBlue/DEF tank

Symbol Part No. Part name Q'ty Remarks
Commercially
A Oil container 4 Made of plastic (for drained AdBlue/DEF)
available
Commercially
- Remote breather hose 1
available
Commercially ASOH Co., LTD ASOH CICCOLO:
1 Valve 1
available CY-2208 or equivalent
B
Commercially Approximately. 2 m, TOYOX TOYOSILI-
2 Hose 1
available CONE: TSI-8 or equivalent
Commercially
3 Joint 1 Stainless steel
available
C Commercially
AdBlue/DEF 1 For flushing: : 30 ℓ
available
D Commercially
Rubber gloves 1
available

k Place the machine on a level ground, lower the work equipment to the ground in a stable posture, set
the lock lever to LOCK position, and stop the engine.
k For handling the AdBlue/DEF, see Operation and Maintenance Manual, “Precautions for AdBlue/
DEF.”
k When handling AdBlue/DEF injector, always wear the protective eyeglasses and rubber gloves.
• For cleaning AdBlue/DEF tank to perform troubleshooting or others, refer to this section.
• Replace AdBlue/DEF tank filter at the same time when cleaning AdBlue/DEF tank.

METHOD FOR CLEANING AdBlue/DEF TANK (HB335_3_E-K-AFF0-255-00-B)

1. Connect the valve B1, hose B2, and joint B3.
REMARK
The remote breather hose B, which connects the valve B1,
hose B2, and joint B3, is used to adjust the amount for
drainage of AdBlue/DEF.
2. Swing the upper structure counterclockwise approximately
45 °.

3. Place the oil container A on the top of center frame (1) di-
rectly under the AdBlue/DEF tank.
k Never use an iron or aluminum container when dis-
posing AdBlue/DEF fluid, because toxic gas may
develop and a chemical reaction may corrode the
container. Use a container made of resin (PP, PE) or
stainless steel when catching the draining
AdBlue/DEF as waste liquid.

30-90 HB365LC-3
30 TESTING AND ADJUSTING CLEAN AdBlue/DEF TANK

4. Drain AdBlue/DEF in AdBlue/DEF tank (2) according to the

following procedure.
1) Check that cap (3) of AdBlue/DEF tank (2) is closed
securely.
REMARK
If AdBlue/DEF tank cap (3) is not closed completely,
close it securely.

2) Disconnect the breather hose (4) from breather block

(5), and connect the remote breather hose B to it.
REMARK
When connecting remote breather hose B, be sure to
close valve B1 of remote breather hose B.
3) Open the valve B1 of remote breather hose B.
REMARK
Valve B1 does not need to be opened fully.

4) See “METHOD FOR SETTING WITH TESTING

MENU (SCR SERVICE TEST)” of “SETTING AND
OPERATION OF MACHINE MONITOR”, and select
“AdBlue/DEF Pump Pressure Up Test”.
REMARK
By performing “AdBlue/DEF Pump Pressure Up Test”,
foreign material stuck to AdBlue/DEF tank strainer can
be dropped inside the tank. Injection of AdBlue/DEF
injector is not executed.

HB365LC-3 30-91
CLEAN AdBlue/DEF TANK 30 TESTING AND ADJUSTING

5) On “AdBlue/DEF Pump Pressure Up Test” screen,

check that “0” is flashing in “Test State”.
REMARK
Flashing of “0” indicates “Ready for the start (default)”,
and the test can be performed. When the display is
not “0”, perform the required action according to “Pa-
rameter list of test state”.
6) Press F1 to start “AdBlue/DEF Pump Pressure Up
Test”.
F1: Starts “AdBlue/DEF Pump Pressure Up Test”.
F2: Stops “AdBlue/DEF Pump Pressure Up Test”. (When “STOP” is displayed.)
F5: Returns to the “SCR Service Test” screen.
REMARK
When “AdBlue/DEF Pump Pressure Up Test” starts, AdBlue/DEF pump operates.
7) When the value of “AdBlue/DEF Pump Pressure” ex-
ceeds “800 kPa”, press F2.
REMARK
• When the value of “AdBlue/DEF Pump Pressure”
increases to “800 kPa” or higher, the display of
“Test State” changes to flashing of “10”.
• The 1st “AdBlue/DEF Pump Pressure Up Test” is
completed. Perform the test 3 times in total.
8) Repeat above steps 5 to 7 for 2 times.
9) Close the valve B1 of remote breather hose B secure-
ly.

10) Loosen the drain plug (6) by 6 turns and drain

AdBlue/DEF into oil container A.

30-92 HB365LC-3
30 TESTING AND ADJUSTING CLEAN AdBlue/DEF TANK

REMARK
There is the slit (a) at threaded portion of the drain
plug (6) so that AdBlue/DEF is not drained too much
and splashed.
11) It is almost drained in approximately 2 minutes, re-
move the drain plug (6).

12) Fully open the valve B1 of remote breather hose B.

13) When the container A is almost filled up, close the
valve B1 of the remote breather hose B securely.
14) It is almost drained in approximately 15 seconds,
change the oil container A.
15) Repeat steps 12) to 14). When AdBlue/DEF tank be-
comes empty, install drain plug (6) securely.
5. Clean AdBlue/DEF tank according to the following proce-
dure.

1) Check that the drain plug (6) is closed securely.

2) Refill AdBlue/DEF tank with the new AdBlue/DEF.

5 AdBlue/DEF tank:
30 ℓ
3) Repeat steps 10) to 15) of procedure 2, and drain
AdBlue/DEF.

6 AdBlue/DEF tank:
30 ℓ
Cleaning of AdBlue/DEF tank is completed.
6. Refill AdBlue/DEF tank with AdBlue/DEF according to the following procedure.
1) Check that the drain plug (6) is closed securely.

HB365LC-3 30-93
CLEAN AdBlue/DEF TANK 30 TESTING AND ADJUSTING

2) Disconnect the remote breather hose B from breather

block (5).
3) Connect the breather hose (4) to breather block (5).
4) Refill AdBlue/DEF tank with the new AdBlue/DEF.

5 AdBlue/DEF tank:
60 ℓ
NOTICE
AdBlue/DEF freezes at -11 °C. When adding AdBl-
ue/DEF where the ambient temperature is –11 °C
or below, add it only to the lowest line. For adding
AdBlue/DEF, see Operation and Maintenance Man-
ual, “METHOD FOR CHECKING DEF LEVEL AND
ADDING DEF”.
Check the refilling amount of AdBlue/DEF through sight gauge.

30-94 HB365LC-3
30 TESTING AND ADJUSTING PRECAUTIONS FOR USING HYBRID SYSTEMS

HYBRID SYSTEM (ALL-K-PQG9-001-30-B)

PRECAUTIONS FOR USING HYBRID SYSTEMS (HB335_3-K-PQG9-001-01-B)

This machine is equipped with the hybrid system consisting of an electric motor and a diesel engine.
Before starting work, see Operation and Maintenance Manual, and FOREWORD, SAFETY, BASIC INFORMA-
TION, “PRECAUTIONS FOR HANDLING HYBRID COMPONENTS AND HIGH VOLTAGE WIRING”.
NOTICE
When testing or adjusting a hybrid machine, ensure that you fully understand the following matters.
• The hybrid devices (motor-generator, capacitor, inverter, swing electric motor) and high-voltage wir-
ings (orange conduit wiring) must be removed by only workers who have completed the special
training for handling low-voltage electric device.
• Even a qualified person must not disassemble the hybrid devices (motor-generator, capacitor, inver-
ter, swing electric motor).
• The hybrid devices and high-voltage wirings (orange conduit wiring) must be replaced by the unit.
• When handling the hybrid devices, be sure to discharge the capacitor first. See “SET AND OPERATE
MACHINE MONITOR”, “METHOD FOR OPERATING TESTING MENU (Capacitor Discharge)”.
When certain failure codes are displayed, the capacitor cannot be discharged.

HB365LC-3 30-95
DRAIN, REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT 30 TESTING AND ADJUSTING

DRAIN, REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT

(HB335_3-K-PQJA-304-00-B)

Tools for draining, refilling, air bleeding of hybrid system coolant

Symbol Part No. Part name Q'ty Remarks
Commercially
A Oil container 2 Capacity: Approx. 20 ℓ
available
SYCG-AF-
B Super Coolant 1 Undiluted solution: 3.5 to 6.8 ℓ
NACCNK
C 207-03-22480 Clip 1

Commercially • Length: Approx. 2 m

D Hose 1
available • Hose inside diameter: 25 mm

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot and it may cause burn in-
jury. Wait for the temperature to go down, and then start the work.
k When draining or adding coolant, or bleeding air, never start the engine for safety reasons.
k Undiluted super coolant is flammable. Keep away from open flame.
k Check that the system operating lamp is not lit. Turn the battery disconnect switch to OFF position,
and remove the key.
k Never disconnect the high-voltage wiring (orange conduit wiring) during the removal and installation
work.
k When draining the coolant, be careful that the coolant does not touch your skin or get in your eyes.
Non-Amine Engine Coolant (AF-NAC) contained in the coolant is toxic. If the coolant gets in your
eyes or on your skin, wash it off with water thoroughly and consult a doctor.
Worker of draining, refilling, and air bleeding of hybrid system coolant does not have to be a “qualified person”.

30-96 HB365LC-3
30 TESTING AND ADJUSTING DRAIN, REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT

For draining, refilling, or air bleeding of hybrid system coolant to perform troubleshooting, refer to this section.

SM: Electric swing motor HI: Inverter

HR: Hybrid radiator HC: Capacitor
WP: Hybrid water pump
(1): Coolant filler port (5): Elbow plug (inlet) of swing motor
(2): Water filler cap (6): Elbow plug (outlet) of swing motor
(3): Drain valve (7): Overflow hose
(4): Air bleeder plug of swing motor

METHOD FOR DRAINING THE HYBRID SYSTEM COOLANT (HB335_3-K-PQJA-220-00-B)

Method for draining coolant through water pump drain plug

1. Start the engine.
2. Swing the upper structure clockwise approximately 45 °, and stop the engine.
3. Open the engine hood.
4. Check that the surface of hybrid radiator cap (1) can be
touched with bare hands, then slowly open the coolant fill-
er cap (1).

HB365LC-3 30-97
DRAIN, REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT 30 TESTING AND ADJUSTING

5. Remove the undercover (2).

6. Pull out the drain hose (3).

7. Place the oil container A under the drain hose (3).
8. Loosen the water pump drain plug (4), and drain the hybrid
system coolant.

6 Hybrid system coolant:

8.8 ℓ
9. After draining the coolant, install the water pump drain plug
(4).
3 Water pump drain plug (4):
58.6 to 78.2 Nm {6.0 to 8.0 kgm}
After finishing the work, restore the machine.

Method for draining coolant through capacitor drain plug

Drain the coolant through the plug at the bottom of capacitor
1. Remove the cover (5).

2. Place the oil container A under the drain plug (6).

3. Remove the capacitor drain plug (6), and drain the hybrid
system coolant.

6 Hybrid system coolant:

1.9 ℓ
4. After draining the coolant, install the capacitor drain plug
(6).
3 Capacitor drain plug (6):
5.88 to 8.82 Nm {0.6 to 0.9 kgm}
Drain the coolant through the plug inside capacitor case
5. Open the capacitor cover at the front right of machine.

30-98 HB365LC-3
30 TESTING AND ADJUSTING DRAIN, REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT

6. Place the oil container A under the capacitor drain hose

(7).

7. Loosen the drain plug (8), and drain the hybrid system
coolant.

6 Hybrid system coolant:

11.7 ℓ
8. After draining the coolant, install the drain plug (8).
3 Drain plug (8):
58.6 to 78.2 Nm {6.0 to 8.0 kgm}

After finishing the work, restore the machine.

Method for replacing all hybrid system coolant

Follow the below procedures and replace the coolant in the following situations. When changing the mixing pro-
portion of super coolant or replacing all the coolant because the swing motor lubricating oil is mixed with the
coolant.
1. Drain the coolant through the water pump and capacitor (2 places). See “METHOD FOR DRAINING THE
HYBRID SYSTEM COOLANT”.
2. Open the cover on the right side of the machine.
3. Place the oil container A under the return hose (2) from the
swing motor.
REMARK
If it is difficult to loosen the clip (3), you may cut the hook
(a) of the clip (3).
4. Loosen the clip (3).
5. Disconnect the return hose (2) from the hybrid system ra-
diator (4).

HB365LC-3 30-99
DRAIN, REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT 30 TESTING AND ADJUSTING

6. Install the drain hose D to portion (b) from which the return
hose of hybrid system radiator (4) was disconnected, by
using the clip (3).
7. Insert the end of hose D into oil container A.

8. Check the hybrid system radiator cap (1) is tightened se-

curely.
9. Supply air into return hose (2) and discharge all hybrid
system coolant through drain hose D.

6 Hybrid system coolant:

15.4 ℓ
10. Connect the return hose (2) to portion (b) from which the
hose was disconnected, and fix it with clamp (3).
11. Add the specified quantity of coolant and clean the inside
of the circuit. See “Methods for adding and air bleeding of hybrid system coolant”.
12. Perform steps 1 to 12 again, and discharge all coolant.
REMARK
Drain the coolant and clean the inside of circuit by performing steps 11 to 12 as necessary, depending on
how dirty is the inside of the circuit.
13. Connect the return hose (2) to hybrid system radiator (4), and fix it with clip (3).
REMARK
If the hook (a) of the clip (3) was cut, replace the clip with a new one.
14. Add the hybrid system coolant and bleed air. See “Methods for adding and air bleeding of hybrid system
coolant”.
After finishing the work, restore the machine.

REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT (HB335_3-K-PQJA-216-00-B)

NOTICE
Bleed air immediately after refiling the hybrid coolant.
If a long time passes after coolant is refiled and the air is bled, air may be trapped on the suction side of
the water pump and the water pump may have a suction trouble.
1. Check the hybrid coolant level with upper sight gauge (1)
of hybrid system radiator.
2. Referring to the table below, mix in hybrid coolant.
NOTICE
• The minimum necessary volumetric percentage of
super coolant is 30%.
• Check the data of the lowest temperature in the
past and mixing proportion table and then decide
the mixing proportion of the coolant to the water. In
fact, set the temperature about 10 °C lower than the
lowest temperature.
• Use city water to dilute the coolant.

30-100 HB365LC-3
30 TESTING AND ADJUSTING DRAIN, REFILLING, AIR BLEEDING OF HYBRID SYSTEM COOLANT

Mixing proportion of city water and super coolant

(Refill capacity of hybrid system radiator: 11.7 ℓ)
Mixing proportion Lowest temperature (°C)
Min. -10 -15 -20 -25 -30 (-35) (-40)
Quantity of super coolant (ℓ) 3.5 4.2 4.8 5.4 5.9 6.3 6.8
Quantity of water (ℓ) 8.2 7.5 6.9 6.3 5.9 5.4 4.9
Volumetric percentage (%) 30 36 41 46 50 54 58
3. Remove the radiator cap (2) of the hybrid system radiator.
4. Slowly add coolant into the water filler up to upper sight
gauge (1).
NOTICE
Be careful not to spill the coolant while refiling the
coolant through the coolant filler of the hybrid system
radiator.

5 Hybrid system coolant:

11.7 ℓ
5. Securely tighten the radiator cap (2) of the hybrid system radiator.
6. Turn the starting switch to ON position, and operate the
hybrid water pump (3).
k Never start the engine.
NOTICE
Identify the operation sound of pump to determine
whether the hybrid system water pump (3) is running.
If it is difficult, touch the water pump (3) directly with
the hand.
7. Turn the starting switch to OFF position after 2 minutes,
and stop the operation of the hybrid water pump (3).
REMARK
The hybrid system coolant level decreases as the hybrid water pump operates.
8. Remove the radiator cap (2) of the hybrid system radiator.
9. Slowly refill the coolant up to upper sight gauge (1).
10. Securely tighten the radiator cap (2) of the hybrid system
radiator.

Some air remains in the coolant circuit, perform the following procedure.
1. Approximately 8 hours after the coolant has refiled, check the coolant level in hybrid system radiator with
upper sight gauge (1).
2. Remove the radiator cap (2) of the hybrid system radiator.
3. If the coolant level is low, refill the coolant up to upper sight gauge (1).
4. Securely tighten the radiator cap (2) of the hybrid system radiator.

HB365LC-3 30-101
WATER PRESSURE TEST OF THE HYBRID SYSTEM COOLANT 30 TESTING AND ADJUSTING

WATER PRESSURE TEST OF THE HYBRID SYSTEM COOLANT

(HB335_3-K-PQJA-304-01-B)

Tools for water pressure test of hybrid system coolant

Symbol Part No. Part name Q'ty Remarks
- 796-403-1100 Pressure checker 1
1 796-403-1110 Pressure sensor 1
A 2 195-40-31670 Plug 1
3 07002-11823 O-ring 1
4 796-403-1120 Tool box 1

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Be careful not to touch any hot parts when installing or removing the testing tools.
Check this item under the following conditions.
Engine coolant temperature: 60 to 100 °C
For testing of water pressure of hybrid system coolant to perform troubleshooting, refer to this section.

METHOD FOR TESTING THE WATER PRESSURE OF THE HYBRID SYSTEM

COOLANT (HB335_3_E-K-PQJA-362-00-B)
1. Remove the plug (1) of water inlet elbow of the swing mo-
tor.

2. Install the pressure sensor A1 of pressure checker A.

3. Open the L.H. side cover of the machine.

4. Disconnect the main harness service connector (P49).

5. Connect the pressure sensor A1 to disconnected service
connector (P49).
6. Start the engine.
7. Check that no water leaks from the mounting portion of
pressure sensor A1.
8. Select and display “Pre-defined Monitoring” (01/28). For
details, see “SPECIAL FUNCTIONS OF MACHINE MONI-
TOR”.

30-102 HB365LC-3
30 TESTING AND ADJUSTING WATER PRESSURE TEST OF THE HYBRID SYSTEM COOLANT

9. Raise the coolant temperature to the specified range.

10. Select and display the following monitoring items on “Pre-
defined Monitoring” (26/28) or “Monitoring Selection
Menu”.
Monitoring code: 01142“ Service Press (HYB Water
Pump)”

11. Test “Service Press (HYB Water Pump)” when fuel control
dial is in MIN (Low idle) and MAX (High idle) positions.
REMARK
Water pressure (MPa) is obtained by converting value (a)
displayed on the machine monitor screen by the following
formula.
Water pressure (MPa) = a/500
For standard values, see “STANDARD VALUE TABLE,
STANDARD VALUE TABLE FOR MACHINE”.

Method for testing water pressure change of the hybrid system coolant
The pump is normal if the pressure changes when the connector of either hybrid water pump is disconnected.
The pump is abnormal if the pressure does not change when the connector is disconnected.
1. Disconnect the connector (HK01) of water pump 1, and
check if the pressure changes.
After checking, connect the connector (HK01) of water
pump 1 again.
2. Disconnect the connector (HK04) of water pump 2, and
check if the pressure changes.
After checking, connect the connector (HK04) of water
pump 2 again.
For standard values, see “STANDARD VALUE TABLE,
STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.
3 Plug (1):
34.3 to 44.1 Nm {3.5 to 4.5 kgm}

HB365LC-3 30-103
TEST LUBRICATION CIRCUIT OIL PRESSURE OF HYBRID SYSTEM 30 TESTING AND ADJUSTING

TEST LUBRICATION CIRCUIT OIL PRESSURE OF HYBRID SYSTEM

(HB335_3-K-PQKB-304-00-B)

Testing tools for lubrication circuit oil pressure of hybrid system

Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A
1 799-101-5140 Gauge 1 Pressure range: 2.5 MPa
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-101-5220 Nipple 1 Size: M10x1.25
D 07002-11023 O-ring 1

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot and it may cause burn in-
jury. Wait for the temperature to go down, and then start the work.
For testing of lubrication circuit oil pressure of hybrid system to perform troubleshooting, refer to this section.

TEST LUBRICATION CIRCUIT OIL PRESSURE OF ELECTRIC SWING MOTOR

CASE (HB335_3-K-PQHK-362-00-B)
1. Remove the measurement plug (1) of electric swing motor.

2. Install the nipple C and connect it to gauge A1 of hydraulic

tester A.
3. Start the engine.
4. Adjust the hydraulic oil temperature within the specified
range.
5. Turn the fuel control dial to MAX (High idle) position, and
measure the oil pressure.
For standard values, see “STANDARD VALUE TABLE,
STANDARD VALUE TABLE FOR MACHINE”.

After finishing the test, remove the testing tools and restore the machine.
3 Measurement plug (1):
9.8 to 12.74 Nm {1.0 to 1.3 kgm}

TEST LUBRICATION CIRCUIT OIL PRESSURE OF MOTOR-GENERATOR OIL

CASE (HB335_3-K-PQH7-362-00-B)
1. Open the cover on the left side of the machine.

30-104 HB365LC-3
30 TESTING AND ADJUSTING TEST LUBRICATION CIRCUIT OIL PRESSURE OF HYBRID SYSTEM

2. Remove the measurement plug (1).

3. Install the nipple C and connect it to gauge A1 of hydraulic

tester A.
4. Start the engine.
5. Adjust the hydraulic oil temperature within the specified
range.
6. Turn the fuel control dial to MAX (High idle) position, and
measure the oil pressure.
For standard values, see “STANDARD VALUE TABLE,
STANDARD VALUE TABLE FOR MACHINE”.

After finishing the test, remove the testing tools and restore the machine.
3 Measurement plug (1):
9.8 to 12.74 Nm {1.0 to 1.3 kgm}

HB365LC-3 30-105
TEST SWING PARKING BRAKE PRESSURE 30 TESTING AND ADJUSTING

TEST SWING PARKING BRAKE PRESSURE (HB335_3-K-J6A0-304-00-B)

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k The swing parking brake disc is one of the wear parts. If disc wear has been found, replace the
swing parking brake disc with a new one.
k If the hybrid system has abnormality, the swing parking brake stops swinging. However, if the swing
parking brake has abnormality such as brake disc wear, swinging operation cannot be stopped.
k Refer to this section and test the swing parking brake in the following situations. When swinging op-
eration is stopped while the swing parking brake switch is pressed, or when the hydraulic drift of
swinging occurs on a slope because of abnormality in swing parking brake, or when a customer
pointed out the abnormalities in the swing parking brake.
k If any other related failures have found, make sure to clear up all the problems.
Test this item under the following conditions.
On a flat and level ground with no obstacles around the machine
For testing of swing parking brake to perform troubleshooting, refer to this section.

METHOD FOR TESTING THE SWING PARKING BRAKE PRESSURE

(HB335_3_J-K-J6A0-340-00-B)
1. Start the engine.
2. Operate the work equipment control lever and set the arm
at a right angle to the ground, and keep the bucket at 40 to
50 cm above the ground.
3. Turn the swing lock switch to ON position.

4. Operate the swing control lever and slowly swing the up-
per structure to right or left, and check the condition at this
time.
• When upper structure swings neither right nor left:
Swing parking brake of swing motor (1) is normal.
Stop the engine and finish the test.
• When upper structure swings:
• There are abnormalities in the electrical system if
the swing lock switch, etc. does not operate nor-
mality.
• There are abnormalities in the hydraulic system if
the swing parking brake solenoid valve (2) does
not operate normally.
• There are abnormalities in the mechanical system
such as wear of swing parking brake of swing mo-
tor (1).
The above abnormalities may have occurred. Go to
the next procedure.
5. Stop the engine.

30-106 HB365LC-3
30 TESTING AND ADJUSTING TEST SWING PARKING BRAKE PRESSURE

6. Check the swing lock switch, etc. in the electrical system and check the swing parking brake solenoid valve
(2), etc. in the hydraulic system.
• When there are abnormalities in electrical system or hydraulic system:
Check the spot where abnormality is detected.
• When there is no abnormality in electrical system and hydraulic system:
The mechanical system may have abnormality. Disassemble the swing machinery assembly, and
check the swing parking brake disc (1) for wear. See DISASSEMBLY AND ASSEMBLY, “DISASSEM-
BLE AND ASSEMBLE SWING MACHINERY ASSEMBLY”.
If there are signs of wear on the swing parking brake of swing motor (1) after disassembling the swing
machinery assembly, replace it with a new one.
7. Assemble the machine again.
8. Perform steps 3 to 4, and check again that the swing parking brake operates normally.

HB365LC-3 30-107
TEST AND CLEAN DELIVERY FILTER OF SWING MOTOR 30 TESTING AND ADJUSTING

TEST AND CLEAN DELIVERY FILTER OF SWING MOTOR (HB335_3-K-PQK5-304-00-B)

Testing tools for delivery filter of swing motor

Symbol Part No. Part name Q'ty Remarks
A 7875-13-3421 Oil filter 1
B 07002-11623 O-ring 1
C 07000-11010 O-ring 1

The coolant delivery filter of swing motor is installed to the circuit of lubricating oil and cooling oil system and is
used to collect dirt in the oil.
Test and clean the oil filter and then replace the electric swing motor oil every 2000 hours.
For testing and cleaning of delivery filter of swing motor to perform troubleshooting, refer to this section.

METHOD FOR CHECKING AND CLEANING ELECTRIC SWING MOTOR COOLING

OIL DELIVERY FILTER (HB335_3-K-PQK5-929-00-B)
1. Remove the oil filter (2) of the electric swing motor (1).
2. Clean or replace the filter (2) as necessary.

3. Install the oil filter (2).

REMARK
When installing the oil filter (2), be sure to install the O-
rings (3) and (4).
3 Oil filter (2):
24.5 to 34.3 Nm {2.5 to 3.5 kgm}

30-108 HB365LC-3
30 TESTING AND ADJUSTING TEST SWING CIRCLE BEARING CLEARANCE

POWER TRAIN (ALL-K-C100-001-30-B)

TEST SWING CIRCLE BEARING CLEARANCE (PC400_10-K-J117-304-00-B)

Tools for testing swing circle bearing clearance

Symbol Part No. Part name Q'ty Remarks
Commercially
A Dial gauge 1
available

k Do not put your hand or foot under the truck during the test.
For testing of swing circle bearing clearance to perform troubleshooting, refer to this section.

METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE (PC400_10-K-J117-365-01-B)

1. Fix dial gauge A to outer race (1) or inner race (2) of the
swing circle, and put the probe to the end surface of inner
race (2) or outer race (1) on the opposite side.
Set dial gauge A in the front or rear of the machine.

2. Set the work equipment to the maximum reach posture,

and set the bucket tip to the height of the underside of the
revolving frame.
The front side of the upper structure lowers and the rear
side rises.
3. Set dial gauge A to the zero point.

4. Set the arm almost perpendicular to the ground and lower

the boom until the front part of the tracks float by 150 to
200 mm.
The front side of the upper structure rises and the rear side
lowers.
5. Read the value indicated by dial gauge A.
The value indicated by dial gauge A is the clearance of the
bearing.
6. Return the machine to the state in step 2, and check that
dial gauge A indicates 0 point again.
If the dial gauge does not indicate 0 point, repeat steps 3
through 5.

HB365LC-3 30-109
TEST AND ADJUST TRACK TENSION 30 TESTING AND ADJUSTING

UNDERCARRIAGE AND FRAME (ALL-K-DT00-001-30-B)

TEST AND ADJUST TRACK TENSION (PC400_10-K-DTL0-304-00-B)

Tools for testing track tension

Symbol Part No. Part name Q'ty Remarks
Commercially
A Wooden block 1
available

k Place the machine on a level ground, lower the work equipment to the ground so that it is stable, set
the lock lever to LOCK position, and stop the engine.
For testing and adjusting the tension of track shoe to perform troubleshooting, refer to this section.

METHOD FOR TESTING TRACK TENSION (PC300_11-K-DTL0-285-00-B)

1. Set the fuel control dial to MIN (Low idle) position, travel the machine forward by the length of track on
ground, and then slowly stop it.
2. Put a bar A on the track shoe between the idler and the
first carrier roller.
REMARK
Use an L shape steel bar, etc. which has few deformation
for bar A.
3. Measure the maximum clearance (a) between bar A and
track shoe.
Standard maximum clearance (a): 10 to 33 mm

METHOD FOR ADJUSTING TRACK TENSION (PC400_10-K-DTL0-27C-00-B)

If the track tension is abnormal, adjust it according to the following procedure.

Method for increasing tension

1. Pump in grease through grease fitting (1) by using a
grease gun.
2. To check if the tension is correct, run the engine with the
fuel control dial at MIN (low idle) position, move the ma-
chine slowly forward by length of track on ground, then
stop the machine.

3. After finishing adjustment, recheck that the tension is cor-

rect according to the above procedure.
NOTICE
The grease can be pumped in until dimension (b) be-
tween the idler guide and the track frame end becomes
0 mm. If the tension is still loose, the wear of pins and
bushings is large. In such a case, the pins and bush-
ings need to be turned 180 deg. or replaced.

30-110 HB365LC-3
30 TESTING AND ADJUSTING TEST AND ADJUST TRACK TENSION

Method for decreasing tension

1. Loosen valve (2), remove the grease, and tighten valve
(2).
k Do not loosen the valve more than one turn, be-
cause the valve may fly out due to the high internal
pressure of the grease.
2. To check if the tension is correct, run the engine with the
fuel control dial at MIN (low idle) position, move the ma-
chine slowly forward by length of track on ground, then
stop the machine.
3. After finishing adjustment, check that the tension is correct
according to the above procedure.

HB365LC-3 30-111
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 30 TESTING AND ADJUSTING

HYDRAULIC SYSTEM (ALL-K-C000-001-30-B)

RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM

(PC400_10-K-C000-304-00-B)

For releasing the remaining pressure from hydraulic system to perform troubleshooting, refer to this section.

METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK

(PC300_11-K-C000-22A-01-B)
Release remaining pressure from the hydraulic tank according to the following procedure since hydraulic tank is
sealed and pressurized when removing a hose or a clamp connected to the hydraulic tank.
1. Lower the work equipment to the ground so that it is stable, and stop the engine.
2. Loosen oil filler cap (1) of the hydraulic tank gradually to
release the air in the tank.

METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER

CIRCUIT (PC300_11-K-C000-22A-02-B)
When disconnecting a pipe between a hydraulic cylinder and the control valve, release the remaining pressure
from the piping according to the following procedure.

Without anti-drop valve

1. Lower the work equipment to the ground and release the remaining pressure in the hydraulic tank. For de-
tails, see “Release remaining pressure in hydraulic tank”.
REMARK
Leave the oil filler cap of the hydraulic tank removed.
2. Turn the starting switch to ON position, set the work equipment lock lever to FREE position, and operate
the right and left work equipment control levers forward and backward, and to the right and left.
REMARK
The work equipment is operated by the pressure in the accumulator. Pressure in the accumulator is lost by
operating the work equipment 2 or 3 times.
3. Set the work equipment lock lever to LOCK position, start the engine, and run it with the fuel control dial at
MIN (Low idle) position for approximately 5 seconds to increase the pressure in the accumulator.
4. Repeat step 2 and 3 several times, and all remaining pressure is released from the piping completely.

With anti-drop valve of boom

k Place the machine on a level ground.
1. Check the function of PPC accumulator

30-112 HB365LC-3
30 TESTING AND ADJUSTING RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM

1) Retract arm cylinder and bucket cylinder to the stroke

ends, and hold the work equipment at height (a)
above the ground.
a: 1.5 m
2) Keep the arm cylinder and bucket cylinder retracted to
the stroke ends, turn the starting switch to OFF posi-
tion, and stop the engine.
3) Turn the starting switch to ON position.
4) Set the work equipment lock lever in FREE position.

5) Check that the work equipment is lowered to the

ground by slowly operating the work equipment con-
trol lever to the boom LOWER direction fully to the
stroke end.
REMARK
• If the work equipment is lowered under its weight
to the ground, the accumulator is normal.
• Pressure of accumulator drops gradually after
stopping the engine. Be sure to perform this work
(step 2) and 3)) in 15 seconds after stopping the
engine.
• If the work equipment is not lowered or stops while
lowering, pressure in the accumulator may be
dropped. Pressure cannot be released with this
procedure if the pressure in the accumulator is
low.
• Accumulator is a periodic inspection item and an
important periodic replacement part.
2. Start the engine.
3. Extend or retract arm cylinder and bucket cylinder to the
end, lower the work equipment to the ground, and stop the
engine.
REMARK
Since anti-drop valve is attached to boom cylinder bottom
side, hydraulic oil on bottom side of boom cylinder is
drained when work equipment is lowered to the ground,
and remaining pressure drops.
4. Release remaining pressure in hydraulic cylinder circuit
1) Turn the starting switch to ON position and set the
work equipment lock lever in FREE position, and then
operate the right and left work equipment control lev-
ers forward and backward, and to the right and left.
REMARK
The work equipment is operated by the pressure in
the accumulator. Pressure in the accumulator is lost
by operating the work equipment control levers 2 or 3
times.
2) Set the work equipment lock lever to LOCK position,
start the engine, and run it with the fuel control dial at

HB365LC-3 30-113
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 30 TESTING AND ADJUSTING

MIN (Low idle) position for approximately 5 seconds to increase the pressure in the accumulator.
5. Repeat step 1) and 2) 4 or 5 times to release the remaining pressure from the cylinders.
6. Loosen oil filler cap of the hydraulic tank gradually to release the air in the tank.
REMARK
Leave the oil filler cap of the hydraulic tank removed.
NOTICE
When disassembling the anti-drop valve, perform releasing remaining pressure in cylinders, loosen
anti-drop valve assembly mounting bolts gradually. Check that hydraulic oil pressure is released,
remove it as an assembly, and disassemble it.

With anti-drop valve of arm

1. Check the function of PPC accumulator
Function of PPC accumulator can be checked by performing the same procedure as that of “With anti-drop
valve of boom”.
2. Extend or retract arm cylinder and bucket cylinder to the end.
You can release the remaining pressure by either of 2 methods, depending on the work equipment posture.
• When arm cylinder and bucket cylinder are extended
to the end
1) Extend arm cylinder and bucket cylinder to the end,
lower the work equipment to the ground, and stop the
engine.
REMARK
Since anti-drop valve is attached to arm cylinder head
side, hydraulic oil on head side of arm cylinder is
drained when work equipment is lowered to the
ground in this posture, and remaining pressure drops.
Also, remaining oil on head side is reduced.
• When arm cylinder and bucket cylinder are retracted
to the end
1) Extend arm cylinder and bucket cylinder to the end,
lower the work equipment to the ground, and stop the
engine.
NOTICE
Since anti-drop valve is attached to arm cylinder
head side, remaining pressure increases due to
more hydraulic oil applied to head side when work
equipment is lowered to the ground. In this case,
release the pressure by performing step 4 “Re-
lease remaining pressure in hydraulic cylinder cir-
cuit” more times.
3. Release remaining pressure in hydraulic cylinder circuit
1) Turn the starting switch to ON position and set the work equipment lock lever in FREE position, and
then operate the right and left work equipment control levers forward and backward, and to the right
and left.
REMARK
The work equipment is operated by the pressure in the accumulator. Pressure in the accumulator is
lost by operating the work equipment control levers 2 or 3 times.
2) Set the work equipment lock lever to LOCK position, start the engine, and run it with the fuel control
dial at MIN (Low idle) position for approximately 5 seconds to increase the pressure in the accumulator.

30-114 HB365LC-3
30 TESTING AND ADJUSTING RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM

4. Repeat step 1) and 2) 4 or 5 times to release the remaining pressure from the cylinders.
5. Loosen oil filler cap of the hydraulic tank gradually to release the air in the tank.
REMARK
Leave the oil filler cap of the hydraulic tank removed.
NOTICE
When disassembling the anti-drop valve, perform releasing remaining pressure in cylinders, loosen
anti-drop valve assembly mounting bolts gradually. Check that hydraulic oil pressure is released,
remove it as an assembly, and disassemble it.

METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR

CIRCUIT (HB335_3-K-C000-22A-00-B)
• Before disconnecting a pipe between the travel motor and control valve, release the remaining pressure
from the piping according to the following procedure.
• The control valve spool of the travel circuit is an open type circuit, so the remaining pressure can be re-
leased by performing the same operation as that described in “METHOD FOR RELEASING REMAINING
PRESSURE FROM HYDRAULIC TANK”.
1. Lower the work equipment to the ground in a stable posture, and stop the engine.
2. Loosen the oil filler cap (1) of the hydraulic tank gradually
to release the air in the tank.

HB365LC-3 30-115
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT AND
TRAVEL CIRCUITS 30 TESTING AND ADJUSTING

TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT AND TRAVEL

CIRCUITS (HB335_3-K-C200-304-00-B)

Tools for testing and adjusting the oil pressure in work equipment circuit and travel circuit
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A 1 799-101-5110 Gauge 1 Pressure range: 60 MPa
2 799-101-5130 Gauge 1 Pressure range: 6 MPa
B - 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-101-5220 Nipple 2 SizeM10x1.25 mm
D 07002-11023 O-ring 2
• MaterialSS400
Commercially
E Pin 1 • Diameter: 80 mm
available
• Length: 200 mm

Commercially • MaterialSS400
F Plate 1
available • Size250 × 260 × 32 (mm)

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
k Lower the work equipment to the ground, and stop the engine. Operate the control lever several
times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hy-
draulic tank slowly to release the pressure in the tank.
Check this item under the following conditions.
Hydraulic oil temperature: 45 to 55 °C

Combination of pump, actuator, and valve

• When the oil flow is divided at pumps, front pump and rear pump act individually to each actuator as follow-
ing table. The valve to be relieved differs depending on the actuator.
• The oil flow is divided at pumps during relief with work equipment and swing single.

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 TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT AND
30 TESTING AND ADJUSTING TRAVEL CIRCUITS

• The actuators in the following table are arranged in the order that the control valves are viewed from the
front of the machine. ("Service" of "Actuator" is for when 1 attachment is installed)
Pump Actuator Valve to be relieved
(F unload valve) (F main relief valve)
Service Safety valve for Service
Boom Hi
F main relief valve
Arm Hi
Front
BUCKET F main relief valve
L.H. travel F main relief valve
RAISE: F main relief valve
Boom
LOWER: Safety and suction valve
(Merge-divider valve) (Travel junction valve)
(Self-pressure reducing valve)
R.H. travel R main relief valve
Rear
Arm Lo R main relief valve
(R unload valve) (R main relief valve)
(Centralized safety valve) (Back pressure valve)

For testing and adjusting the oil pressure in the work equipment circuit and travel circuit to perform troubleshoot-
ing, refer to this section.

METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, AND TRAVEL

CIRCUITS (PC78_10-K-C200-362-00-B)

METHOD FOR TESTING UNLOAD PRESSURE BY MACHINE MONITOR

(HB335_3_E-K-PNJ0-362-00-B)
1. Start the engine.
2. Select “Pre-defined Monitoring” (09/28) or “Monitoring Se-
lection Menu” and display the following monitoring items
by referring to “SET AND OPERATE MACHINE MONI-
TOR”.
Monitoring code: 01100 “Front Pump Pressure”
Monitoring code: 01101 “Rear Pump Pressure”
Monitoring code: 04401 “Hydraulic Oil Temperature”
3. Adjust the hydraulic oil temperature within the specified
range.
4. Set the working mode to P (“Power Mode”).
5. Turn off the auto-deceleration.
6. Turn the swing lock switch to OFF position.
7. Turn the fuel control dial to MAX (High idle) position.
8. Check “Front Pump Pressure” and “Rear Pump Pressure” when all control levers and control pedals are in
NEUTRAL position.
The pressure when the unload valve operates is displayed.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.

HB365LC-3 30-117
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT AND
TRAVEL CIRCUITS 30 TESTING AND ADJUSTING

METHOD FOR TESTING UNLOAD PRESSURE BY TESTING TOOLS

(HB335_3-K-PNJ0-362-10-B)
1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.
2. Open the cover on the left side of the machine.
3. Install the nipple C to the pump discharged pressure pick-
up ports (PFC) and (PRC) for work equipment and travel,
and then connect the gauge A1 of the hydraulic tester A.
(PFC): Front pump discharged pressure pickup port
(PRC): Rear pump discharge pressure pickup port
REMARK
Gauge in the digital hydraulic tester B can also be used in-
stead of the gauge A1.
4. Start the engine.
5. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
6. Adjust the hydraulic oil temperature within the specified
range.
7. Set the working mode to P (“Power Mode”).
8. Turn off the auto-deceleration.
9. Turn the fuel control dial to MAX (High idle) position.
10. Check the pump pressure when all control levers and con-
trol pedals are in NEUTRAL position.
The pressure when the unload valve operates is displayed.
For standard values, see “STANDARD VALUE TABLE,
STANDARD VALUE TABLE FOR MACHINE”.

After finishing the test, remove the testing tools and restore the machine.

METHOD FOR TESTING WORK EQUIPMENT RELIEF PRESSURE BY MACHINE

MONITOR (HB335_3_E-K-PNJ0-362-01-B)
1. Start the engine.
2. Select “Pre-defined Monitoring” (09/28) or “Monitoring Se-
lection Menu” and display the following monitoring items
by referring to “SET AND OPERATE MACHINE MONI-
TOR”.
Monitoring code: 01100 “Front Pump Pressure”
Monitoring code: 01101 “Rear Pump Pressure”
Monitoring code: 04401 “Hydraulic Oil Temperature”
3. Adjust the hydraulic oil temperature within the specified
range.
4. Set the working mode to P (“Power Mode”).
5. Turn the swing lock switch to OFF position.

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 TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT AND
30 TESTING AND ADJUSTING TRAVEL CIRCUITS

6. Operate the cylinders to check to the stroke end.

7. Turn the fuel control dial to MAX (High idle) position.
8. Measure “Front Pump Pressure” and “Rear Pump Pressure” while operating the work equipment lever to
relieve the work equipment circuit to be tested.
Relieved pressure of the main relief valve is displayed.
• If the one-touch power maximizing switch is not pressed, the low relief pressure is obtained. If the for-
mer is pressed, the high relief pressure is obtained.
• If the swing lock switch is turned ON, the 2-stage relief valve is kept on and the relief pressure is set
high. Keep the swing lock switch in OFF position during the test.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.

METHOD FOR TESTING WORK EQUIPMENT RELIEF PRESSURE BY TESTING

TOOLS (HB335_3-K-PNJ0-362-11-B)
1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.
2. Open the rear cover on the left side of the machine.
3. Install the nipple C to the pump discharged pressure pick-
up ports (PFC) and (PRC) for work equipment and travel,
and then connect the gauge A1 of the hydraulic tester A.
(PFC): Front pump discharged pressure pickup port
(PRC): Rear pump discharge pressure pickup port
REMARK
Gauge in the digital hydraulic tester B can also be used in-
stead of the gauge A1.
4. Start the engine.
5. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
6. Adjust the hydraulic oil temperature within the specified
range.
7. Set the working mode to P (“Power Mode”).
8. Turn the swing lock switch to OFF position.
9. Operate the cylinders to check to the stroke end.
10. Turn the fuel control dial to MAX (High idle) position.
11. Measure the pump pressure while operating the work
equipment lever to relieve the work equipment circuit to be
tested.
Relieved pressure of the main relief valve is displayed.
• If the one-touch power maximizing switch is not press-
ed, the low relief pressure is obtained. If the former is
pressed, the high relief pressure is obtained.
• If the swing lock switch is turned ON, the 2-stage relief
valve is kept on and the relief pressure is set high.
Keep the swing lock switch in OFF position during the
test.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.

HB365LC-3 30-119
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT AND
TRAVEL CIRCUITS 30 TESTING AND ADJUSTING

METHOD FOR TESTING TRAVEL RELIEF PRESSURE BY MACHINE MONITOR

(HB335_3_E-K-J000-362-00-B)
1. Start the engine.
2. Insert the pin E and the plate F between the sprocket and
the track frame to securely lock the track.

3. Select “Pre-defined Monitoring” (09/28) or “Monitoring Se-

lection Menu” and display the following monitoring items
by referring to “SET AND OPERATE MACHINE MONI-
TOR”.
Monitoring code: 01100 “Front Pump Pressure”
Monitoring code: 01101 “Rear Pump Pressure”
Monitoring code: 04401 “Hydraulic Oil Temperature”
4. Adjust the hydraulic oil temperature within the specified
range.
5. Set the working mode to P (“Power Mode”).
6. Turn the fuel control dial to MAX (High idle) position.
7. Measure the “Pump Pressure” by operating the travel lever and the pedal and then relieve the travel circuit.
k Give clear signals otherwise a mistake in lever operation can cause an accident.
k Before operating the travel lever and the pedal, check the sprocket position locked with pin and
locked direction of the travel again.
The machine monitor displays the pressure when the main relief valve is relieved. The travel circuit is al-
ways relieved at high pressure.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.

METHOD FOR TESTING TRAVEL RELIEF PRESSURE BY TESTING TOOLS

(HB335_3-K-J000-362-10-B)
1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.
2. Open the cover on the left side of the machine.

30-120 HB365LC-3
 TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT AND
30 TESTING AND ADJUSTING TRAVEL CIRCUITS

3. Install the nipple C to the pump discharged pressure pick-

up ports (PFC) and (PRC) for work equipment and travel,
and then connect the gauge A1 of the hydraulic tester A.
(PFC): Front pump discharged pressure pickup port
(PRC): Rear pump discharge pressure pickup port
REMARK
Gauge in the digital hydraulic tester B can also be used in-
stead of the gauge A1.
4. Start the engine.

5. Insert the pin E and the plate F between the sprocket and
the track frame to securely lock the track.
6. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
7. Adjust the hydraulic oil temperature within the specified
range.
8. Set the working mode to P (“Power Mode”).
9. Turn the fuel control dial to MAX (High idle) position.
10. Measure the pump pressure by operating the travel lever
and the pedal and then relieve the travel circuit.
k Give clear signals otherwise a mistake in lever operation can cause an accident.
k Before operating the travel lever and the pedal, check the sprocket position locked with pin and
locked direction of the travel again.
The machine monitor displays the pressure when the main relief valve is relieved. The travel circuit is al-
ways relieved at high pressure.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.

HB365LC-3 30-121
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT AND
TRAVEL CIRCUITS 30 TESTING AND ADJUSTING

METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT,AND TRAVEL

CIRCUITS (HB335_3-K-C200-270-00-B)

METHOD FOR ADJUSTING UNLOAD PRESSURE (HB335_3-K-PNJ0-270-00-B)

The unload valve (unload pressure) cannot be adjusted.

METHOD FOR ADJUSTING WORK EQUIPMENT AND TRAVEL RELIEF PRES-

SURE (PC300_11-K-PNJ0-270-00-B)
If the work equipment and travel relief pressure are not normal,
adjust main relief valves (3) and (4) according to the following
procedure.
(3): Front main relief valve
(4): Rear main relief valve
• When adjusting the main relief valve on the front pump
side, remove the upper cover of the control valve.
• When adjusting the main relief valve on the rear pump
side, remove the control valve undercover.
• The main relief valve regulates only the low-pressure relief
pressure. By adjusting the low-pressure relief pressure,
the high-pressure relief pressure is also set automatically.
• For the low-pressure relief pressure, the 2-stage relief solenoid valve is OFF. The pilot pressure is not ap-
plied to the selector port.
1. Disconnect the pilot hose (5).
The drawing shows the front main relief valve.

2. While fixing holder (6), loosen lock nut (7).

3. Turn holder (6) to adjust the pressure.
REMARK
• Turn holder (6) to the right to raise the pressure or turn
it to the left to lower the pressure.
• Quantity of pressure adjustment per turn of holder (6):
Approximately20.5 MPa { 209 kg/cm2}
4. While fixing holder (6), tighten lock nut (7).
3 Locknut (7):
49 to 58.8 Nm {5 to 6 kgm}
5. Connect the pilot hose (5).
After the adjustment, recheck the oil pressure according to the testing procedure described above.

30-122 HB365LC-3
 TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT AND
30 TESTING AND ADJUSTING TRAVEL CIRCUITS

METHOD FOR ADJUSTING BOOM LOWER RELIEF PRESSURE (HIGH PRES-

SURE SET SIDE) (PC300_11-K-PNJ0-270-01-B)
• If the high-pressure relief pressure of boom LOWER is not
normal, adjust suction safety valve for boom LOWER (8)
on the high-pressure set side according to the following
procedure.
• For the high-pressure relief pressure, the machine push-up
switch is ON. The pilot pressure is applied to the selector
port.

1. Disconnect the pilot hose (9).

2. While fixing holder (10), loosen lock nut (11).
3. Turn holder (10) to adjust the pressure.
REMARK
• Turn holder (10) to the right to raise the pressure or
turn it to the left to lower the pressure.
• Quantity of pressure adjustment per turn of holder (10):
Approximately21.8 MPa {222 kg/cm2}
4. While fixing holder (10), tighten lock nut (11).
3 Locknut (11):
93 to 123 Nm {9.5 to 12.5 kgm}
5. Connect the pilot hose (9).
After the adjustment, recheck the oil pressure according to the testing procedure described above.

METHOD FOR ADJUSTING BOOM LOWER RELIEF PRESSURE (LOW PRES-

SURE SET SIDE) (PC300_11-K-PNJ0-270-02-B)
• If the low-pressure relief pressure of boom LOWER is not
normal and the pressure on the high-pressure set side is
adjusted, adjust suction safety valve for boom LOWER (8)
on the low-pressure set side according to the following
procedure.
• For the low-pressure relief pressure, the machine push-up
switch is OFF. The pilot pressure is applied to the selector
port.

1. Disconnect the pilot hose (9).

2. While fixing holder (12), loosen lock nut (13).
3. Turn holder (12) to adjust the pressure.
REMARK
• Turn holder (10) to the right to raise the pressure or
turn it to the left to lower the pressure.
• Quantity of pressure adjustment per turn of holder: Ap-
proximately21.8 MPa {222 kg/cm2}
4. While fixing holder (12), tighten lock nut (13).

HB365LC-3 30-123
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT AND
TRAVEL CIRCUITS 30 TESTING AND ADJUSTING

3 Lock nut (13):

78 to 93 Nm {8.0 to 9.5 kgm}
5. Connect the pilot hose (9).
After the adjustment, recheck the oil pressure according to the testing procedure described above.

30-124 HB365LC-3
30 TESTING AND ADJUSTING TEST OIL PRESSURE OF CONTROL CIRCUIT

TEST OIL PRESSURE OF CONTROL CIRCUIT (HB335_3-K-C010-304-00-B)

Testing and adjusting tools for oil pressure in the control circuit
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A
1 799-101-5130 Gauge 1 Pressure range: 6 MPa
B - 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-101-5220 Nipple 1 Size: M10x1.25 mm
D 07002-11023 O-ring 1

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
k Lower the work equipment to the ground, and stop the engine. Operate the control lever several
times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hy-
draulic tank slowly to release the pressure in the tank.
Check this item under the following conditions.
Hydraulic oil temperature: 45 to 55 °C
For testing and adjusting of control circuit pressure to perform troubleshooting, refer to this section.

METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT (HB335_3-K-C010-362-00-B)

1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.
2. Remove the upper cover of the control valve.
3. Remove the oil pressure pickup plug (1) of the control
valve.

HB365LC-3 30-125
TEST OIL PRESSURE OF CONTROL CIRCUIT 30 TESTING AND ADJUSTING

4. Install the nipple C and connect it to the gauge A1 of the

hydraulic tester A.
REMARK
Gauge in the digital hydraulic tester B can also be used in-
stead of the gauge A1.
5. Start the engine.
6. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
7. Adjust the hydraulic oil temperature within the specified
range.
8. Set the working mode to P (“Power Mode”).
9. Turn off the auto-deceleration.
10. Turn the fuel control dial to MAX (High idle) position.
11. Check the oil pressure when all control levers and control pedals are in NEUTRAL position.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.
REMARK
Control circuit oil pressure can also be checked by using the
pickup port (PEPB) on the pump side.

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30 TESTING AND ADJUSTING TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT

TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT

(HB335_3-K-C2A3-304-00-B)

Testing and adjusting tools for the oil pressure in the pump PC control circuit
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A 1 799-101-5110 Gauge 1 Pressure range: 60 MPa
2 799-101-5130 Gauge 1 Pressure range: 6 MPa
B - 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-101-5220 Nipple 4 Size: M10x1.25 mm
D 07002-11023 O-ring 4

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
k Lower the work equipment to the ground, and stop the engine. Operate the control lever several
times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hy-
draulic tank slowly to release the pressure in the tank.
Check this item under the following conditions.
Hydraulic oil temperature: 45 to 55 °C
Before starting the test, check that the oil pressures in the work equipment, travel circuits and control circuits are
normal.
For testing and adjusting of pump PC control circuit oil pressure to perform troubleshooting, refer to this section.

METHOD FOR TESTING PC VALVE OUTLET PRESSURE (SERVO PISTON INLET

PRESSURE) (HB335_3-K-C2A3-362-00-B)

NOTICE
To measure the PC valve outlet pressure (servo piston inlet pressure), measure the pump discharge
pressure simultaneously and compare them.
1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.
2. Open the cover on the left side of the machine.

HB365LC-3 30-127
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 30 TESTING AND ADJUSTING

3. Remove the pump discharge pressure pickup plugs (PFC)

and (PRC), and the PC valve outlet pressure (servo piston
inlet pressure) pickup plugs (PenF) and (PenR).
(PFC): Front pump discharged pressure pickup port
(PRC): Rear pump discharge pressure pickup port
(PenF): Front control pressure pickup port
(PenR): Rear control pressure pickup port

4. Install the nipple C, and connect the gauge A1 in the hy-

draulic tester A.
REMARK
Gauge in the digital hydraulic tester B can also be used in-
stead of the gauge A1.
5. Start the engine.
6. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
7. Adjust the hydraulic oil temperature within the specified
range.
8. Set the working mode to P (“Power Mode”).
9. Turn the swing lock switch to ON position.
10. Turn the fuel control dial to MAX (High idle) position.
11. Operate the work equipment control lever and relieve the arm IN circuit, and measure the pump discharge
pressure and PC valve outlet pressure (servo piston inlet pressure) simultaneously.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
REMARK
• If the PC valve or servo piston is abnormal, the PC valve outlet pressure (servo piston inlet pressure)
has the same pressure as the pump discharge pressure or the pressure becomes approximately 0 MPa
{0 kg/cm2} .
After finishing the test, remove the testing tools and restore the machine.

METHOD FOR TESTING PC-EPC VALVE OUTLET PRESSURE (HB335_3-K-L2P5-362-00-B)

1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.
2. Open the cover on the left side of the machine.

30-128 HB365LC-3
30 TESTING AND ADJUSTING TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT

3. Remove the oil pressure pickup plugs (PMF) and (PMR).

(PMF): Front PC mode selector pressure pickup port
(PMR): Rear PC mode selector pressure pickup port

4. Install the nipple C, and connect the gauge A2 in the hy-

draulic tester A.
REMARK
Gauge in the digital hydraulic tester B can also be used in-
stead of gauge A2.
5. Start the engine.
6. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
7. Adjust the hydraulic oil temperature within the specified
range.
8. Set the working mode to P (“Power Mode”).
9. Turn the swing lock switch to OFF position.
10. Check that all control levers and control pedals are at NEUTRAL position.
11. Test the oil pressure when the fuel control dial is at MAX (High idle) and MIN (Low idle) positions.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.

METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT

(HB335_3-K-C2A3-270-00-B)
When the phenomena shown below occur and PC valves (1) and (2) seem to be defective, adjust them accord-
ing to the following procedure.
• When the working load increases, the engine speed drops
largely.
• The engine speed is normal but the work equipment speed
is low.
(1): Front pump PC valve
(2): Rear pump PC valve
NOTICE
The width across flats of PC valve lock nut is 13 mm, and
the width across flats (inside width) of adjustment screw is
4 mm.
Do not turn the other lock nuts and adjustment screws
since they affect the hydraulic pump performance.

HB365LC-3 30-129
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 30 TESTING AND ADJUSTING

1. Put matchmarks on the end surface of adjustment screw

(4).
Matchmarks are necessary for proper alignment. (Adjust-
ment screw can be returned to the original position when
turning it in reverse)
2. Loosen the lock nut (3).
3. Turn adjustment screw (4) clockwise or counterclockwise
to adjust it.
REMARK
• Turn the adjustment screw clockwise when the work
equipment speed is low (to increase the pump absorp-
tion torque). Turn it counterclockwise when the engine
speed is low (to decrease the pump absorption torque).
• Adjustable range of adjustment screw (4) is as descri-
bed below.
Counterclockwise: Within 1 turn
Clockwise: Within 1 turn
4. Tighten the lock nut (3).
3 Lock nut (3):
27 to 34 Nm {2.8 to 3.5 kgm}
After the adjustment, see “METHOD FOR TESTING PC VALVE OUTLET PRESSURE (SERVO PISTON INLET
PRESSURE)” to check whether PC valve outlet pressure (servo piston inlet pressure) is normal.

30-130 HB365LC-3
30 TESTING AND ADJUSTING TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT

TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT

(HB335_3-K-C2A4-304-00-B)

Testing and adjusting tools for the oil pressure in the pump LS control circuit
Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A 1 799-101-5110 Gauge 1 Pressure range: 60 MPa
2 799-101-5130 Gauge 1 Pressure range: 6 MPa
B - 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-101-5220 Nipple 4 Size: M10x1.25 mm
D 07002-11023 O-ring 4
E 799-401-2701 Differential pressure gauge 1 Pressure range: 50 MPa
796T–440–
F Sensor adapter 1 Pressure range: 50 MPa
1101

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
k Lower the work equipment to the ground, and stop the engine. Operate the control lever several
times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hy-
draulic tank slowly to release the pressure in the tank.
k Provide enough work space to run the raised track idle off the ground for testing.
Check this item under the following conditions.
Hydraulic oil temperature: 45 to 55 °C
Before starting the test, check that the oil pressures in the work equipment, the travel circuits and the control
circuits are normal.
For testing and adjusting of pump LS control circuit oil pressure to perform troubleshooting, refer to this section.

METHOD FOR TESTING LS DIFFERENTIAL PRESSURE WITH MACHINE MONI-

TOR (HB335_3_E-K-C2A4-362-00-B)
1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.
2. Open the cover on the left side of the machine.
3. Remove the oil pressure pickup plugs (PLSFC) and
(PLSRC).
(PLSFC): Front load pressure pickup port
(PLSRC): Rear load pressure pickup port

HB365LC-3 30-131
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 30 TESTING AND ADJUSTING

4. Install the nipples C to oil pressure pickup plugs (PLSFC)

and (PLSRC), and connect the sensor adapter assembly
F.

5. Connect the sensor adapter assembly F to service oil

pressure connector (P49).
6. Set all control levers and control pedals in NEUTRAL posi-
tion, and set the lock lever in FREE position.
7. Start the engine.

8. Select “Monitoring Selection Menu” and display the follow-

ing monitoring items by referring to “SET AND OPERATE
MACHINE MONITOR”.
Monitoring code: 01141 “Service Pressure Sensor”
Monitoring code: 04401 “Hydraulic Oil Temperature”
9. Adjust the hydraulic oil temperature within the specified
range.
10. Set the working mode to P (“Power Mode”).
11. Set the travel speed to “Hi”.
12. Raise the track to be tested off the ground by operating the
work equipment.
When measuring the front circuit: L.H. track
When measuring the rear circuit: R.H. track
13. Turn the fuel control dial to MAX (High idle) position.
14. Measure the pump discharge pressure and LS pressure
(actuator load pressure) simultaneously when each control
lever and control pedal are in NEUTRAL position and
when the travel control lever and the pedal are moved to
half stroke position.
k When idling the track pushed up with the work
equipment, secure the safety of surroundings.
REMARK
Figuring out the LS differential pressure: LS differential pressure = Pump discharge pressure - LS pressure
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.

METHOD FOR TESTING LS DIFFERENTIAL PRESSURE (HB335_3-K-C2A4-362-01-B)

To obtain the LS differential pressure, measure the pump discharged pressure and LS pressure (actuator load
pressure) simultaneously, and calculate the difference.

30-132 HB365LC-3
30 TESTING AND ADJUSTING TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT

1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.
2. Open the cover on the left side of the machine.
3. Remove the pump discharge pressure pickup plugs (PFC)
and (PRC), and LS pressure (actuator load pressure) pick-
up plugs (PLSFC) and (PLSRC).
(PFC): Front pump discharged pressure pickup port
(PRC): Rear pump discharge pressure pickup port
(PLSFC): Front load pressure pickup port
(PLSRC): Rear load pressure pickup port

HB365LC-3 30-133
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 30 TESTING AND ADJUSTING

4. Install the nipple C to pickup port and connect it to the

gauge A1 of the hydraulic tester A or the differential pres-
sure gauge E.
• When using the differential pressure gauge E, connect
the high-pressure side (rear side) to the pump dis-
charged pressure and the low-pressure side (bottom
side) to the LS pressure.
REMARK
Differential pressure gauge needs 12 V DC power,
connect it to 1 battery.
• When using the gauge A1, measure the pressure
while replacing the same gauge since the differential
pressure goes up to approximately 3.9 MPa {approxi-
mately 40 kg/cm2} at maximum.
REMARK
Gauge in the digital hydraulic tester B can also be
used instead of the gauge A1.
5. Set all the control levers and the control pedals in NEU-
TRAL position, and set the lock lever in OFF position.
6. Start the engine.
7. Select and display “SET AND OPERATE MACHINE MONITOR” (01/28). See “SET AND OPERATE MA-
CHINE MONITOR”.
8. Adjust the hydraulic oil temperature within the specified range.
9. Set the working mode to P (“Power Mode”).
10. Set the travel speed to “Hi”.
11. Raise the track to be tested off the ground by operating the
work equipment.
When measuring the front circuit: L.H. track
When measuring the rear circuit: R.H. track
12. Turn the fuel control dial to MAX (High idle) position.
13. Measure the pump discharge pressure and LS pressure
(actuator load pressure) simultaneously when each control
lever and control pedal are in NEUTRAL position and
when the travel control lever and the pedal are moved to
half stroke position.
k When idling the track pushed up with the work
equipment, secure the safety of surroundings.
REMARK
Figuring out the LS differential pressure: LS differential pressure = Pump discharge pressure - LS pressure
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.

METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET

PRESSURE) (HB335_3-K-C2A4-362-02-B)

NOTICE
To measure the PC valve outlet pressure (servo piston inlet pressure), measure the pump discharge
pressure simultaneously and compare them.
1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.

30-134 HB365LC-3
30 TESTING AND ADJUSTING TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT

2. Open the cover on the left side of the machine.

3. Remove the pump discharge pressure pickup plugs (PFC)
and (PRC), and the LS valve outlet pressure (servo piston
inlet pressure) pickup plugs (PenF) and (PenR).
(PFC): Front pump discharged pressure pickup port
(PRC): Rear pump discharge pressure pickup port
(PenF): Front LS valve outlet pressure pickup port
(PenR): Rear LS valve outlet pressure pickup port

4. Install the nipple C, and connect the gauge A1 in the hy-

draulic tester A.
REMARK
Gauge in the digital hydraulic tester B can also be used in-
stead of the gauge A1.
5. Start the engine.
6. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
7. Adjust the hydraulic oil temperature within the specified
range.
8. Set the working mode to P (“Power Mode”).
9. Set the travel speed to “Hi”.
10. Raise the track to be tested off the ground by operating the
work equipment control lever.
When measuring the front circuit: L.H. track
When measuring the rear circuit: R.H. track
11. Turn the fuel control dial to MAX (High idle) position.
12. Check the pump discharge pressure and the LS valve out-
let pressure (servo piston inlet pressure) simultaneously
when all the control levers and the pedals are in NEU-
TRAL and when the travel lever is at half stroke.
k When idling the track pushed up with the work
equipment, secure the safety of surroundings.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.

HB365LC-3 30-135
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 30 TESTING AND ADJUSTING

METHOD FOR TESTING LS-EPC VALVE OUTLET PRESSURE (HB335_3-K-C2M0-362-00-B)

1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.
2. Open the cover on the left side of the machine.
3. Remove the oil pressure pickup plug (PSIG).
(PSIG): Outlet pressure of LS-EPC valve (LS set selector
pressure)

4. Install the nipple C, and connect the gauge A2 in the hy-

draulic tester A.
REMARK
Gauge in the digital hydraulic tester B can also be used in-
stead of gauge A2.
5. Start the engine.
6. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
7. Adjust the hydraulic oil temperature within the specified
range.
8. Set the working mode to P (“Power Mode”).
9. Turn the fuel control dial to MAX (High idle) position.
10. Set the travel speed to “Lo” or “Hi”.
11. Measure the pressure when operating the travel lever and the pedal.
REMARK
Pressure can be tested with a little operation of the travel control lever which the PPC oil pressure switch
turns on (the position just before the machine starts moving).
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.

METHOD FOR ADJUSTING LS VALVE (HB335_3-K-C2A4-270-00-B)

If the LS differential pressure is abnormal, adjust the LS valves
(1) and (2) according to the following procedure.
(1): Front LS valve
(2): Rear LS valve

30-136 HB365LC-3
30 TESTING AND ADJUSTING TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT

1. While fixing the adjustment screw (3), loosen the lock nut
(4).
2. Turn the adjustment screw (3) to adjust the differential
pressure.
REMARK
• Turn the adjustment screw (3) clockwise to raise the
differential pressure or turn it counterclockwise to lower
the differential pressure.
• Quantity of pressure adjustment (LS differential pres-
sure) per turn of adjustment screw (3): 1.3 MPa
{13.3 kg/cm2}
3. With adjustment screw (3) fixed, tighten the lock nut (4).
3 Lock nut (4):
49 to 68.6 Nm {5 to 7 kgm}
After the adjustment, see “METHOD FOR TESTING LS VALVE OUTLET PRESSURE (SERVO PISTON INLET
PRESSURE)” to check whether LS valve outlet pressure (servo piston inlet pressure) is normal.

HB365LC-3 30-137
TEST OUTLET PRESSURE OF SOLENOID VALVE 30 TESTING AND ADJUSTING

TEST OUTLET PRESSURE OF SOLENOID VALVE (HB335_3-K-C020-304-00-B)

Tools for testing the outlet pressure of the solenoid valve

Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A 1 799-101-5130 Gauge 1 Pressure range: 6 MPa
2 799-101-5160 Nipple 1 Size: R1/8
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 799-401-3100 Adapter 1 Size: 02
D 02896-11008 O-ring 1
E 799-401-3200 Adapter 1 Size: 03
F 02896-11009 O-ring 1

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
k Lower the work equipment to the ground, and stop the engine. Operate the control lever several
times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hy-
draulic tank slowly to release the pressure in the tank.
Check this item under the following conditions.
Hydraulic oil temperature: 45 to 55 °C
Before the test, check the control circuit oil pressure is normal.
For testing of solenoid valve outlet pressure to perform troubleshooting, refer to this section.

METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE

(HB335_3_E-K-C020-362-00-B)
1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.
2. Remove the upper cover of control valve.
3. Disconnect the outlet hoses (1) to (7) of the solenoid valve
to be tested.
(1): 2-stage relief solenoid valve
(2): Attachment selector solenoid valve
(3): Machine push-up solenoid valve
(4): Swing parking brake solenoid valve
(5): Travel speed solenoid valve
(6): Travel junction solenoid valve
(7): PPC lock solenoid valve
Use the adapter E for the outlet hoses (4), (5), and (7), and use the adapter C for other hoses.
4. Install the adapter C or adapter E, and connect the disconnected hose again.
5. Install the nipple A2 to the adapter C or the adapter E, and connect it to gauge A1.
REMARK
Gauge in the digital hydraulic tester B can also be used instead of the gauge A1.
6. Start the engine.

30-138 HB365LC-3
30 TESTING AND ADJUSTING TEST OUTLET PRESSURE OF SOLENOID VALVE

7. Select and display “SET AND OPERATE MACHINE MONITOR” (01/28). See “SET AND OPERATE MA-
CHINE MONITOR”.
8. Adjust the hydraulic oil temperature within the specified range.
9. Select and display the following monitoring items on “Moni-
toring Selection Menu”.
Monitoring code: 02300 “Solenoid Valve 1”
Monitoring code: 02301 “Solenoid Valve 2”
10. Turn the fuel control dial to MAX (High idle) position.
11. Operate each control lever and switches, and measure the
outlet pressure when the solenoid valve is energized and
de-energized.
REMARK
For the conditions for turning the solenoid valve ON or
OFF, see “OPERATING CONDITION OF SOLENOID
VALVE”.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.

OPERATING CONDITION OF SOLENOID VALVE (HB335_3-K-C020-04C-00-B)

(1) 2-stage relief solenoid valve operation table

Operating
Operating condition of solenoid valve state of sole-
noid valve
When overheat 1st setting is ON
OFF (De-ener-
When overheat 2nd setting is ON
gized)
All signals of work equipment, swing, and travel OFF
Swing lock switch ON
Travel signal ON
In L mode ON (Ener-
gized)
Boom LOWER signal ON
Signals other than swing single opera-
One-touch power maximizing tion signal ON
P-mode, E-mode
switch ON
Swing single operation signal ON OFF (De-ener-
Other than the above conditions gized)

(2) Attachment selector solenoid valve operation table (for the attachment installed specification)
Operating
Operating condition of solenoid valve state of sole-
noid valve
OFF (De-ener-
Other than B
gized)
Working mode
ON (Ener-
B
gized)

HB365LC-3 30-139
TEST OUTLET PRESSURE OF SOLENOID VALVE 30 TESTING AND ADJUSTING

(3): Operation table of machine push-up solenoid valve

Operating
Operating condition of solenoid valve state of sole-
noid valve
ON (Ener-
OFF
gized)
Machine push-up switch
OFF (De-ener-
ON
gized)

(4) Swing parking brake solenoid valve operation table

Operating
Operating condition of solenoid valve state of sole-
noid valve
OFF (De-ener-
All OFF
Signal of work equipment and swing (work equipment in- gized)
cluding services) ON (Ener-
Any one OFF
gized)

(5) Operation table of travel speed solenoid valve

Operating
Operating condition of solenoid valve state of sole-
noid valve
Overheat 2nd setting ON
Engine speed 1200 rpm or below
Travel speed switch at Lo OFF (De-ener-
gized)
When travel signals OFF
When F or R pump pressure is
When travel speed switch is at
32.3 MPa {330 kg/cm2} or higher
Mi, Hi Travel signal ON
When F or R pump pressure is
18.6 MPa {190 kg/cm2} or higher ON (Ener-
gized)
Other than the above conditions

(6) Travel junction solenoid valve operation table

Operating
Operating condition of solenoid valve state of sole-
noid valve
When signal of travel steering is ON
ON (Ener-
When travel single sig- When F or R pump pressure is gized)
When signal of travel steering is nal is ON 24.5 MPa {250 kg/cm2} or higher
OFF OFF (De-ener-
Other than the above conditions
gized)

30-140 HB365LC-3
30 TESTING AND ADJUSTING TEST OUTLET PRESSURE OF SOLENOID VALVE

(7) PPC lock solenoid valve operation table

Operating
Operating condition of solenoid valve state of sole-
noid valve
OFF (De-ener-
LOCK position (Lock)
gized)
PPC lock lever
ON (Ener-
FREE position (Free)
gized)

HB365LC-3 30-141
TEST PPC VALVE OUTPUT PRESSURE 30 TESTING AND ADJUSTING

TEST PPC VALVE OUTPUT PRESSURE (HB335_3-K-C020-304-01-B)

Tools for testing the PPC valve outlet pressure

Symbol Part No. Part name Q'ty Remarks
- 799-101-5002 Hydraulic tester 1
A 1 799-101-5130 Gauge 1 Pressure range: 6 MPa
2 799-101-5160 Nipple 1 Size: R1/8
B 790-261-1205 Digital hydraulic tester 1 Pressure range: 70 MPa
C 790-301-1730 Joint 1 PF1/4 × Rc1/8
D 07000-12011 O-ring 1

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
k Lower the work equipment to the ground, and stop the engine. Operate the control lever several
times to release the remaining pressure in the piping, and then loosen the oil filler cap of the hy-
draulic tank slowly to release the pressure in the tank.
Before the test, check the control circuit oil pressure is normal.
Check this item under the following conditions.
Hydraulic oil temperature: 45 to 55 °C
Below PPC valve outlet pressure can be checked with monitoring function of the machine monitor. (For the de-
tail, see “SET AND OPERATE MACHINE MONITOR”.)
Monitoring code: 07300 “Bucket CURL PPC Pressure”
Monitoring code: 07500 “Boom Lower PPC Pressure”
Monitoring code: 09002 “Swing Right PPC Pressure”
Monitoring code: 07200 “Arm IN PPC Pressure”
Monitoring code: 07301 “Bucket DUMP PPC Pressure”
Monitoring code: 07400 “Boom Raise PPC Pressure”
Monitoring code: 09001 “Swing Left PPC Pressure”
Monitoring code: 07600 “Arm OUT PPC Pressure”
Monitoring code: 07102 “Travel Forward Left PPC Press”
Monitoring code: 07103 “Travel Forward Right PPC Press”
Monitoring code: 07104 “Travel Reverse Left PPC Press”
Monitoring code: 07105 “Travel Reverse Right PPC Press”
For testing of PPC valve output pressure to perform troubleshooting, refer to this section.

METHOD FOR TESTING PPC VALVE OUTLET PRESSURE (HB335_3-K-C020-362-01-B)

1. Release the remaining pressure by referring to “RELEASE REMAINING PRESSURE FROM HYDRAULIC
SYSTEM”.
2. Remove the cover on the upper part of the control valve and the operator's cab undercover (front).

30-142 HB365LC-3
30 TESTING AND ADJUSTING TEST PPC VALVE OUTPUT PRESSURE

3. Disconnect the pressure sensor of the PPC circuit to be

tested, and install the joint C.
(1): Bucket CURL (White)
(2): Boom LOWER (Brown)
(3): Swing Right (-)
(4): Arm IN (Blue)
(5): Bucket DUMP (Black)
(6): Boom RAISE (Green)
(7): Swing Left (Red)
(8): Arm OUT (Yellow)
(9): Travel L.H. FORWARD (Red)
(10): Travel R.H. FORWARD (Green)
(11): Travel L.H. REVERSE (-)
(12): Travel R.H. REVERSE (Blue)
The colors in ( ) are the colors of the bands installed for
piping identification.

4. Install the nipple A2 of the hydraulic tester A to the joint C,

and connect it to gauge A1.
REMARK
Gauge in the digital hydraulic tester B can also be used in-
stead of the gauge A1.
5. Start the engine.
6. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
7. Adjust the hydraulic oil temperature within the specified
range.
8. Set the working mode to P (“Power Mode”).
9. Turn the fuel control dial to MAX (High idle) position.
10. Check the oil pressure when all the control levers and the
pedals are in NEUTRAL and also when the control lever
and the pedal of the circuit to be tested are operated to
stroke end.
For standard values, see “STANDARD VALUE TABLE,
STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, remove the testing tools and restore the machine.

HB365LC-3 30-143
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 30 TESTING AND ADJUSTING

ADJUST WORK EQUIPMENT AND SWING PPC VALVES (PC400_10-K-PL28-304-00-B)

If the right and left work equipment levers have large play, adjust them according to the following procedure.
Play at the lever end is 0.5 to 3 mm at the position of 200 mm away from the pivot of lever.
For adjusting the play of work equipment PPC valve and swing PPC valve to perform troubleshooting, refer to
this section.

METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC

VALVES (PC78_10-K-PL28-270-00-B)
1. Remove the boot (1).
2. Loosen the locknut (2) and tighten it until disc (3) touches
the heads of pistons (4) (4 pieces).
REMARK
Do not move the piston when tightening.
3. Fix the position of disc (3) and tighten lock nut (2) to the
specified torque.
3 Lock nut (2):
68 to 88 Nm {7 to 9 kgm}

4. Apply gear oil and grease to the rocking portion of the

joint.
2 Rocking portion of joint:
Grease (G2-LI)
REMARK
• Apply 7 to10 mℓ of grease to all periphery (a) of the pin.
• Apply 0.2 to 0.4 mℓ of gear oil to sliding portions (b) of
joint and pin (4 places).
5. Install the boot (1).

30-144 HB365LC-3
 MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE
30 TESTING AND ADJUSTING OUTPUT PRESSURE

MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUT-

PUT PRESSURE (PC240_11-K-LGCA-360-00-B)

Measuring and adjusting tools for oil pressure in quick coupler circuit.
Symbol Part No. Part name
799-101-5002 Hydraulic tester
1
790-261-1204 Digital hydraulic tester
N
799-101-5220 Nipple (10 x 1.25 mm)
2
07002-11023 O-ring

k Stop the machine on a level ground and lower the work equipment to the ground. Then, release the
residual pressure from the hydraulic circuit. For details, see RELEASE REMAINING PRESSURE
FROM HYDRAULIC SYSTEM (30-112)
k When setting the machine in a safe posture, ensure that the bucket is not fitted in the coupler as the
coupler will be changed from the closed to open positions during the adjustment procedure.

Measuring
• Confirm work equipment working pressures are correct as listed in the shop manual before carrying out any
quick coupler pressure adjustments.
• Fit nipple N2 to port B2 and connect it to oil pressure gauge of hydraulic tester. Port B2 measures the out-
put pressure from the Secondary pressure regulating valve (PRV).
• Use an oil pressure gauge with the capacity of 59 MPa {600 kg/cm2}
• Start the engine. In order to raise the pressure to the set pressure of the PRVs it will be necessary to oper-
ate the swing control circuit. Set the swing lock to ON and operate the swing lever.
NOTICE
When delivered from the factory the regulated pressure is set to 4 MPa {41 kg/cm2}.
• During closing and when closed, both Master and Secondary PRV are used in series. During opening only
the Master PRV is used to control pressure. The Master PRV controls the input pressure into the Secon-
dary PRV. When solenoid (V40) is energised (open coupler to attach bucket) the open pressure is control-
led by the Master PRV. When the solenoid is de-energised, (coupler closing and bucket hold), the close
pressure is regulated firstly by the Master PRV and then the Secondary PRV. This allows the open pressure
to be set higher by the Master PRV and the close pressure to be set at a lower level by the Secondary PRV.
The default position is solenoid de-energised and the close pressure hold the quick coupler in a closed po-
sition.

HB365LC-3 30-145
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE
OUTPUT PRESSURE 30 TESTING AND ADJUSTING

Adjusting
• Firstly, adjust the open pressure by energising the solenoid V40 and test the pressure at output Hose A
using a T adaptor. Adjust the pressure at the Master PVR, opposite face of the block from the solenoid
valve.
• After the Master PVR pressure is set (open pressure), the adjust the close pressure (Secondary PVR), test-
ing at Port B2 or Hose B. Secondary PVR is near port B2 on side of the quick coupler valve block.
• If the regulated pressure is not suitable for the quick coupler to be installed, adjust the pressure of the regu-
lating valve as follows:
1. Loosen the locknut (1a). (Using a 17 mm spanner).
2. Turn the adjustment screw (1b) to adjust the pressure. (Using a 5 mm hexagon key).
• If the screw is turned to the right the pressure increases.
• If the screw is turned to the left the pressure reduces.
• Quantity of adjustment per turn of the screw: Approx. 5.5 MPa {57 kg/cm2}.
3. After required pressure is achieved, hold adjustment screw (1b) and tighten the lock nut (1a). (Torque of
lock nut (1a): 12 ± 2 Nm)
4. NOTICE
Both PRVs are adjusted by above method.
5. NOTICE
Secondary PRV cannot be adjusted to a higher setting than the Master PRV. Secondary PRV maxi-
mum setting is the same as the Master PRV.
6. NOTICE
if un-lock pressure required Secondary PRV should be set lower than Master PRV.
7. NOTICE
Refer to quick coupler manufacturers' literature for recommended open and close pressures.

30-146 HB365LC-3
30 TESTING AND ADJUSTING TEST PUMP SWASH PLATE SENSOR

TEST PUMP SWASH PLATE SENSOR (HB335_3-K-C3WG-304-00-B)

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
Check this item under the following conditions.
Hydraulic oil temperature: 45 to 55 °C
Before testing the pump swash plate sensor, check that oil pressure in the work equipment circuit, travel circuit,
control circuit, and travel speed at running track idle off the ground are correct.
For testing of pump swash plate sensor to perform troubleshooting, refer to this section.

METHOD FOR TESTING PUMP SWASH PLATE SENSOR (HB335_3_E-K-C3WG-36J-00-B)

1. Start the engine.
2. Select and display “SET AND OPERATE MACHINE MONITOR” (01/28). See “SET AND OPERATE MA-
CHINE MONITOR”.
3. Adjust the hydraulic oil temperature within the specified range.
4. Select and display the following monitoring items on “Moni-
toring Selection Menu”.
Monitoring code: 01138 “F Pump Swash Plate Sensor volt”
Monitoring code: 01140 “R Pump Swash Plate Sensor volt”

5. Raise the track to be tested off the ground by operating the

work equipment.
When testing the front pump: L.H. track
When testing the rear pump: R.H. track
k Provide enough work space to run the raised track
idle off the ground for testing.
6. Set the working mode to P (“Power Mode”).
7. Set the travel speed to “Hi”.
8. Turn on the swing lock switch.
9. Turn the fuel control dial to MAX (High idle) position.
10. Set all the control levers and pedals to NEUTRAL, and then set the travel control lever and pedal to stroke
end in order to run the track idle off the ground, and measure the voltage.
k When idling the track pushed up with the work equipment, secure the safety of surroundings.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.

HB365LC-3 30-147
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIP-
MENT 30 TESTING AND ADJUSTING

TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT

(PC400_10-K-L400-304-00-B)

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
If the cause of hydraulic drift is defective cylinder packing, lowering speed may increase during the test because
of the reasons as follows.
• Oil leaks from the bottom side to the head side when the machine is set in the measuring posture for hy-
draulic drift (where the holding pressure is applied to the bottom side). Since the volume on the head side is
less than that on the bottom side by the volume of the rod, the pressure in the head side is increased by the
oil flowing in from the bottom side.
• As the pressure in the bottom side (varies depending on the leakage amount) increases, the pressure in the
head side also increases. The pressures are balanced on both side, and then lowering speed decreases. At
this time, operate the lever to the direction that head side oil in tested cylinder is drained to tank circuit, and
head side oil flows to drain circuit (bottom side is blocked by check valve), and. Pressure balance between
head side and bottom side is lost, and then lowering speed increases.
For testing of the isolating of the part causing hydraulic drift in work equipment to perform troubleshooting, refer
to this section.

METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM

CYLINDER AND BUCKET CYLINDER (PC400_10-K-L540-38F-00-B)
1. Set the work equipment in the same posture as when
measuring hydraulic drift, and stop the engine
Put a weight equivalent to the rated load in the bucket or
fill the bucket with the earth and sand.
2. When testing the boom cylinder, set the boom control lever
to RAISE position. When testing the bucket cylinder, set
the bucket control lever to CURL position.
Judging method
• When the lowering speed is increased at this time:
The cylinder packing is defective.
• No change: The control valve is defective.
REMARK
• Operate the control lever when the starting switch is turned to ON position.
• If the accumulator pressure is reduced, run the engine for approximately 10 seconds to accumulate the
pressure.

METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM

CYLINDER (PC400_10-K-L950-38F-00-B)
1. Move the arm cylinder, stop it at approximately 100 mm
before IN stroke end, and stop the engine.
2. Operate the arm control lever to IN to test.
Judging method
• When the lowering speed is increased at this time:
The cylinder packing is defective.
• No change: The control valve is defective.

30-148 HB365LC-3
 TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIP-
30 TESTING AND ADJUSTING MENT

REMARK
• Operate the control lever when the starting switch is turned to ON position.
• If the accumulator pressure is reduced, run the engine for approximately 10 seconds to accumulate the
pressure.

METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC

VALVE (PC400_10-K-C021-38F-00-B)
Measure the hydraulic drift of the work equipment when the work equipment lock lever is in LOCK and FREE
positions with the accumulator charged fully.
In case there is a difference of hydraulic drift between LOCK and FREE positions, the PPC valve is defective
(internal defect).
REMARK
• Operate the control lever when the starting switch is turned to ON position.
• If the accumulator pressure is reduced, run the engine for approximately 10 seconds to accumulate the
pressure.

HB365LC-3 30-149
TEST OIL LEAKAGE 30 TESTING AND ADJUSTING

TEST OIL LEAKAGE (HB335_3-K-C000-304-01-B)

Tools for testing the oil leakage

Symbol Part No. Part name Q'ty Remarks
Commercially
A Measuring cylinder 1
available
B 07379-01044 Flange 2 Size: 10
C 07379-00640 Flange 1 Size: 06
D 07376-70522 Plug 1 Size: 04
• MaterialSS400
Commercially
E Pin 1 • Diameter: 80 mm
available
• Length: 200 mm

Commercially • MaterialSS400
F Plate 1
available • Size250 × 260 × 32 (mm)

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
Check this item under the following conditions.
Hydraulic oil temperature: 45 to 55 °C
For testing oil leakage to perform troubleshooting, refer to this section.

METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER (HB335_3-K-L540-364-00-B)

1. Set the boom cylinder at RAISE stroke end, and stop the engine.
2. Release the remaining pressure from the piping on the boom cylinder head side. See “RELEASE REMAIN-
ING PRESSURE FROM HYDRAULIC SYSTEM”.
REMARK
Operate the lever in the boom RAISE direction only to release the remaining pressure.
3. Disconnect the hose (1) on the cylinder head side, and
block the hose side by using the flange B.
k Be careful not to disconnect the hose on the cylin-
der bottom side.
4. Start the engine.
5. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
6. Adjust the hydraulic oil temperature within the specified
range.
7. Turn the fuel control dial to MAX (High idle) position.
8. Operate the work equipment control lever to raise the boom, and relieve the boom RAISE circuit.
k Be careful not to operate the lever to “Boom LOWER” side.
9. 30 seconds after swing relief has started, measure the amount of oil leakage for 1 minute.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, restore the machine.

30-150 HB365LC-3
30 TESTING AND ADJUSTING TEST OIL LEAKAGE

METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER (HB335_3-K-L950-364-00-B)

1. Set the arm cylinder at IN stroke end, and stop the engine.
2. Release the remaining pressure from the piping on the arm cylinder head side. See “RELEASE REMAIN-
ING PRESSURE FROM HYDRAULIC SYSTEM”.
REMARK
Operate the lever in the arm IN direction only to release the remaining pressure.
3. Disconnect the hose (2) on the cylinder head side, and
block the hose side by using the flange B.
k Be careful not to disconnect the hose on the cylin-
der bottom side.
4. Start the engine.
5. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
6. Adjust the hydraulic oil temperature within the specified
range.
7. Turn the fuel control dial to MAX (High idle) position.
8. Operate the work equipment control lever and relive the arm IN circuit.
k Be careful not to operate the lever to “Arm OUT” side.
9. 30 seconds after swing relief has started, measure the amount of oil leakage for 1 minute.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, restore the machine.

METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER

(HB335_3-K-LCD0-364-00-B)
1. Set the bucket cylinder at CURL stroke end, and stop the engine.
2. Release the remaining pressure from the piping on the bucket cylinder head side. See “RELEASE RE-
MAINING PRESSURE FROM HYDRAULIC SYSTEM”.
REMARK
Operate the lever in the bucket CURL direction only to release the remaining pressure.
3. Disconnect the hose (3) on the cylinder head side, and
block the hose side by using the flange C.
k Be careful not to disconnect the hose on the cylin-
der bottom side.
4. Start the engine.
5. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
6. Adjust the hydraulic oil temperature within the specified
range.
7. Turn the fuel control dial to MAX (High idle) position.
8. Operate the work equipment control lever and relieve the bucket CURL circuit.
k Be careful not to operate the lever to “Bucket DUMP” side.
9. 30 seconds after swing relief has started, measure the amount of oil leakage for 1 minute.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
After finishing the test, restore the machine.

HB365LC-3 30-151
TEST OIL LEAKAGE 30 TESTING AND ADJUSTING

METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR (HB335_3-K-C400-364-00-B)

1. Remove the travel motor cover.
2. Start the engine, insert the pin E and the plate F between
the sprocket and the track frame to securely lock the track,
and stop the engine.

3. Disconnect the drain hose (5) of the travel motor, and

block the hose side by using the plug D.
4. Start the engine.
5. Select and display “SET AND OPERATE MACHINE MON-
ITOR” (01/28). See “SET AND OPERATE MACHINE
MONITOR”.
6. Adjust the hydraulic oil temperature within the specified
range.
7. Turn the fuel control dial to MAX (High idle) position.
8. Operate the work equipment control lever and relieve the
bucket CURL circuit.
k Give clear signals otherwise a mistake in lever operation can cause an accident.
k Before operating the travel lever, check the position and direction of locked sprocket again.
9. 30 seconds after swing relief has started, measure the amount of oil leakage for 1 minute.
For standard values, see “STANDARD VALUE TABLE, STANDARD VALUE TABLE FOR MACHINE”.
10. Move the motor a little each time and test the oil leakage several times (changing the relative position be-
tween the valve plate and cylinder and that between the cylinder and piston).
After finishing the test, restore the machine.

30-152 HB365LC-3
30 TESTING AND ADJUSTING BLEED AIR FROM HYDRAULIC CIRCUIT

BLEED AIR FROM HYDRAULIC CIRCUIT (HB335_3-K-C000-304-00-B)

k Place the machine on a level ground, lower the work equipment completely to the ground in a stable
posture, set the lock lever to LOCK position, and then stop the engine.
k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
For releasing the air from hydraulic systems to perform troubleshooting, refer to this section.
Bleed air in the hydraulic system which marked with ●. Start bleeding air from step 1.
Air in the hydraulic system which marked with “x” does not need to be bled.
Air bleeding procedure and items
1 2 3 4 5 6
Details of work Bleeding Bleeding
Bleeding Bleeding Check of oil
Start the air from air from
air from air from level and
engine. swing mo- travel mo-
main pump cylinder operation
tor tor
• Hydraulic oil change ● ●
● ● ● ●
• Strainer cleaning (*1) (*1)
• Replacement of return filter ele-
× ● × × × ●
ment
• Replacement and repair of
main pump ● ● ● × × ●
• Removal of suction piping
• Replacement and repair of con-
trol valve × ● ● × × ●
• Removal of control valve piping
• Replacement and repair of cyl-
inder × ● ● × × ●
• Removal of cylinder piping
• Replacement and repair of trav-
el motor × ● × × ● ●
• Removal of travel motor piping
• Replacement and repair of
swivel joint × ● × × × ●
• Installation of swivel joint piping

*1: Bleed air from the travel motor only when the oil in the motor case is drained.

METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT (HB335_3-K-C000-231-00-B)

Method for bleeding air from main pump

NOTICE
If the pump is operated without filling the pump case with hydraulic oil, abnormal heat will be generated
and this may cause a premature damage to the pump. Make sure that the air is bled from the pump.
Be sure to perform the following procedures when any hydraulic component or oil is replaced.
1. Close the hydraulic tank oil filler cap.
2. Open the cover on the left side of the machine.
3. Start the engine, and set the fuel control dial to MIN (Low idle) position.

HB365LC-3 30-153
BLEED AIR FROM HYDRAULIC CIRCUIT 30 TESTING AND ADJUSTING

REMARK
When performing the automatic warm-up operation while engine coolant temperature is low, stop the en-
gine once and cancel the automatic warm-up function with fuel control dial. (Turn the starting switch to ON
position and keep the fuel control dial at MAX position for 3 seconds or more, and automatic warm-up func-
tion will be canceled.)
4. Loosen air bleeder (1), and tighten it when hydraulic oil
containing no bubbles starts to flow out.
3 Air bleeder (1):
7.8 to 9.8 Nm {0.8 to 1.0 kgm}
5. Keep the fuel control dial in MIN (Low idle) position for 10
minutes to circulate the hydraulic oil in the main pump.
6. Close the oil filler cap.

• After finishing the air bleeding work, remove the tools and restore the machine.
• Check the hydraulic oil level.

Method for bleeding air from cylinder

REMARK
When the cylinder is replaced, perform this work before connecting the work equipment. Especially, LOWER
side of the boom cylinder can not be operated to the stroke end with the work equipment installed.
1. Start the engine, and run it for approximately 5 minutes with the fuel control dial at MIN (Low idle) position.
2. Repeat raising the boom and lowering it 4 to 5 times while running the engine with the fuel control dial at
MIN (Low idle) position.
REMARK
Be careful to stop the piston rod approximately100 mm before each stroke end to avoid relieving.
3. Repeat raising the boom and lowering it 4 to 5 times while running the engine with the fuel control dial at
MAX (High idle) position.
REMARK
Be careful to stop the piston rod approximately100 mm before each stroke end to avoid relieving.
4. Set the fuel control dial to MIN (Low idle) position, extend and retract the piston rod to each stroke end, and
relieve the circuit.
5. Bleed air from the arm cylinder and bucket cylinder according to steps 2 to 4.
When starting the engine after performing “Bleeding air from main pump”, run the engine for 10 minutes with the
fuel control dial at MIN (Low idle) position.
REMARK
When performing the automatic warm-up operation while engine coolant temperature is low, stop the engine
once and cancel the automatic warm-up function with fuel control dial. (Turn the starting switch to ON position
and keep the fuel control dial at MAX position for 3 seconds or more, and automatic warm-up function will be
canceled.)

Method for bleeding air from travel motor

1. Remove the travel motor cover.
2. Start the engine, and run it with the fuel control dial at MIN (Low idle) position.

30-154 HB365LC-3
30 TESTING AND ADJUSTING BLEED AIR FROM HYDRAULIC CIRCUIT

3. Loosen the bleeder (3) and check that the oil flows out.
4. When the oil without air starts to flow out, tighten the
bleeder (3).
3 Bleeder (3):
27.4 to 35.3 Nm 2.8 to 3.6 kgm

Bleeding air from swivel joint

1. Start the engine, and run it with the fuel control dial at MIN (Low idle) position.
2. Raise the track and idle off from the ground one side at a
time with left forward, left reverse, right forward, and right
reverse to bleed the air.

Method of checking oil level and operation

1. Start the engine, retract the arm cylinder and bucket cylin-
der fully, lower the work equipment to the ground, and stop
the engine.

2. Check the oil level by sight gauge (4) at the rear of the hy-
draulic tank.
When the oil level is between the lines “H” and “L”, it is ap-
propriate.
When the oil level is below line L, it is insufficient. Add
more oil.

HB365LC-3 30-155
TEST CAB TIPPING STOPPER 30 TESTING AND ADJUSTING

CAB AND ITS ATTACHMENTS (ALL-K-K000-001-30-B)

TEST CAB TIPPING STOPPER (PC400_10-K-K138-304-00-B)

For testing cab tipping stopper, refer to this section.

METHOD FOR TESTING CAB TIPPING STOPPER (PC400_10-K-K138-280-01-B)

Check the tightening torque of mounting bolt (2) of lock plate

3 Bolt (2):
(1).

98 to 123 Nm {10 to 12.5 kgm}

Note that the tightening torque for mounting bolt (4) of cab tip-
ping stopper (3) is different from that of a common bolt whose
thread diameter is 30 mm.
3 Bolt (4):
245 to 309 Nm {25 to 31.5 kgm}

30-156 HB365LC-3
30 TESTING AND ADJUSTING METHOD FOR ADJUSTING MIRRORS

METHOD FOR ADJUSTING MIRRORS (PC300_11-K-K810-270-00-B)

k Be sure to adjust the mirrors before starting work. If they are not adjusted properly, you cannot se-
cure the visibility and may be injured or may lead to a serious personal injury or death.
k To prevent the machine from moving during the work, make sure that the following conditions are
met before starting the work.
k The machine is placed on a firm, level ground.
k The work equipment is lowered to the ground in secure posture.
k The lock lever is in LOCK position.
k The engine is stopped.
Mirror (A): Machine L.H. front mirror
Mirror (B): Machine R.H. front mirror
Mirror (C): Machine R.H. side mirror

PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A)

(PC400_10-K-K810-270-10-B)

k To prevent the machine from moving during the work, make sure that the following conditions are
met before starting the work.
k The machine is placed on a firm, level ground.
k The work equipment is lowered to the ground in secure posture.
k The lock lever is in LOCK position.
k The engine is stopped.
Adjust the mirror so that the operator can see a person at the rear left of the machine.
1. Adjust the mirror with your hand so that the side of the ma-
chine is reflected in the mirror as shown in the figure.
2. Check that you can see a person at the rear left end of the
machine.

3. If you cannot adjust, loosen mounting bolts (1) of the mir-

ror and stay, and adjust the angles.

HB365LC-3 30-157
METHOD FOR ADJUSTING MIRRORS 30 TESTING AND ADJUSTING

If the mirror is adjusted by loosening the mounting bolts, be sure to adjust the mirror to its specified position. For
the adjustment method, see the “Procedure for adjusting regular position of machine left front mirror (A)”.

PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT

FRONT MIRROR (A) (PC300_11-K-K810-270-02-B)

k To prevent the machine from moving during the work, make sure that the following conditions are
met before starting the work.
k The machine is placed on a firm, level ground.
k The work equipment is lowered to the ground in secure posture.
k The lock lever is in LOCK position.
k The engine is stopped.
When returning the mirror to its regular position, perform the
following adjustment.

1. Adjust stay (1).

Mounting position (2): 69 mm
Mounting angle (3): 83 °
Mounting angle (4): 88 °
2. Adjust mirror (5).
Tightening torque of mounting bolt (6): 6.0 to 7.0 Nm {0.61
to 0.71 kgm}
Mounting position (7): 166 mm

30-158 HB365LC-3
30 TESTING AND ADJUSTING METHOD FOR ADJUSTING MIRRORS

NOTICE
• Tighten the right and left bolts of each bracket al-
ternately so that their right and left clearances (R)
and (L) become equal.
• If the mirror and stay mounting bolts are tightened
excessively, the bracket may be damaged. Be sure
to tighten bolts to the specified torque.

Adjust the mirror so that the side of the machine is reflec-

ted in it as shown in the figure.

PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B)

(PC400_10-K-K810-270-30-B)

k To prevent the machine from moving during the work, make sure that the following conditions are
met before starting the work.
k The machine is placed on a firm, level ground.
k The work equipment is lowered to the ground in secure posture.
k The lock lever is in LOCK position.
k The engine is stopped.
Adjust the mirror so that you can see a person at the rear right
of the machine.

1. Adjust the mirror with your hand so that the side of the ma-
chine is reflected in the mirror as shown in the figure.
2. Check that you can see a person at the rear right of the
machine.

HB365LC-3 30-159
METHOD FOR ADJUSTING MIRRORS 30 TESTING AND ADJUSTING

3. If you cannot adjust, loosen mounting bolts (1) of the mir-

ror and stay, and adjust the angles.

If the mirror is adjusted by loosening the mounting bolts, be sure to adjust the mirror to its regular position. For
the adjustment method, see the “Procedure for adjusting regular position of machine right front mirror (B)”.

PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT

FRONT MIRROR (B) (PC400_10-K-K810-270-40-B)

k To prevent the machine from moving during the work, make sure that the following conditions are
met before starting the work.
k The machine is placed on a firm, level ground.
k The work equipment is lowered to the ground in secure posture.
k The lock lever is in LOCK position.
k The engine is stopped.
When returning the mirror to its regular position, perform the following adjustment.
Adjust mirror (1).
Tightening torque of mounting bolt (2): 6.0 to 7.0 Nm {0.61 to
0.71 kgm}
Mounting position (3): 120 mm
Mounting angle (4): 30 °

NOTICE
• Tighten the right and left bolts of each bracket alter-
nately so that their right and left clearances (R) and (L)
become equal.
• If the mirror and stay mounting bolts are tightened ex-
cessively, the bracket may be damaged. Be sure to
tighten bolts to the specified torque.

30-160 HB365LC-3
30 TESTING AND ADJUSTING METHOD FOR ADJUSTING MIRRORS

Adjust the mirror so that the side of the machine is reflected in

it as shown in the figure.

PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C)

(PC300_11-K-K810-270-01-B)

k To prevent the machine from moving during the work, make sure that the following conditions are
met before starting the work.
k The machine is placed on a firm, level ground.
k The work equipment is lowered to the ground in secure posture.
k The lock lever is in LOCK position.
k The engine is stopped.
• Adjust it so that people within 1 m around the machine can
be seen from the operator's seat.
(W): 1 m

HB365LC-3 30-161
METHOD FOR ADJUSTING MIRRORS 30 TESTING AND ADJUSTING

• The regular position of the mirror is as follows:

Adjust mirror (13).
Tightening torque of mounting bolt (12): 6.0 to 7.0 Nm{0.61
to 0.71 kgm}
Mounting angle (14): 20 °
Mounting position (15): 22 mm

30-162 HB365LC-3
30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

ELECTRICAL SYSTEM (ALL-K-0H00-001-30-B)

SET AND OPERATE MACHINE MONITOR (HB335_3_E-K-Q170-04D-00-B)

HB365LC-3 30-163
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

Upper part of machine monitor

(a): Multi-information display
When starting the engine, the battery voltage may suddenly drop depending on the temperature and the battery
condition. If this happens, the display on the machine monitor may momentarily go out, but this does not indi-
cate any abnormality.
Upper part of machine monitor (switch part)
F1: F1 Function switch
F2: F2 Function switch
F3: F3 Function switch
F4: F4 Function switch
F5: F5 Function switch
F6: F6 Function switch
The function of switches are indicated by the icon on the screen. Icons are displayed just above the function
switch on the multi-information display panel (a).
If the icon for a function switch is not displayed, that function switch is not working.
Lower part of machine monitor (switch part)
1: Numeral 1 input switch/Auto-deceleration switch
2: Numeral 2 input switch/Working mode selector switch
3: Numeral 3 input switch/Travel speed selector switch
4: Numeral 4 input switch/Buzzer cancel switch
5: Numeral 5 input switch/Wiper switch
6: Numeral 6 input switch/Window washer switch
7: Numeral 7 input switch/Air conditioner switch
8: Numeral 8 input switch/Air conditioner switch
9: Numeral 9 input switch/Air conditioner switch
0: Numeral 0 input switch/Air conditioner switch
Each switch has the function indicated by the icon on it and the function of inputting a numeral.
The machine monitor automatically judges which function of each switch is currently enabled according to the
screen display of the multi-information display (a).
Operator mode and service mode of machine monitor
Machine monitor has operator mode and service mode. Various information is displayed on multi-information
display (a).
Some items are displayed automatically according to the configuration of the machine monitor whereas the oth-
er items can be displayed only when the machine monitor is operated with switches.
• Operator mode
The information items in this mode are ordinarily displayed. The operator can display and set them by the
operation with switches. (Display and setting of some items need special operation of switches.)
For details, see Operation and Maintenance Manual.
Operator mode
“EXPLANATION OF MACHINE MONITOR EQUIPMENT”
“BASIC OPERATION OF MACHINE MONITOR”
“ACTION LEVEL DISPLAY”
“CURRENT ABNORMALITY DISPLAY SWITCH”
“MAINTENANCE TIME CAUTION LAMP”

30-164 HB365LC-3
30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

Operator mode
“WORKING MODE DISPLAY”
“AFTERTREATMENT DEVICES REGENERATION PILOT LAMP”
“ECO GUIDANCE”
“SERVICE METER / CLOCK”
“WORKING MODE SELECTOR SWITCH”
“AUTO-DECELERATION SWITCH”
“TRAVEL SPEED SELECTOR SWITCH”
“WIPER SWITCH”
“WINDOW WASHER SWITCH”
“BUZZER CANCEL SWITCH”
“AIR CONDITIONER SWITCH”
“CAMERA IMAGE SELECTOR SWITCH”
“USER MENU”
“SCR INFORMATION”
“MAINTENANCE SCREEN SETTING”
“ENGINE SHUTDOWN SECONDARY SWITCH”
“METHOD FOR OPERATIONS AND CHECKS BEFORE STARTING ENGINE”
“HANDLE KOMVISION”

Following functions become operational by performing special operations.

Operator mode
Display function of the technician identification status screen
Display function of the operator identification input screen
Checking function by LCD (liquid crystal display)
Checking function of service meter
Usage limitation and changing maintenance password function

• Service Mode
The information items in this mode are not ordinarily displayed. Technicians can change display and set-
tings by operating the switches specially. This mode is used for testing, adjusting, or troubleshooting.
Service Mode
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION
METHOD FOR CONFIRMING ABNORMALITY RECORD (MECHANICAL SYSTEMS)
METHOD FOR CONFIRMING ABNORMALITY RECORD (ELECTRICAL SYSTEMS)
METHOD FOR CONFIRMING MAINTENANCE RECORD
METHOD FOR OPERATING MAINTENANCE MODE SETTING
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING
METHOD FOR SETTING DEFAULT (KEY-ON MODE)
METHOD FOR SETTING DEFAULT (UNIT)
METHOD FOR SETTING DEFAULT (WITH/WITHOUT ATTACHMENT)

HB365LC-3 30-165
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

Service Mode
METHOD FOR SETTING DEFAULT (CAMERA)
METHOD FOR OPERATING TESTING MENU (AUTO IDLE STOP TIME FIXING)
METHOD FOR SETTING WITH DEFAULT SETTING MENU (WITH/WITHOUT QUICK COUPLER)
METHOD FOR SETTING WITH DEFAULT SETTING MENU (WITH/WITHOUT KomVision)
METHOD FOR OPERATING TESTING MENU (CYLINDER CUT-OUT OPERATION)
METHOD FOR OPERATING TESTING MENU (REGENERATION FOR SERVICE)
METHOD FOR OPERATING TESTING MENU (KDPF MEMORY RESET)
METHOD FOR OPERATING TESTING MENU (SCR SERVICE TEST)
METHOD FOR OPERATING TESTING MENU (ENGINE CONTROLLER ACTIVE FAULT CLEAR)
METHOD FOR OPERATING TESTING MENU (ASH IN SOOT ACCUMULATION CORRECTION)
METHOD FOR OPERATING TESTING MENU (RESET NUMBER OF ABRUPT ENGINE STOP BY AIS)
METHOD FOR OPERATING TESTING MENU (ENGINE STOP AdBlue/DEF INJ OVERHEAT COUNT RESET)
METHOD FOR OPERATING TESTING MENU (Capacitor Discharge)
METHOD FOR ADJUSTING (Pump Absorption Torque (F))
METHOD FOR ADJUSTING (Pump Absorption Torque (R))
METHOD FOR ADJUSTING (Low Speed)
METHOD FOR ADJUSTING (Attachment Flow Adjustment)
METHOD FOR ADJUSTING (CAL F pump swash plate sensor)
METHOD FOR ADJUSTING (CAL R pump swash plate sensor)
METHOD FOR ADJUSTING WITH ADJUSTING MENU (Swing Motor Starting Torque)
METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (Hoist Swing Adjustment)
METHOD FOR ADJUSTING (Fan Rotation Mode Selection)
METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (KomVision SETTING)
METHOD FOR ADJUSTING (Pump calibration: Matching speed check)
METHOD FOR ADJUSTING (Pump calibration: Matching speed calibration)
METHOD FOR ADJUSTING MENU (Pump calibration:RESTORE TO DEFAULT SETTING)
METHOD FOR PERFORMING NO-INJECTION CRANKING
METHOD FOR CONFIRMING KOMTRAX SETTINGS (TERMINAL STATUS)
METHOD FOR CONFIRMING KOMTRAX SETTINGS (GPS AND COMMUNICATION STATUS)
METHOD FOR CONFIRMING KOMTRAX SETTINGS (MODEM STATUS)
METHOD FOR DISPLAYING SERVICE MESSAGE

OPERATOR MODE (PC400_10-K-Q193-042-01-B)

The following are items which needs specific switch operation in operator mode.
For details of contents and operations of each function and display, see STRUCTURE AND FUNCTION, “MA-
CHINE MONITOR”or the “OPERATION AND MAINTENANCE MANUAL”.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN

(PC400_11_E-K-Q19G-100-00-B)
When the operator identification function is enabled, turn the
starting switch to ON position while pressing the numeral input
key 4, and the following technician identification state screen is
displayed for 2 seconds.
REMARK
The purpose of the display function of technician identification
status screen is to distinguish the operating state by technician
(maintenance work, etc.) and operating state by operator when
the customer controls operating state by operator, fuel con-
sumption, machine trouble by using operator ID function.

DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN

(PC400_11_E-K-Q19G-100-10-B)
After displaying the technician identification state screen, the operator ID input screen
• The screen shown in the figure is displayed only when the
operator ID No. input setting is enabled.
• Before performing checking and adjusting, check in ad-
vance that the input setting of ID of the operator identifica-
tion function has already been set by the customer.
• When the customer has done the ID input setting with
SKIP, press F1 after displaying the technician identification
state screen, and the engine can be started.
• When the customer has done the ID input setting without
SKIP, the engine cannot be started unless the registered
ID is provided for the technician to use, from a person in
charge of the machine on the customer side.
• When turning the starting switch to ON position, input ID,
press F6 or F1, and the screen changes to check before
starting screen without switch operation. Confirm that it is
not necessary to identify the technician beforehand by ask-
ing administrator of the machine.

HB365LC-3 30-167
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) (PC400_10-K-Q180-042-38-B)

While the standard screen is displayed, if the numeral input
switches or function switches are operated in the following
manner, the entire LCD screen turns white.
Switch operations (simultaneously): 4 + F2
• When finishing the operation of the switches, release F2
first.
• If there is a display error in the LCD, only that part is indi-
cated in black.
• To return to the former screen, press any one of the func-
tion switches.

CHECKING FUNCTION OF SERVICE METER (PC400_11-K-Q180-042-12-B)

When checking the service meter with the starting switch in
OFF position, operate the numeral input switches as follows to
display only the service meter section.
Operate the switches (simultaneously): 4 + 1
REMARK
• There is some time lag in start of the LCD, so hold down
the switches until the service meter is displayed.
• If you release one of the switches, the monitor goes off.

METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD

(HB335_3_E-K-Q180-042-00-B)
On the machine monitor, a password can be set as an user limitation setting. If the password is set, password
input screen appears when resetting the maintenance items.
Observe the following procedure when setting usage limitation or changing the password.

30-168 HB365LC-3
30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

1. While the standard screen is displayed, perform the follow-

ing operation with the numeral input switches.
Switch operation (While pressing 4, press other switches
in order): 4 + 5 → 5 → 5
REMARK
This switch operation is available in 10 minutes after the
starting switch is turned to ON position.

2. On “Usage Limitation Password” screen, input the current

password with the numeral input switches and enter it with
the function switch.
F5: Clears the inputted numbers/Returns to the standard
screen
F6: Enters the inputted password
REMARK
• Default password: 000000
• When the inputted password is correct, the screen
changes to the next screen.
• When the inputted password is incorrect, the monitor
displays a message prompting reinput of the password.
• The password for the inducement and the engine start
lock password are the same.
3. On “Usage Limitation Setting” screen, select a setting with
the function switch.
F3: Moves down the selected item
F4: Moves up the selected item
F5: Cancels the selection and returns the screen to the
previous screen
F6: Enters the selected item

HB365LC-3 30-169
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

4. On “Usage Limitation ON/OFF” screen, select a setting

with the function switch.
OFF: Password enter screen is not displayed.
ON: Displays the password enter screen for resetting of
maintenance items.
F3: Moves down the selected item
F4: Moves up the selected item
F5: Cancels the selection and returns the screen to the
previous screen
F6: Enters the selected item
5. On “Usage Limitation New Password Input” screen, input a
new password with the numeral input switches and enter it
with the function switch.
• F5: Clears inputted numbers/Returns to the previous
screen
• F6: Enters the inputted password
REMARK
• Default password: 000000
• When the inputted password is correct, the screen
changes to the next screen.
• When the inputted password is incorrect, the monitor
displays a message prompting re-input of the pass-
word.
• Set a new password of 4 to 6 digits. (If the password is
less than 3 digits or has 7 or more digits, it cannot be
accepted).
6. After “Usage Limitation New Password Input” screen is
displayed again, input a new password again with the nu-
meral input switches and enter it with the function switch.
F5: Clears the inputted numbers/Returns to the standard
screen
F6: Enters the inputted password
REMARK
If the password is different from the previous one, the mon-
itor displays a message prompting reinput of the pass-
word.
If the standard screen is displayed after the screen to noti-
fy completion of the setting is displayed, the password has
been changed successfully.

30-170 HB365LC-3
30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

SERVICE MODE (PC400_11-K-Q194-100-01-B)

METHOD FOR OPERATING SERVICE MODE (HB335_3_E-K-Q194-100-00-B)

To change the mode of the machine monitor to the service mode from the operator mode, perform the following
operation.
This operation is always required when you use the service mode.
1. When the standard screen displayed, while pressing 4,
press other switches in order 4 + 1 → 2 → 3.
REMARK
This operation of the switches is accepted only while the
standard screen is displayed.

2. When the “Service Menu” screen is displayed, the service

mode is selected. Select an item on service menu with the
function switches or numeral input switches.
F3: Moves down the selected item
F4: Moves up the selected item
F5: Returns the screen to the standard screen (operator
mode)
F6: Enters the selected item
REMARK
• When you input a code (2-digit) by using the numeral
input switches, the corresponding menu is directly se-
lected. Accordingly, you may enter the selected item by
using F6.
• Items with 2-digit codes are the menus displayed on
“Service Menu” screen. The items on the right are the
menus on the next hierarchy.
The following shows the items selectable with “Service Menu” (including some items which need special switch-
ing operations).

Selectable items in service menu

Code Item Reference page
01 Pre-defined Monitoring METHOD FOR CHECKING PRE-DEFINED MONITORING
INFORMATION
02 Self-define Monitoring METHOD FOR CHECKING SELF-DEFINE MONITORING
INFORMATION

HB365LC-3 30-171
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

Code Item Reference page

03 Abnormality Mechanical Sys Abnormali- METHOD FOR CONFIRMING ABNORMALITY RECORD
Record ty Record (MECHANICAL SYSTEMS)
Electrical Sys Abnormality METHOD FOR CONFIRMING ABNORMALITY RECORD
Record (ELECTRICAL SYSTEMS)
04 Maintenance Record METHOD FOR CONFIRMING MAINTENANCE RECORD
05 Maintenance Mode Setting METHOD FOR OPERATING MAINTENANCE MODE SET-
TING
06 Phone Number Entry METHOD FOR OPERATING PHONE NUMBER ENTRY
SETTING
07 Default Key-on Mode METHOD FOR SETTING WITH DEFAULT SETTING MENU
(KEY-ON MODE)
Unit METHOD FOR SETTING WITH DEFAULT SETTING MENU
(UNIT)
With/Without Attachment METHOD FOR SETTING WITH DEFAULT SETTING MENU
(WITH/WITHOUT ATTACHMENT)
Camera METHOD FOR SETTING WITH DEFAULT SETTING MENU
(CAMERA)
Auto Idle Stop Time Fixing METHOD FOR SETTING WITH DEFAULT SETTING MENU
(AUTO IDLE STOP TIMER FIXING)
“With/Without Quick Cou- METHOD FOR SETTING WITH DEFAULT SETTING MENU
pler ” (WITH/WITHOUT QUICK COUPLER)
With/Without KomVision METHOD FOR SETTING WITH DEFAULT SETTING MENU
(WITH/WITHOUT KomVision)
08 Diagnostic Cylinder Cutout Mode Op- METHOD FOR OPERATING TESTING MENU (CYLINDER
Tests eration CUT-OUT OPERATION)
Active Regeneration for METHOD FOR OPERATING TESTING MENU (REGENER-
Service ATION FOR SERVICE)
KDPF Memory Reset METHOD FOR OPERATING TESTING MENU (KDPF MEM-
ORY RESET)
SCR Service Test METHOD FOR OPERATING TESTING MENU (SCR SERV-
ICE TEST)
Engine Controller Active METHOD FOR OPERATING TESTING MENU (ENGINE
Fault Clear CONTROLLER ACTIVE FAULT CLEAR)
Ash in Soot Accumulation METHOD FOR OPERATING TESTING MENU (Ash in Soot
Correction Accumulation Correction)
Reset Number of Abrupt METHOD FOR OPERATING TESTING MENU (RESET
Engine Stop by AIS NUMBER OF ABRUPT ENGINE STOP BY AIS)
Engine Stop at AdBlue/DEF METHOD FOR OPERATING TESTING MENU (Engine Stop
Inj Overheat Count Reset at AdBlue/DEF Inj Overheat Count Reset)
Capacitor Discharge METHOD FOR OPERATING TESTING MENU (Capacitor
Discharge)

30-172 HB365LC-3
30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

Code Item Reference page

09 Adjustment Pump Absorption Torque METHOD FOR ADJUSTING (Pump Absorption Torque (F))
(F)
Pump Absorption Torque METHOD FOR ADJUSTING (Pump Absorption Torque (R))
(R)
Travel Low Speed METHOD FOR ADJUSTING (Low Speed)
Att Flow Adjust in Com- METHOD FOR ADJUSTING WITH ADJUSTMENT MEMU
bined Ope (Att Flow Adjust in Combined Ope)
Calibrate F Pump Swash METHOD FOR ADJUSTING (CAL F pump swash plate sen-
Plate Sensor sor)
Calibrate R Pump Swash METHOD FOR ADJUSTING (CAL R pump swash plate sen-
Plate Sensor sor)
Swing Motor Starting Tor- METHOD FOR ADJUSTING WITH ADJUSTING MENU
que (Swing Motor Starting Torque)
Hoist Swing Adjustment METHOD FOR ADJUSTING WITH ADJUSTMENT MEMU
(Fan Speed Mode Select)
Fan Speed Mode Select METHOD FOR ADJUSTING WITH ADJUSTMENT MENU
(Fan Speed Mode Select)
KomVision Adjustment METHOD FOR ADJUSTING WITH ADJUSTMENT MENU
(KomVision SETTING)
Pump Calibration:Matching METHOD FOR ADJUSTING (Pump calibration: Matching
Speed Check Speed Check)
Pump Calibration:Matching METHOD FOR ADJUSTING (Pump calibration: Matching
Speed Calibration speed calibration)
Pump Calibration:Restore METHOD FOR OPERATING ADJUSTMENT MENU (PUMP
to Default Setting CALIBRATION: RESTORE TO DEFAULT SETTING)
10 No-Injection Cranking METHOD FOR PERFORMING NO-INJECTION CRANKING
11 KOMTRAX Terminal Status METHOD FOR CONFIRMING KOMTRAX SETTINGS (TER-
Settings MINAL STATUS)
GPS & Communication METHOD FOR CONFIRMING KOMTRAX SETTINGS (GPS
State AND COMMUNICATION STATUS)
Modem Information METHOD FOR CONFIRMING KOMTRAX SETTINGS (MO-
DEM STATUS)
12 Service Message METHOD FOR DISPLAYING SERVICE MESSAGE

METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION

(HB335_3_E-K-Q1S1-100-00-B)
The machine monitor monitors the condition of the machine in real time using signals from various switches,
sensors, actuators, and their controllers which are installed on various parts of the machine.
In “Pre-defined Monitoring”, frequently used monitoring items are selected beforehand.

HB365LC-3 30-173
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

1. Select “Pre-defined Monitoring” on “Service Menu” screen.

REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On “Pre-defined Monitoring”, select an item to be con-

firmed by using the function switches.
F1: Moves to the next page
F2: Returns to the previous page
F4: Selects HOLD or releasing HOLD. (When HOLD is se-
lected, “HOLD” part is hatched.)
F5: Returns the display to the “Service Menu” screen

REMARK
• For the items not displayed in “Pre-defined Monitoring”,
you can freely select and check from “Self-define Moni-
toring” items.
• When the working mode is changed to B (“Breaker
Mode ”), the screen to confirm the change of the set-
ting is displayed as in changing the working mode on
the standard screen.

3. By pressing switch F3 during pre-defined monitoring, the

monitor display screen switches to the energy monitor
screen.

30-174 HB365LC-3
30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

On the Energy Monitor screen, the power transmitting con-

dition between the components and the momentary fuel
consumption are displayed.
• (A) to (F) indicate the power flow condition between
the components.
(A): Between engine and motor-generator
(B): Between motor-generator and capacitor
(C): Between motor-generator and electric swing mo-
tor
(D): Between capacitor and electric swing motor
(E): Between hydraulic pump and work equipment cyl-
inder
(F): Between motor-generator and hydraulic pump
• (G) indicates the momentary fuel consumption.
• To return to pre-defined monitoring, press switch F5.

TABLE OF PRE-DEFINED MONITORING ITEMS (HB335_3-K-Q1S1-208-00-B)

Pre-defined Monitoring (01/28) Machine standard

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 04107 Coolant Temperature °C °C °F ENG
3 37212 Engine Oil Pressure SW ON/OFF ON/OFF ON/OFF ENG
4 18400 Intake Temperature °C °C °F ENG
5 04401 Hydraulic Oil Temperature °C °C °F PUMP
6 03203 Battery Power Supply V V V ENG

Pre-defined Monitoring (02/28) Fuel injection system

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 47300 KDOC 1 Inlet Temperature °C °C °F ENG
3 36400 Rail Pressure MPa kg/cm2 psi ENG
4 36200 Rail Pressure Command MPa kg/cm2 psi ENG
5 48000 IMV Current A A A ENG
6 48001 IMV Command Current A A A ENG

HB365LC-3 30-175
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

Pre-defined Monitoring (03/28) EGR, VGT actuator

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 48100 Turbocharger Speed r/min rpm rpm ENG
3 18100 EGR Valve Position mm mm in ENG
4 48600 EGR Solenoid Current mA mA mA ENG
5 48700 VGT Position mm mm in ENG
6 48800 VGT Solenoid Current mA mA mA ENG

Pre-defined Monitoring (04/28) Engine temperature related items

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 48100 Turbocharger Speed r/min rpm rpm ENG
3 04107 Coolant Temperature °C °C °F ENG
4 18400 Intake Temperature °C °C °F ENG
5 18500 Charge Temperature °C °C °F ENG

Pre-defined Monitoring (05/28) Intake and exhaust pressure, etc.

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 37400 Ambient Pressure kPa kg/cm2 psi ENG
3 36500 Charge Pressure kPa kg/cm2 psi ENG
4 48300 Exhaust Manifold Pressure kPa kg/cm2 psi ENG
5 48100 Turbocharger Speed r/min rpm rpm ENG
6 48200 MAF kg/sec kg/min lb/min ENG

Pre-defined Monitoring (06/28) Aftertreatment related items

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 47000 KDPF Outlet Pressure kPa kg/cm2 psi ENG

2 47100 KDPF Differential Pressure kPa kg/cm2 psi ENG
3 47200 KDPF 1 Outlet Temperature °C °C °F ENG
4 47300 KDOC 1 Inlet Temperature °C °C °F ENG
5 47400 KDOC 1 Outlet Temperature °C °C °F ENG
6 36400 Rail Pressure MPa kg/cm2 psi ENG

30-176 HB365LC-3
30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

Pre-defined Monitoring (07/28) Engine related

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 37212 Engine Oil Pressure SW ON/OFF ON/OFF ON/OFF ENG
3 48400 Crankcase Pressure kPa mmAq psi ENG
4 47300 KDOC 1 Inlet Temperature °C °C °F ENG
5 36500 Charge Pressure kPa kg/cm2 psi ENG
6 48100 Turbocharger Speed r/min rpm rpm ENG

Pre-defined Monitoring (08/28) F&R pump standard

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 01100 Front Pump Pressure MPa kg/cm2 psi PUMP
3 01101 Rear Pump Pressure MPa kg/cm2 psi PUMP
4 01300 PC-EPC Front Solenoid Current mA mA mA PUMP
5 01302 PC-EPC Rear Solenoid Current mA mA mA PUMP
6 04401 Hydraulic Oil Temperature °C °C °F PUMP

Pre-defined Monitoring (09/28) F&R pump application

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 01100 Front Pump Pressure MPa kg/cm2 psi PUMP
3 01101 Rear Pump Pressure MPa kg/cm2 psi PUMP
4 01137 Front Pump Displacement cc/rev cc/rev cc/rev PUMP
5 01139 Rear Pump Displacement cc/rev cc/rev cc/rev PUMP
6 04401 Hydraulic Oil Temperature °C °C °F PUMP

Pre-defined Monitoring (10/28) F pump application

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 01100 Front Pump Pressure MPa kg/cm2 psi PUMP
3 01141 Service Pressure Sensor MPa kg/cm2 psi PUMP
4 01300 PC-EPC Front Solenoid Current mA mA mA PUMP
5 01137 Front Pump Displacement cc/rev cc/rev cc/rev PUMP
6 01500 LS-EPC Solenoid Current mA mA mA PUMP

HB365LC-3 30-177
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

Pre-defined Monitoring (11/28) R pump application

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 01101 Rear Pump Pressure MPa kg/cm2 psi PUMP
3 01141 Service Pressure Sensor MPa kg/cm2 psi PUMP
4 01302 PC-EPC Rear Solenoid Current mA mA mA PUMP
5 01139 Rear Pump Displacement cc/rev cc/rev cc/rev PUMP
6 01500 LS-EPC Solenoid Current mA mA mA PUMP

Pre-defined Monitoring (12/28) PPC pressure (1)

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 07400 Boom Raise PPC Pressure MPa kg/cm2 psi PUMP
3 07500 Boom Lower PPC Pressure MPa kg/cm2 psi PUMP
4 07200 Arm IN PPC Pressure MPa kg/cm2 psi PUMP
5 07600 Arm OUT PPC Pressure MPa kg/cm2 psi PUMP
6 04401 Hydraulic Oil Temperature °C °C °F PUMP

Pre-defined Monitoring (13/28) PPC pressure (2)

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 09002 Swing Right PPC Pressure MPa kg/cm2 psi PUMP
3 09001 Swing Left PPC Pressure MPa kg/cm2 psi PUMP
4 07300 Bucket CURL PPC Pressure MPa kg/cm2 psi PUMP
5 07301 Bucket DUMP PPC Pressure MPa kg/cm2 psi PUMP
6 04401 Hydraulic Oil Temperature °C °C °F PUMP

Pre-defined Monitoring (14/28) PPC pressure (3)

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 07102 Travel Forward Left PPC Press MPa kg/cm2 psi PUMP
3 07103 Travel Forward Right PPC Press MPa kg/cm2 psi PUMP
4 07104 Travel Reverse Left PPC Press MPa kg/cm2 psi PUMP
5 07105 Travel Reverse Right PPC Press MPa kg/cm2 psi PUMP
6 04401 Hydraulic Oil Temperature °C kg/cm2 °F PUMP

30-178 HB365LC-3
30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

Pre-defined Monitoring (15/28) Fan clutch related items

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 04107 Coolant Temperature °C °C °F ENG
3 04401 Hydraulic Oil Temperature °C °C °F PUMP
4 10019 Fan Speed Deviation r/min rpm rpm PUMP
5 10010 Fan Speed Command r/min rpm rpm PUMP
6 10007 Fan Speed r/min rpm rpm PUMP

Pre-defined Monitoring (16/28) Engine operating state

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 18600 Inject Fueling Command mg/st mg/st mg/st ENG
3 19200 Exhaust Gas Flow Rate kL/h kL/h kgal/h ENG
4 47300 KDOC 1 Inlet Temperature °C °C °F ENG
5 19300 SCR Temperature °C °C °F SCR
6 19302 SCR Outlet Temperature °C °C °F SCR

Pre-defined Monitoring (17/28) AdBlue/DEF injector

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 47200 KDPF 1 Outlet Temperature °C °C °F ENG

2 19304 AdBlue/DEF Pump State - - - SCR
3 19120 AdBlue/DEF Injection Quantity ml/sec ml/sec gal/sec SCR
4 19205 SCR NH3 Concentration Corrected ppm ppm ppm SCR
5 19202 Turbo Outlet NOx Corrected ppm ppm ppm SCR
6 19209 SCR Outlet NOx Corrected ppm ppm ppm SCR

Pre-defined Monitoring (18/28) AdBlue/DEF pump

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 19120 AdBlue/DEF Injection Quantity ml/sec ml/sec gal/sec SCR

2 19108 AdBlue/DEF Pump Pressure kPa kPa psi SCR
3 19109 AdBlue/DEF Pump PressSensor Volt V V V SCR
4 19304 AdBlue/DEF Pump State - - - SCR
5 19136 AdBlue/DEF Pump Temperature °C °C °F SCR
6 19114 AdBlue/DEF Reverting Valve Cmd - - - SCR

HB365LC-3 30-179
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

Pre-defined Monitoring (19/28) SCR catalyst NOXsensor /NH3 sensor

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 19120 AdBlue/DEF Injection Quantity ml/sec ml/sec gal/sec SCR

2 19205 SCR NH3 Concentration Corrected ppm ppm ppm SCR
3 19202 Turbo Outlet NOx Corrected ppm ppm ppm SCR
4 19209 SCR Outlet NOx Corrected ppm ppm ppm SCR
5 19203 Turbo Outlet NOx Sensor State - - - SCR
6 19210 SCR Outlet NOx Sensor State - - - SCR

Pre-defined Monitoring (20/28) AdBlue/DEF level, quality sensor

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 19100 AdBlue/DEF Concentration % % % SCR

2 19110 AdBlue/DEF Level % % % SCR
3 19111 AdBlue/DEF Level Corrected % % % SCR
4 19115 AdBlue/DEF Temperature in Tank °C °C °F SCR
5 19400 Ambient Temperature °C °C °F SCR
6 19305 AdBlue/DEF Tank Heating State - - - SCR

Pre-defined Monitoring (21/28) AdBlue/DEF tank defrost control

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 19305 AdBlue/DEF Tank Heating State - - - SCR

2 19102 AdBlue/DEF Tank HtrValve Command - - - SCR
3 19115 AdBlue/DEF Temperature in Tank °C °C °F SCR
4 04107 Coolant Temperature °C °C °F ENG
5 19400 Ambient Temperature °C °C °F SCR
6 19133 Engine Room Temperature °C °C °F SCR

Pre-defined Monitoring (22/28) AdBlue/DEF pump defrost control

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 19107 AdBlue/DEF Pump Heater 1 Command - - - SCR

2 19309 AdBlue/DEF Pump Heater State - - - SCR
3 19136 AdBlue/DEF Pump Temperature °C °C °F SCR
4 19304 AdBlue/DEF Pump State - - - SCR
5 19400 Ambient Temperature °C °C °F SCR
6 03203 Battery Power Supply V V V ENG

30-180 HB365LC-3
30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

Pre-defined Monitoring (23/28) AdBlue/DEF hose defrost control

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 19306 AdBlue/DEF Line Heater 1 State - - - SCR

2 19106 AdBlue/DEF Line Heater 1 Command - - - SCR
3 19307 AdBlue/DEF Line Heater 2 State - - - SCR
4 19135 AdBlue/DEF Line Heater 2 Command - - - SCR
5 19400 Ambient Temperature °C °C °F SCR
6 19133 Engine Room Temperature °C °C °F SCR

Pre-defined Monitoring (24/28) Environmental condition

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 37400 Ambient Pressure kPa kg/cm2 psi ENG

2 19400 Ambient Temperature °C °C °F SCR
3 18400 Intake Temperature °C °C °F ENG
4 19133 Engine Room Temperature °C °C °F SCR
5 19115 AdBlue/DEF Temperature in Tank °C °C °F SCR

Pre-defined Monitoring (25/28) Hybrid related items (1)

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 09200 High-voltage Side DC Voltage V V V HYB
3 09300 Capacitor Voltage V V V HYB
4 09603 Motor-Generator Torque Nm kgm lbft HYB
5 09102 Swing Motor Speed r/min rpm rpm HYB
6 09103 Swing Motor Torque Nm kgm lbft HYB

Pre-defined Monitoring (26/28) Hybrid related items (2)

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 09306 Capacitor Cell Temperature °C °C °F HYB
3 09402 Booster Inductor Temperature °C °C °F HYB
4 09403 Booster IGBT Base Temperature °C °C °F HYB
5 09404 Booster IGBT Junction Temp °C °C °F HYB
6 01142 Service Press (HYB Water Pump) MPa kg/cm2 psi PUMP

HB365LC-3 30-181
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

Pre-defined Monitoring (27/28) Hybrid related items (3)

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 09101 Swing Motor Coil Temperature °C °C °F HYB
3 09507 Swing Driver IGBT Junction Temp °C °C °F HYB
4 09600 Motor-Generator Temperature °C °C °F HYB
5 09607 Motor-Gene IGBT Base Temp #0 °C °C °F HYB
6 09608 Motor-Gene IGBT Base Temp #1 °C °C °F HYB

Pre-defined Monitoring (28/28) Hybrid related items (4)

Monitoring Self-define Monitoring items (screen Unit Applicable

No.
code display) SI Metric Imperial component

1 01002 Engine Speed r/min rpm rpm ENG

2 01142 Service Press (HYB Water Pump) MPa kg/cm2 psi PUMP
3 03203 Battery Power Supply V V V ENG
4 04300 Battery Charge Voltage V V V HYB
5 09300 Capacitor Voltage V V V HYB
6 09400 Booster Low-voltage Side Voltage V V V HYB

METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION

(HB335_3_E-K-Q000-100-00-B)
The machine monitor monitors the condition of the machine in real time using signals from various switches,
sensors, actuators, and their controllers which are installed on various parts of the machine.
“Self-define Monitoring” is used to select a desired monitoring item.
1. Select “Self-define Monitoring” on “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Monitoring Selection Menu” screen, select items to

be monitored by using the function switches or numeral in-
put switches.
F1: Moves the selected item leftward
F2: Moves the selected item rightward
F3: Moves down the selected item
F4: Moves up the selected item
F5: Clears input numbers/Returns the screen to " Service
Menu" screen
F6: Enters the selected item

30-182 HB365LC-3
30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

• Setting of the monitoring changes to “ENG” → “KDPF” → “SCR” → “PUMP” → “HYB” → “MON” in this
order when function switch F2 is pressed. (When F1 is pressed, sequential switching takes place in the
reverse order.)
• Selection with function switches: Select an applicable equipment by using F1 or F2, select an item by
using F3 or F4, and then enter it by using F6.
• For the selected item with numeral input switches, enter a 5-digit code, and the item of that code is
selected directly, and then enter it with F6.
• If the color of the selected box changes from yellow to red, the selected item of the item of that box is
entered.
• Up to six monitoring items are selectable at a time. However, the items may not be set up to six de-
pending on the form of display of the selected item.
3. After selecting monitoring items, execute monitoring with
the function switch or numeral input switch.
• To execute with the function switch, double click or
keep pressing F6. (Approx. 2 seconds)
• Execution with numeral input switch: Input “99999”
and press F6.
• If monitoring items are selected up to the limit number,
monitoring is executed automatically.
REMARK
When performing monitoring of only two items, select each
item, and confirm them with F6. If F6 is pressed once
again, monitoring is executed.
4. On “Monitoring” screen, perform the necessary operation
of the machine and check the self-define monitoring infor-
mation.
REMARK
• Monitoring information is indicated by value, ON/OFF,
or special display.
• The display unit can be set to “SI”, “Metric”, or “Imperi-
al” with “Default” function.

5. You can hold and release holding of the monitoring infor-

mation by using the function switches.
F4: Selects HOLD or releasing HOLD. (When HOLD is se-
lected, “HOLD” part is hatched.)
F5: Returns to the “Monitoring Selection Menu” screen

HB365LC-3 30-183
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

6. To change the setting of the auto-deceleration, working

mode, or travel speed, during monitoring, operate the cor-
responding switch under the current condition, and the cor-
responding mode is selected.
REMARK
• If the setting is changed during monitoring, the new
setting is held even after the screen returns to the nor-
mal screen after monitoring is finished.
• When the working mode is changed to B (“Breaker
Mode ”), the screen to confirm the change of the set-
ting is displayed as in changing the working mode on
the standard screen.

7. Selected monitoring item can be saved and deleted with

function switches.
F1: Saves monitoring item
F2: Clears monitoring item
• When an item is saved, it can be displayed as many
times as required unless it is cleared.
• If another item is saved while having the previous item
saved, the previously saved item is overwritten by the
latest one.

8. By pressing switch F3 during monitoring, the monitor dis-

play screen switches to the energy monitor screen.

30-184 HB365LC-3
30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

On the Energy Monitor screen, the power transmitting con-

dition between the components and the momentary fuel
consumption are displayed.
• (A) to (F) indicate the power flow condition between
the components.
(A): Between engine and motor-generator
(B): Between motor-generator and capacitor
(C): Between motor-generator and electric swing mo-
tor
(D): Between capacitor and electric swing motor
(E): Between hydraulic pump and work equipment cyl-
inder
(F): Between motor-generator and hydraulic pump
• (G) indicates the momentary fuel consumption.
• To return to monitoring, press switch F5.

TABLE OF SELF-DEFINE MONITORING (HB335_3-K-Q000-208-00-B)

Unit Applicable
Monitoring Self-define Monitoring items (screen dis-
compo- Remarks
code play) SI Metric Imperial nent
01002 Engine Speed r/min rpm rpm ENG
04107 Coolant Temperature °C °C °F ENG
48000 IMV Current A A A ENG
48001 IMV Command Current A A A ENG
03203 Battery Power Supply V V V ENG
37212 Engine Oil Pressure SW ON/OFF ON/OFF ON/OFF ENG
36400 Rail Pressure MPa kg/cm2 psi ENG
37400 Ambient Pressure kPa kg/cm2 psi ENG
18400 Intake Temperature °C °C °F ENG
18500 Charge Temperature °C °C °F ENG
Display of ab-
solute value
36500 Charge Pressure kPa kg/cm2 psi ENG
(including am-
bient pressure)
48100 Turbocharger Speed r/min rpm rpm ENG
48200 MAF kg/sec kg/min lb/min ENG
48400 Crankcase Pressure kPa mmAq psi ENG
18100 EGR Valve Position mm mm in ENG
48600 EGR Solenoid Current mA mA mA ENG
48700 VGT Position mm mm in ENG
48800 VGT Solenoid Current mA mA mA ENG
36700 Engine Torque Ratio % % % ENG

HB365LC-3 30-185
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

Unit Applicable
Monitoring Self-define Monitoring items (screen dis-
compo- Remarks
code play) SI Metric Imperial nent
18700 Engine Output Torque Nm kgm lbft ENG
03000 Throttle Position Sensor Voltage V V V ENG
04105 Coolant Temperature Sensor Volt V V V ENG
37401 Ambient Pressure Sensor Voltage V V V ENG
18401 Intake Temperature Sensor Volt V V V ENG
18501 Charge Temperature Sensor Volt V V V ENG
36501 Charge Pressure Sensor Voltage V V V ENG
36401 Rail Pressure Sensor Voltage V V V ENG
48401 Crankcase Pressure Sensor Volt V V V ENG
18101 EGR Valve Position Sensor Volt V V V ENG
48701 VGT Position Sensor Voltage V V V ENG
17500 Engine Power Mode Selection - - - ENG
48900 Engine Operation Mode - - - ENG
08402 Droop SW Selection - - - ENG
31701 Throttle Position % % % ENG
31706 Final Throttle Position % % % ENG
18600 Inject Fueling Command mg/st mg/st mg/st ENG
36200 Rail Pressure Command MPa kg/cm2 psi ENG
37300 Instantaneous Fuel Consumption(*1) l/h l/h gal/h ENG
18800 Water in Fuel Sensor State - - - ENG
18801 Water in Fuel Sensor Voltage V V V ENG
20216 Engine Controller Build Version - - - ENG
20217 Engine Con Calibration Data Ver - - - ENG
18900 Engine Con Internal Temperature °C °C °F ENG
20400 Engine Controller S/N - - - ENG
47000 KDPF Outlet Pressure kPa kg/cm2 psi KDPF
47001 KDPF Outlet Pressure Sensor Volt V V V KDPF
47100 KDPF Differential Pressure kPa kg/cm2 psi KDPF
47101 KDPF Diff Pressure Sensor Volt V V V KDPF
47300 KDOC 1 Inlet Temperature °C °C °F KDPF
47400 KDOC 1 Outlet Temperature °C °C °F KDPF
47200 KDPF 1 Outlet Temperature °C °C °F KDPF
47500 Dosing Instant Fuel Consumption l/h l/h gal/h KDPF
47700 Soot Accumulation g/L g/L g/gal KDPF
47802 Soot Correction by Ash Influence g/L g/L g/gal KDPF
19100 AdBlue/DEF Concentration % % % SCR
19200 Exhaust Gas Flow Rate kL/h kL/h kgal/h SCR

30-186 HB365LC-3
30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

Unit Applicable
Monitoring Self-define Monitoring items (screen dis-
compo- Remarks
code play) SI Metric Imperial nent
19201 Turbo Outlet NOx Concentration ppm ppm ppm SCR
19202 Turbo Outlet NOx Corrected ppm ppm ppm SCR
0: Unmeasura-
ble
19203 Turbo Outlet NOx Sensor State - - - SCR
1: Being meas-
ured
19204 SCR NH3 Concentration ppm ppm ppm SCR
19205 SCR NH3 Concentration Corrected ppm ppm ppm SCR
0: Unstable
19206 SCR NH3 Sensor Stability State - - - SCR 1: Stable
2: Error
0: Unmeasura-
ble
19207 SCR NH3 Sensor State - - - SCR
1: Being meas-
ured
19208 SCR Outlet NOx Concentration ppm ppm ppm SCR
19209 SCR Outlet NOx Corrected ppm ppm ppm SCR
0: Unmeasura-
ble
19210 SCR Outlet NOx Sensor State - - - SCR
1: Being meas-
ured
0: CLOSED
19102 AdBlue/DEF Tank HtrValve Command - - - SCR
1: OPEN
19103 AdBlue/DEF Level Low Error 1 % % % SCR
19104 AdBlue/DEF Level Low Error 2 % % % SCR
19105 AdBlue/DEF Level Low Error 3 % % % SCR
0: OFF
19106 AdBlue/DEF Line Heater 1 Command - - - SCR
1: ON
0: OFF
19107 AdBlue/DEF Pump Heater 1 Command - - - SCR
1: ON
19108 AdBlue/DEF Pump Pressure kPa kg/cm2 psi SCR
19109 AdBlue/DEF Pump PressSensor Volt V V V SCR
19110 AdBlue/DEF Level % % % SCR
19111 AdBlue/DEF Level Corrected % % % SCR
0: CLOSED
19114 AdBlue/DEF Reverting Valve Cmd - - - SCR
1: OPEN
19300 SCR Temperature °C °C °F SCR
19302 SCR Outlet Temperature °C °C °F SCR

HB365LC-3 30-187
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

Unit Applicable
Monitoring Self-define Monitoring items (screen dis-
compo- Remarks
code play) SI Metric Imperial nent
0: Initial state
1: Stop injec-
tion
2: Pressure-fed
19304 AdBlue/DEF Pump State - - - SCR
3: Being inject-
ed
4: Being
purged
1: Being
thawed
19305 AdBlue/DEF Tank Heating State - - - SCR 2: Being kept
warm
3: OFF
1: Being
thawed
19306 AdBlue/DEF Line Heater 1 State - - - SCR 2: Being kept
warm
3: OFF
1: Being
thawed
19307 AdBlue/DEF Line Heater 2 State - - - SCR 2: Being kept
warm
3: OFF
0: OFF
1: Being
thawed
19309 AdBlue/DEF Pump Heater State - - - SCR
2: Being kept
warm
3: OFF
19115 AdBlue/DEF Temperature in Tank °C °C °F SCR
19119 Total AdBlue/DEF Injection Qty L L gal SCR
19120 AdBlue/DEF Injection Quantity ml/sec ml/sec gal/sec SCR
19400 Ambient Temperature °C °C °F SCR
19401 Ambient Temperature Sensor Volt V V V SCR
19130 AdBlue/DEF Key off Refill Count - - - SCR
19133 Engine Room Temperature °C °C °F SCR
19134 Engine Room Temp Sensor Voltage V V V SCR
0: OFF
19135 AdBlue/DEF Line Heater 2 Command - - - SCR
1: ON
19136 AdBlue/DEF Pump Temperature °C °C °F SCR
19137 Total AdBlue/DEF Heating Time h h h SCR
01601 2nd Engine Speed Command r/min rpm rpm PUMP
01100 Front Pump Pressure MPa kg/cm2 psi PUMP

30-188 HB365LC-3
30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

Unit Applicable
Monitoring Self-define Monitoring items (screen dis-
compo- Remarks
code play) SI Metric Imperial nent
01101 Rear Pump Pressure MPa kg/cm2 psi PUMP
07400 Boom Raise PPC Pressure MPa kg/cm2 psi PUMP
07500 Boom Lower PPC Pressure MPa kg/cm2 psi PUMP
07200 Arm IN PPC Pressure MPa kg/cm2 psi PUMP
07600 Arm OUT PPC Pressure MPa kg/cm2 psi PUMP
07300 Bucket CURL PPC Pressure MPa kg/cm2 psi PUMP
07301 Bucket DUMP PPC Pressure MPa kg/cm2 psi PUMP
09001 Swing Left PPC Pressure MPa kg/cm2 psi PUMP
09002 Swing Right PPC Pressure MPa kg/cm2 psi PUMP
07102 Travel Forward Left PPC Press MPa kg/cm2 psi PUMP
07103 Travel Forward Right PPC Press MPa kg/cm2 psi PUMP
07104 Travel Reverse Left PPC Press MPa kg/cm2 psi PUMP
07105 Travel Reverse Right PPC Press MPa kg/cm2 psi PUMP
01137 Front Pump Displacement cc/rev cc/rev cc/rev PUMP
01138 F Pump Swash Plate Sensor volt V V V PUMP
01139 Rear Pump Displacement cc/rev cc/rev cc/rev PUMP
01140 R Pump Swash Plate Sensor volt V V V PUMP
04401 Hydraulic Oil Temperature °C °C deg.F PUMP
10007 Fan Speed r/min rpm rpm PUMP
10010 Fan Speed Command r/min rpm rpm PUMP
10019 Fan Speed Deviation r/min rpm rpm PUMP
01300 PC-EPC Front Solenoid Current mA mA mA PUMP
01302 PC-EPC Rear Solenoid Current mA mA mA PUMP
01500 LS-EPC Solenoid Current mA mA mA PUMP
10018 Fan Clutch Solenoid PWM Command % % % PUMP
08000 Merge-divider Main Sol Current mA mA mA PUMP
08001 Merge-divider LS Sol Current mA mA mA PUMP
01700 Attachment Sol Current mA mA mA PUMP
01701 Attachment Sol 2 Current mA mA mA PUMP
01702 Attachment Sol 3 Current mA mA mA PUMP
01703 Attachment Sol 4 Current mA mA mA PUMP
01704 Attachment Sol 5 Current mA mA mA PUMP
42008 Lever Main Potentiometer 1 Volt V V V PUMP
42009 Lever Sub Potentiometer1 Voltage V V V PUMP
42010 Lever Main Potentiometer 2 Volt V V V PUMP
42011 Lever Sub Potentiometer2 Voltage V V V PUMP
42012 Lever Potentiometer 1 Stroke % % % PUMP

HB365LC-3 30-189
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

Unit Applicable
Monitoring Self-define Monitoring items (screen dis-
compo- Remarks
code play) SI Metric Imperial nent
42013 Lever Potentiometer 2 Stroke % % % PUMP
03200 Battery Voltage V V V PUMP
04402 Hydraulic Oil Temp Sensor Volt V V V PUMP
01602 2nd Engine Speed Command % % % PUMP
17301 Dynamic Torque Command % % % PUMP
13113 Main Pump Absorb Torque Nm kgm lbft PUMP
01141 Service Pressure Sensor MPa kg/cm2 psi PUMP
01142 Service Press (HYB Water Pump) MPa kg/cm2 psi PUMP
01337 PC-EPC Cal Torque 1(Factory) Nm kgm lbft PUMP
01341 PC-EPC Cal Current 1 (Factory) mA mA mA PUMP
01345 PC-EPC Calibration Torque 1 Nm kgm lbft PUMP
01349 PC-EPC Calibration Current 1 mA mA mA PUMP
Swing ON/OFF ON/OFF ON/OFF PUMP
Travel ON/OFF ON/OFF ON/OFF PUMP
Boom Lower ON/OFF ON/OFF ON/OFF PUMP
01900 Pressure SW 1
Boom Raise ON/OFF ON/OFF ON/OFF PUMP
Arm IN ON/OFF ON/OFF ON/OFF PUMP
Arm OUT ON/OFF ON/OFF ON/OFF PUMP
Bucket CURL ON/OFF ON/OFF ON/OFF PUMP
Bucket DUMP ON/OFF ON/OFF ON/OFF PUMP
01901 Pressure SW 2
Service ON/OFF ON/OFF ON/OFF PUMP
Travel Diff Pressure ON/OFF ON/OFF ON/OFF PUMP
Travel Junction ON/OFF ON/OFF ON/OFF PUMP
Swing Brake ON/OFF ON/OFF ON/OFF PUMP
Solenoid Valve
02300 Merge-divider ON/OFF ON/OFF ON/OFF PUMP
1
2-Stage Relief ON/OFF ON/OFF ON/OFF PUMP
Travel Speed ON/OFF ON/OFF ON/OFF PUMP
Service Return ON/OFF ON/OFF ON/OFF PUMP
Solenoid Valve
02301 Variable Back Pressure ON/OFF ON/OFF ON/OFF PUMP
2
PPC Lock Relay ON/OFF ON/OFF ON/OFF PUMP
02200 SW Input 1 Knob SW ON/OFF ON/OFF ON/OFF PUMP
Model Selection 1 ON/OFF ON/OFF ON/OFF PUMP
Model Selection 2 ON/OFF ON/OFF ON/OFF PUMP
Model Selection 3 ON/OFF ON/OFF ON/OFF PUMP
02201 SW Input 2
Model Selection 4 ON/OFF ON/OFF ON/OFF PUMP
Model Selection 5 ON/OFF ON/OFF ON/OFF PUMP
Overload Alarm ON/OFF ON/OFF ON/OFF PUMP

30-190 HB365LC-3
30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

Unit Applicable
Monitoring Self-define Monitoring items (screen dis-
compo- Remarks
code play) SI Metric Imperial nent
02202 SW Input 3 Key SW (ACC) ON/OFF ON/OFF ON/OFF PUMP
Lock Lever SW ON/OFF ON/OFF ON/OFF PUMP
Lock Lever SW 2 ON/OFF ON/OFF ON/OFF PUMP
PPC Lock Solenoid
ON/OFF ON/OFF ON/OFF PUMP
02203 SW Input 4 State
Lever AutoLock Relea-
ON/OFF ON/OFF ON/OFF PUMP
seSW
Quick Coupler ON/OFF ON/OFF ON/OFF PUMP
Window Limit SW ON/OFF ON/OFF ON/OFF PUMP
02204 SW Input 5 P Limit SW ON/OFF ON/OFF ON/OFF PUMP
W Limit SW ON/OFF ON/OFF ON/OFF PUMP
20229 Pump Controller Assembly P/N - - - PUMP
20403 Pump Controller S/N - - - PUMP
20230 Pump Controller Program P/N - - - PUMP
20212 Pump Controller Program Version - - - PUMP
04300 Battery Charge Voltage V V V MON
04200 Fuel Level Sensor Voltage V V V MON
Key SW ON/OFF ON/OFF ON/OFF MON
Start ON/OFF ON/OFF ON/OFF MON
04500 Monitor Input 1 Preheat ON/OFF ON/OFF ON/OFF MON
Light ON/OFF ON/OFF ON/OFF MON
Radiator Coolant Level ON/OFF ON/OFF ON/OFF MON
Air Cleaner ON/OFF ON/OFF ON/OFF MON
Engine Oil Level ON/OFF ON/OFF ON/OFF MON
04501 Monitor Input 2
Battery Charge Voltage ON/OFF ON/OFF ON/OFF MON
Quick Coupler ON/OFF ON/OFF ON/OFF MON
Swing Parking Brake
ON/OFF ON/OFF ON/OFF MON
SW
04502 Monitor Input 3 Engine Shutdown 2nd
ON/OFF ON/OFF ON/OFF MON
SW
Seat Belt SW ON/OFF ON/OFF ON/OFF MON
F1 ON/OFF ON/OFF ON/OFF MON
F2 ON/OFF ON/OFF ON/OFF MON

Monitor Func- F3 ON/OFF ON/OFF ON/OFF MON

04503
tion SW F4 ON/OFF ON/OFF ON/OFF MON
F5 ON/OFF ON/OFF ON/OFF MON
F6 ON/OFF ON/OFF ON/OFF MON

HB365LC-3 30-191
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

Unit Applicable
Monitoring Self-define Monitoring items (screen dis-
compo- Remarks
code play) SI Metric Imperial nent
SW 1 ON/OFF ON/OFF ON/OFF MON
SW 2 ON/OFF ON/OFF ON/OFF MON

Monitor 1st & SW 3 ON/OFF ON/OFF ON/OFF MON

04504
2nd Row SW SW 4 ON/OFF ON/OFF ON/OFF MON
SW 5 ON/OFF ON/OFF ON/OFF MON
SW 6 ON/OFF ON/OFF ON/OFF MON
SW 7 ON/OFF ON/OFF ON/OFF MON
SW 8 ON/OFF ON/OFF ON/OFF MON

Monitor 3rd & SW 9 ON/OFF ON/OFF ON/OFF MON

04505
4th Row SW SW 10 ON/OFF ON/OFF ON/OFF MON
SW 11 ON/OFF ON/OFF ON/OFF MON
SW 12 ON/OFF ON/OFF ON/OFF MON
SW 13 ON/OFF ON/OFF ON/OFF MON
Monitor 5th Row
04506 SW 14 ON/OFF ON/OFF ON/OFF MON
SW
SW 15 ON/OFF ON/OFF ON/OFF MON
20227 Monitor Assembly P/N - - - MON
20402 Monitor S/N - - - MON
20228 Monitor Program P/N - - - MON
20200 Monitor Program Version - - - MON
55300 A/C Compressor State ON/OFF ON/OFF ON/OFF MON
55000 A/C Fresh Air Temp Code - - - MON
55100 A/C Recirc Air Temp Code - - - MON
55200 A/C Mode Data (Monitor) - - - MON
55201 A/C Mode Data (A/C ECU) - - - MON
20260 KOMTRAX Assembly P/N - - - MON
20418 KOMTRAX S/N - - - MON
20261 KOMTRAX Program P/N - - - MON
20273 KOMTRAX Program Version - - - MON
20262 ID Key Controller Assembly P/N - - - MON
20419 ID Key Controller S/N - - - MON
20263 ID Key Controller Program P/N - - - MON
20479 KomVision Controller Ass'y P/N - - - MON
20480 KomVision Controller S/N - - - MON
20481 KomVision Controller Program P/N - - - MON
09008 Swing RIGHT PPC Pressure #2 MPa kg/cm2 psi HYB
09009 Swing LEFT PPC Pressure #2 MPa kg/cm2 psi HYB
09006 Swing LEFT PPC Press Sens 2 Volt V V V HYB

30-192 HB365LC-3
30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

Unit Applicable
Monitoring Self-define Monitoring items (screen dis-
compo- Remarks
code play) SI Metric Imperial nent
09007 Swing RIGHT PPC Pres Sens 2 Volt V V V HYB
09200 High-voltage Side DC Voltage V V V HYB
09300 Capacitor Voltage V V V HYB
09400 Booster Low-voltage Side Voltage V V V HYB
09304 Capacitor Base Temperature °C °C °F HYB
09305 Capacitor Bus Bar Temperature °C °C °F HYB
09306 Capacitor Cell Temperature °C °C °F HYB
09403 Booster IGBT Base Temperature °C °C °F HYB
09404 Booster IGBT Junction Temp °C °C °F HYB
09402 Booster Inductor Temperature °C °C °F HYB
09101 Swing Motor Coil Temperature °C °C °F HYB
09504 Swing Driver Ph-U IGBT Base Temp °C °C °F HYB
09505 Swing Driver Ph-V IGBT Base Temp °C °C °F HYB
09506 Swing Driver Ph-W IGBT Base Temp °C °C °F HYB
09600 Motor-Generator Temperature °C °C °F HYB
09607 Motor-Gene IGBT Base Temp #0 °C °C °F HYB
09608 Motor-Gene IGBT Base Temp #1 °C °C °F HYB
09507 Swing Driver IGBT Junction Temp °C °C °F HYB

HYB Controller Booster Not Started ON/OFF ON/OFF ON/OFF HYB

09703
Warning HYB System Stop Input ON/OFF ON/OFF ON/OFF HYB
HYB Controller HYB Swing Parking
09700 ON/OFF ON/OFF ON/OFF HYB
Solenoid Brake
HYB Controller Battery Relay
09705 ON/OFF ON/OFF ON/OFF HYB
Output Drive(HYB)
09602 Motor-Generator Speed r/min rpm rpm HYB
09603 Motor-Generator Torque Nm kgm lbft HYB
09604 Motor-Generator Shaft Output kW kW kW HYB
09605 Motor-Generator Target Speed r/min rpm rpm HYB
09606 Motor-Generator Target Torque Nm kgm lbft HYB
09303 Capacitor Target Voltage V V V HYB
09307 Capacitor Current A A A HYB
42103 Swing Lever Stroke % % % HYB
42104 Boom Lever Stroke % % % HYB
42105 Arm Lever Stroke % % % HYB
42106 Bucket Lever Stroke % % % HYB

HB365LC-3 30-193
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

Unit Applicable
Monitoring Self-define Monitoring items (screen dis-
compo- Remarks
code play) SI Metric Imperial nent
Motor-Gene Speed Con-
ON/OFF ON/OFF ON/OFF HYB
trol
Motor-Gen Torque Con-
ON/OFF ON/OFF ON/OFF HYB
trol
HYB Controller
09701 Motor-Generator Servo
Control Output ON/OFF ON/OFF ON/OFF HYB
ON
Swing Motor Servo ON ON/OFF ON/OFF ON/OFF HYB
Low-Speed Matching
ON/OFF ON/OFF ON/OFF HYB
ON
Key SW (HYB Control-
ON/OFF ON/OFF ON/OFF HYB
ler)
HYB System Stop Input ON/OFF ON/OFF ON/OFF HYB
HYB Controller Operation Lock Lever ON/OFF ON/OFF ON/OFF HYB
09702
SW Input
Swing Brake Release
ON/OFF ON/OFF ON/OFF HYB
SW
Swing Parking Brake
ON/OFF ON/OFF ON/OFF HYB
SW
09102 Swing Motor Speed r/min rpm rpm HYB
09103 Swing Motor Torque Nm kgm lbft HYB
09104 Swing Motor Shaft Output kW kW kW HYB
09105 Swing Motor Target Speed r/min rpm rpm HYB
09106 Swing Motor Torque Limit Value r/min rpm rpm HYB
09900 Insulation Deteriorati Sens Volt V V V HYB
20255 HYB Controller Assembly P/N - - - HYB
20417 HYB Controller Serial Number - - - HYB
20256 HYB Controller Program P/N - - - HYB
20257 HYB Controller Program Version - - - HYB
20269 HYB Controller Swing Program P/N - - - HYB
20270 HYB Controller Swing Program Ver - - - HYB
20271 HYB Cont Motor-Gene Program P/N - - - HYB
20272 HYB Cont Motor-Gene Program Ver - - - HYB

*1: “Instantaneous Fuel Consumption” (Code No.: 37300) is the theoretical fuel consumption ratio. (The theoreti-
cal fuel consumption ratio is slightly different from the actual fuel consumption ratio.)
• Listing order in table
The items are listed in the same order as the display on the monitoring item selection menu screen.
• Unit
The display unit can be set to “SI”, “Metric”, or “Imperial” as required (Select a desired unit from “Unit” of
“Default” in Service Menu).
“mg/st” in the display unit is an abbreviation for milligram/stroke.
• Applicable component
ENG: The engine controller detects the monitoring information.
KDPF: The engine controller detects the monitoring information of KDPF.

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SCR: The engine controller detects the monitoring information of SCR.

PUMP: The pump controller detects the monitoring information.
HYB: The hybrid controller detects the monitoring information of hybrid system.
MON: The machine monitor detects the monitoring information.

ABNORMALITY RECORD MENU (PC400_11-K-Q170-001-00-B)

METHOD FOR CONFIRMING ABNORMALITY RECORD (MECHANICAL SYS-

TEMS) (PC400_10_E-K-Q1S1-100-10-B)
The machine monitor logs the past and currently occurring failures classifying them into the mechanical system
abnormality and electrical system abnormality.
To check the mechanical system abnormality record, perform the following procedures.
For the failure code list, see “Failure code list”for troubleshooting.
1. Select “Abnormality Record” on “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On “Abnormality Record ”screen, select “Mechanical Sys

Abnormality Record” with the function switches or numeral
input switches.
F3: Moves the selection downward
F4: Moves the selection upward
F5: Returns the screen to “Service Menu” screen.
F6: Enters the selection
REMARK
Input a code (2-digit) with the numeral input switches to di-
rectly select the item, and then press F6 to enter the selec-
tion.
3. On “Mechanical Sys Abnormality Record” screen, the fol-
lowing information is displayed.
a: Occurrence order of abnormalities from latest one/ Total
number of records
b: Failure code
c: Detail of failure
d: Number of occurrences (displayable range: 0 to 65535
times)
e: Service meter reading at the first occurrence
f: Service meter reading at the last occurrence
F1: Moves the selection to next page (screen) (- When not being displayed on the screen, this function
switch is enabled.)
F2: Moves the selection to previous page (screen) (- When not being displayed on the screen, this function
switch is enabled.)
F3: Moves the selection downward

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

F4: Moves the selection upward

F5: Returns the screen to “Abnormality Record” screen.
F6: Display of contents of failure is scrolled from right to left again
REMARK
• If no abnormality is recorded, “No Abnormality Record” is displayed.
• In the mechanical systems abnormality record screen, up to 50 cases currently stored are displayed.
• If the number of occurrence is 1 (first occurrence), the service meter reading at the first occurrence and
that at the last occurrence are the same. When the latest service meter reading is recovered, the value
at the recovery time is displayed, thus the above readings may not be the same.
• If “E” is displayed on the left of a failure code, the abnormality is still occurring or correction of it is not
confirmed.
• For all of the failure codes that the machine monitor can record, see “Troubleshooting”, “Failure code
list”.
• If the characters in the failure are many, the character strings display is scrolled.
• The contents of an abnormality record of the mechanical system cannot be deleted.

METHOD FOR CONFIRMING ABNORMALITY RECORD (ELECTRICAL SYSTEMS)

(PC400_10_E-K-Q1S1-100-20-B)
The machine monitor logs the failures that occurred in the past and is occurring currently and classifies them
into the mechanical system abnormality and electrical system abnormality.
To check “Electrical Sys Abnormality Record”, perform the following procedures.
For all of the failure codes that the machine monitor can record, see TROUBLESHOOTING, “Failure code list”.
1. Select “Abnormality Record” on “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On “Abnormality Record” screen, select “Electrical Sys Ab-

normality Record” with the function switches or numeral in-
put switches.
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: Returns the screen to “Service Menu” screen.
F6: Enters the selection.
REMARK
Input a code (2-digit) by using the numeral input switches
to directly select the item, and then press F6 to enter the
selection.

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3. On “Electrical Sys Abnormality Record” screen, the follow-

ing information is displayed.
a: Occurrence order of abnormalities from latest one/ Total
number of records
b: Failure code
c: Detail of failure
d: Number of occurrences (displayable range: 0 to 65535
times)
e: Service meter reading at the first occurrence
f: Service meter reading at the last occurrence
F1: Moves the selection to next page (screen) (- When not being displayed on the screen, this function
switch is enabled.)
F1: Moves the selection to previous page (screen) (- When not being displayed on the screen, this function
switch is enabled.)
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: Returns the screen to “Abnormality Record”screen
F6: Display of contents of failure is scrolled to left again.
REMARK
• If no abnormality is recorded, “No Abnormality Record” is displayed.
• In Electrical system abnormality record, up to 20 of stored records are displayed. If the 21st record is
stored, the oldest record will be deleted and the latest 20 records will be displayed.
• If the number of occurrence is 1 (first occurrence), the service meter reading at the first occurrence and
that at the last occurrence are the same.
• If “E” is displayed on the left of a failure code, the abnormality is still occurring or it has not yet been
normally restored.
• For all of the failure codes that the machine monitor can record, see TROUBLESHOOTING, “Failure
code list”.
• If the characters in the failure are many, the character strings display is scrolled.
4. To delete a selected abnormality record, perform the fol-
lowing operation while “Electrical Sys Abnormality Record”
screen is displayed.

1) Switch operation (While pressing 4, press other

switches in order): 4 + 1 → 2 → 3

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2) Check that the display on the screen becomes the

clear mode, then clear the individual information one
by one or all together by using the function switches.
REMARK
The screen is in deleting mode if “CLEAR” is dis-
played above F2.
F2: Clears all abnormality records.
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: Returns the screen to “Abnormality Record screen”.
F6: Clears the selected abnormality record.
REMARK
• To delete a selected abnormality record, select the abnormality record with F3 or F4, and then
press F6 to execute the deletion of abnormality record.
• To clear all abnormality records together, press F2, and then all the records are deleted regardless
of the selection.
• If “E” is displayed on the left of a failure code, the clearing operation is received but the information
is not cleared.
3) After the “Electrical Sys Abnormality Rec Reset” screen is displayed, operate the function switches to
delete all the records.
F5: Returns the screen to “Electrical Sys Abnormality Record” screen (deleting mode).
F6: Executes the deletion
REMARK
• This is the screen when a selected abnormality re-
cord is going to be deleted.

• This is the screen when all the abnormality records

are going to be deleted.

4) When the screen to notify the completion of the deletion is displayed and then “Electrical Sys Abnor-
mality Record” (deleting mode) screen is displayed, the deletion of the selected abnormality record is
completed.

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REMARK
• This is the screen displayed when the deletion of a
selected abnormality record is completed.

• This is the screen displayed when the deletion of

all abnormality records is completed.

METHOD FOR CONFIRMING MAINTENANCE RECORD (HB335_3_E-K-Q1F1-100-00-B)

The machine monitor records the maintenance information of the filters, oils, etc., which are displayed and
checked by the following operations.
If the data are reset in the operator mode when the maintenance is performed, the number of the times of main-
tenance is recorded here.
1. Select “Maintenance Record” on “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Maintenance Record” screen, select an item to be

checked with function switches or numeral input switches.
F1: Moves to the next page
F2: Returns to the previous page
F3: Moves the selected item down by one item
F4: Moves the selected item up by one item
F5: Returns the display to the “Service Menu” screen
REMARK
Input a code (2-digit) with the numeral input switches to di-
rectly select the item.

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Items which can be selected on maintenance record screen

Code Item
49 Air Cleaner Cleaning or Change
60 Coolant Change
68 Additional Hyd Oil Filter Change
30 Hyd Oil Pilot Filter Change
41 Fuel Prefilter Change
01 Engine Oil Change
02 Engine Oil Filter Change
05 Hyd Oil Tank Breather Change
03 Fuel Main Filter Change
04 Hydraulic Oil Filter Change
09 Swing Machinery Case Oil Change
59 “AdBlue/DEF Tank Breather Change”
45 Gen Oil Change & Filter Clean
46 Electric Swing Motor Oil Change
08 Final Drive Case Oil Change
47 KCCV Filter Change
58 “AdBlue/DEF Filter Change”
48 KDPF Filter Cleaning
37 “AdBlue/DEF Tank Washing”
10 Hydraulic Oil Change
Displayed information of “Maintenance Record” screen
a: Maintenance item
b: Number of replacements up to now
c: Service meter reading (SMR) at the last replacement

METHOD FOR OPERATING MAINTENANCE MODE SETTING (HB335_3_E-K-Q1F1-110-00-B)

Operating condition of the maintenance reminder function in the operator mode can be set and changed by us-
ing this menu.
• To enable or disable the function of maintenance items.
• To change the replacement interval setting of maintenance items (by item).
• To initialize all of the replacement interval setting of maintenance items.

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1. Select “Maintenance Mode Setting” on “Service Menu”.

REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Maintenance Mode Setting” screen, select “Main-

tenance Mode Change” with function switches or numeral
input switches.
F1: Moves to the next page
F2: Returns to the previous page
F3: Moves down the selected item
F4: Moves up the selected item
F5: Returns the display to the “Service Menu” screen
F6: Enters the selected item
REMARK
Input a code (2-digit) with the numeral input switches to directly select the item, and then press F6 to enter
the selected item.

Selectable items on maintenance mode setting screen

Code Item
00 Maintenance Mode Change
49 Air Cleaner Cleaning or Change Interval
60 Coolant Change Interval
68 Additional Hydraulic Oil Filter Change Interval
30 Hydraulic Oil Pilot Filter Change Interval
41 Fuel PreFilter Change Interval
01 Engine Oil Change Interval
02 Engine Oil Filter Change Interval
05 Hydraulic Oil Tank Breather Change Interval
03 Fuel Main Filter Change Interval
04 Hydraulic Oil Filter Change Interval
09 Swing Machinery Case Oil Change Interval
45 Motor-Generator Oil Change & Filter Clean Interval
46 Electric Swing Motor Oil Change Interval
08 Final Drive Case Oil Change Interval
10 Hydraulic Oil Change Interval
99 All Default Value

HB365LC-3 30-201
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

3. On the “Maintenance Mode Change” screen, select “Main-

tenance Mode On or Off” with function switches or numeral
input switches.
F3: Moves down the selected item
F4: Moves up the selected item
F5: Cancels the selection and returns the display to the
“Maintenance Mode Setting” screen
F6: Enters the selected item
4. On “Maintenance Mode On or Off” screen, select “Enable”
or “Disable” with the function switches.
“Enable”: Functions of all maintenance items become ena-
bled in operator mode
“Disable”: Functions of all maintenance items become disabled in operator mode
F3: Moves down the selected item
F4: Moves up the selected item
F5: Cancels the selection and returns the display to the “Maintenance Mode Change” screen
F6: Enters the selected item
REMARK
This setting overrides the ON/OFF setting of each item after this change of setting is entered once.
5. Select “Maintenance Notice Time Setting”. When “Mainte-
nance Notice Time Setting”screen is displayed, set the no-
tice time with the function switches.
“Default”: Maintenance notice time being set on the ma-
chine monitor (Recommended by the manufacturer and
not changeable).
“Set”: Maintenance notice time that can be set freely. Main-
tenance reminder function works according to this set time
in operator mode (the time can be increased or decreased
in multiples of 10 h).
F3: Decreases the set value
F4: Increases the set value
F5: Cancels the setting and returns the display to the
“Maintenance Mode Change” screen
F6: Enters the setting and returns the display to the “Main-
tenance Mode Change” screen
REMARK
• Press F6 and confirm the setting. When the setting is
enabled, the screen returns to the “Maintenance Mode
Setting”.
• If the value of an item which is set to “Enable” is
changed after operating the machine for 1 h or more
from the setup, the change is recognized as a reset op-
eration.

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6. Select one of the maintenance items. When the individual

maintenance item screen is displayed, select “Mainte-
nance Mode On/Off” setting.
F3: Moves down the selected item
F4: Moves up the selected item
F5: Cancels the selection and returns the screen to “Main-
tenance Mode Change” screen.
F6: Enters the selection, and moves the screen to “Enable”
or “Disable” screen for individual maintenance items.
REMARK
• Displayed screen is an example of “Engine Oil Change
Interval”.
7. When the individual maintenance item screen is displayed,
select “Enable” or “Disable”.
“Enable”: Function of the particular maintenance item be-
comes enabled in operator mode.
“Disable”: Function of the particular maintenance item be-
comes ineffective in operator mode.
F3: Moves down the selected item
F4: Moves up the selected item
F5: Cancels the selection and returns the screen to main-
tenance item screen
F6: Enters the selection and returns the screen to mainte-
nance item screen
8. Select “Set” of each maintenance item. When the screen is
displayed, perform the setting of maintenance time with
the function switches.
Default: Maintenance set time set on the machine monitor
(Recommended by the manufacturer and not changea-
ble).
Set: Maintenance notice time that can be freely set. Main-
tenance reminder function works according to this set time
in operator mode (the time can be increased or decreased
in multiples of 25 h).
F3: Decreases the set value
F4: Increases the set value
F5: Cancels the setting and returns the display to the
“Maintenance Mode Change” screen
F6: Enters the setting and returns the display to the “Main-
tenance Mode Change” screen
REMARK
• Press F6 and confirm the setting. When the setting is
enabled, the screen returns to the “Maintenance Mode
Setting”.
• If the value of an item which is set to “Enable” is
changed after one operating hour or more from the set-
up, the change is recognized as a reset operation.

HB365LC-3 30-203
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

9. Select “All Default Value” and when the screen appears,

perform setting with the function switches.
If this item is executed, the set values of all the mainte-
nance items return to the default values.
F5: Returns the display to “Maintenance Mode Setting”
screen
F6: Executes initialization

REMARK
Press F6, and the initialization completion screen is dis-
played after a short time. “Maintenance Mode Setting”
screen is displayed after that, and initialization is complet-
ed.

METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING (PC400_10_E-K-Q19A-110-00-B)

The telephone number can be displayed together with “Current Abnormality” in the operator mode. Phone num-
ber can be registered and changed according to the following procedure.
Phone number must be registered in order to display the number while in operator mode.
1. Select “Phone Number Entry” from the “Service Menu”
screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

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2. On “Phone Number Entry” screen, register/correct the

phone number with the function switches or numeral input
switches.
F2: Deletes all the numbers.
F3: Moves the input position to the next left place (if not
blank).
F4: Moves the input position to the right (if not blank)
F5: Returns the display to the “Service Menu” screen
F6: Enters the input.
REMARK
• Up to 14 digits can be inputted from the left. Leave the
surplus places without inputting any digit.
• If an inputted numeral is wrong, move the cursor (or-
ange background) to that digit and overwrite it with the
correct numeral.
• No telephone number is displayed in the operator
mode when F6 is pressed without inputting any digit,
since there is no information of telephone number for it.

DEFAULT MENU (PC400_11-K-Q170-001-01-B)

METHOD FOR SETTING WITH DEFAULT SETTING MENU (KEY-ON MODE)

(HB335_3_E-K-L010-110-00-B)
Default menu is used to check or change default values of the machine monitor and machine.
Use “Key-on Mode” function to set the working mode selected and displayed on the machine monitor when the
starting switch is turned to ON position.
1. Select “Default” from the “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Default” screen, select “Key-on Mode” with func-

tion switches or numeral input switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

HB365LC-3 30-205
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

3. On the “Key-on Mode” screen, select the mode to be set

with the function switches.
F3: Moves down the selected item
F4: Moves up the selected item
F5: Cancels the selection and returns the screen to “De-
fault” screen
F6: Enters the selected item and returns the screen to “De-
fault” screen
“Power Mode”: monitor displays “P” when the starting
switch is turned on
“Economy Mode”: monitor displays “E” when the starting
switch is turned on
“Fine Operation Mode”: monitor displays “L” when the starting switch is turned on
“Breaker Mode”: monitor displays “B” when the starting switch is turned on
“Attachment-P Mode”: monitor displays “ATT/P” when the starting switch is turned on
“Attachment-E Mode”: monitor displays “ATT/E” when the starting switch is turned on
“Mode at Previous Key-off”: monitor displays the mode which used from the previous operation when the
starting switch is turned on
REMARK
• Default value at shipment is Mode at Previous Key-off.
• If "With Attachment" is not selected, “Attachment-P Mode” and “Attachment-E Mode” are unselectable.
• If you change the setting to "Without attachment" when “Attachment/P-mode” or “Attachment/E-mode” is
selected, P (Power mode) is displayed when the starting switch is turned to ON position.
• If the engine is stopped during operator mode when “Breaker Mode” is selected, the monitor displays
“Breaker Mode” (“B”) regardless of the above setting.

METHOD FOR SETTING WITH DEFAULT SETTING MENU (UNIT) (HB335_3_E-K-Q1F3-110-00-B)

Default menu is used to check or change default values of the machine monitor and machine.
“Unit” function is used to select units of data displayed for monitoring, etc.
1. Select “Default” from the “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

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2. On the “Default” screen, select “Unit” with function

switches or numeral input switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

3. On the “Unit” screen, select the unit to be set with the func-
tion switches.
F3: Moves down the selected item
F4: Moves up the selected item
F5: Cancels the selection and returns the screen to “De-
fault” screen
F6: Enters the selected item and returns the screen to “De-
fault” screen
REMARK
Default value at the shipment is SI Unit.

METHOD FOR SETTING WITH DEFAULT SETTING MENU (WITH/WITHOUT AT-

TACHMENT) (HB335_3_E-K-L400-110-00-B)
Default menu is used to check or change default values of the machine monitor and machine.
Use the sub menu of “With/Without Attachment” function to configure attachment setting when the attachment is
installed or removed.
1. Select “Default” from the “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Default” screen, select “With/Without Attachment”

with function switches or numeral input switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

3. On “With/Without Attachment” screen, select a setting with

the function switch.
Without attachment: When attachment is not installed
With attachment: When attachment is installed
F3: Moves down the selected item
F4: Moves up the selected item
F5: Cancels the selection and returns the screen to “De-
fault” screen
F6: Enters the selected item and returns the screen to “De-
fault” screen
REMARK
When an attachment is installed, if this setting is not configured correctly, the attachment setting in the oper-
ator mode cannot be performed. As a result, the attachment may not work normally or the hydraulic compo-
nents may be damaged.

METHOD FOR SETTING WITH DEFAULT SETTING MENU (CAMERA)

(HB335_3_E-K-Q162-110-00-B)
Default menu is used to check or change default values of the machine monitor and machine.
“Camera” function is for setting of camera when the camera is installed or removed.
1. Select “Default” from the “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Default” screen, select “Camera” with function

switches or numeral input switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

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3. On the “Camera” screen, select the camera to be set with

the function switches.
F3: Moves down the selected item
F4: Moves up the selected item
F5: Cancels contents of setting before the entry and re-
turns the screen to “Default” screen
F6: Enters the selected item in each line.
Not Use: Camera is not used
Use: Images from connected camera are displayed as a
normal image (mirror images if it is used for rearview
monitor).
Я: Reverse images (mirror images if it is used for rear view
monitor) are displayed.
R: Normal images (visual images if it is used for front or
side monitor) are displayed.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

REMARK
• By the settings as shown in the figure, movement of a
person or object can be displayed continuously in the
monitor just like using the rearview mirror up to the
R.H. of the machine body.

• When setting the camera 2 to “R”, the R.H. of the ma-

chine body can be displayed just like a visual image.
• If 2 or more cameras are connected, be sure to set the
use of them from camera 1 in order.
• The simultaneous display function of 2 images be-
comes enabled when camera 1 and camera 2 are set
for use.
• You cannot switch camera 1 between “Я” and “R”.
• After entering selected item on each line with F6, return
the screen to “Default” screen with F5, and the setting
is enabled.
• Unless setting is normally set with this function when
the camera is connected, the graphic mark of camera
is not displayed at F3 in the operator mode. According-
ly, the image of the camera cannot be used.
• When the camera is installed, check that the right and
left portions of the displayed image are correct.

METHOD FOR SETTING WITH DEFAULT SETTING MENU (AUTO IDLE STOP TIM-
ER FIXING) (HB335_3_E-K-AF87-100-00-B)
Default menu is used to check or change the default values of the machine monitor and machine.
“Auto Idle Stop Timer Fixing” function is used to set the time selectable on auto idle stop time setting in the oper-
ator mode.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

1. Select “Default” from the “Service Menu” screen.

REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Default” screen, select “Auto Idle Stop Time Fix-

ing” with function switches or numeral input switches.

3. On “Auto Idle Stop Time Fixing” screen, choose the setting

of time with the function switch.
Flexible: Selection from OFF to 60 minutes is available.
OFF: Auto Idle Stop function is not used.
x-minute fixing: OFF or, longer time than the selected time
is not available.
F3: Moves down the selected item
F4: Moves up the selected item
F5: Cancels contents of setting before the entry and re-
turns the screen to “Default” screen
F6: Enters the selected item and returns the screen to “Default” screen
REMARK
When this setting is “OFF”, Auto Idle Stop does not operate. Auto Idle Stop Time Setting in the operator
mode is disabled.

METHOD FOR SETTING WITH DEFAULT SETTING MENU (WITH/WITHOUT

QUICK COUPLER) (HB335_3_E-K-LGC7-110-00-B)
Default menu is used to check or change default values of the machine monitor and machine.
For setting With/Without of multi-coupler, refer to this section.

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1. Select “Default” from the “Service Menu” screen.

REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Default” screen, select “With/Without Quick Cou-

pler” with function switches or numeral input switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

3. On “With/Without Quick Coupler” screen, select a setting

with the function switch.
Without: When multi-coupler is not installed
With: When multi-coupler is installed
F3: Moves down the selected item
F4: Moves up the selected item
F5: Returns to “Default” screen
F6: Enters the selected item and returns the screen to “De-
fault” screen

METHOD FOR SETTING WITH DEFAULT SETTING MENU (WITH/WITHOUT Kom-

Vision) (HB335_3_E-K-K900-110-00-B)

NOTICE
Change the settings of KomVision after the installation, otherwise the setting mismatch error (“L03”) oc-
curs.
Default menu is used to check or change default values of the machine monitor and machine.
“With/Without KomVision” function enables or disables KomVison function depending on whether KomVision
system is installed or not.

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1. Select “Default” from the “Service Menu” screen.

REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Default” screen, select “With/Without KomVision”

with function switches or numeral input switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

3. On the “With/Without KomVision” screen, select a setting

with the function switch.
“Without KomVision”: When KomVison is not installed
“With KomVision”: When KomVison is installed
F3: Moves down the selected item
F4: Moves up the selected item
F5: Cancels the selection and returns the screen to “De-
fault” screen
F6: Enters the selected item and returns the screen to “De-
fault” screen
REMARK
The KomVision screen can be displayed by changing the setting and performing the calibration.

DIAGNOSTIC TESTS MENU (PC400_11-K-Q170-001-02-B)

METHOD FOR OPERATING TESTING MENU (CYLINDER CUT-OUT OPERATION)

(PC400_10_E-K-AD00-34F-10-B)
Testing menu checks the machine or resets the settings of the machine monitor.
Cylinder cutout mode operation means to run the engine with one or more fuel injectors disabled electrically to
reduce the number of effective cylinders. This operation is used to identify a cylinder that does not output power
normally (combustion in it is abnormal).

HB365LC-3 30-213
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

1. Select “Diagnostic Tests” from the “Service Menu” screen.

REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Diagnostic Tests” screen, select “Cylinder Cutout

Mode Operation” with function switches or numeral input
switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

3. On the “Cylinder Cutout Mode Operation” screen, select

the cylinders and disable them with the function switches.
F1: Moves the selected item leftward
F2: Moves the selected item rightward
F4: Selects HOLD or releasing HOLD. (When HOLD is se-
lected, “HOLD” part is hatched.)
F5: Returns to the “Diagnostic Tests” screen
F6: Enters the selected item
REMARK
• This operation can be performed while the engine is
running.
• If background (a) of the selected cylinder number be-
comes white after you press F6, the cylinder is cutout.
• If the machine monitor cuts out a cylinder but the en-
gine controller cannot cutout that cylinder, the back-
ground (a) of the cylinder number becomes yellow.
• One or more cylinders can be cutout.
• Auto-deceleration function can be selected in the cylin-
der cutout mode operation. When turning auto-deceler-
ation ON, auto-deceleration monitor (b) is displayed.
4. When changing a cylinder to be cutout or when cylinder cutout operation is finished, select a cutout cylinder
to be reset with the function switches.
NOTICE
The cutout cylinder mode operation is not automatically released after the screen returns to the op-
erator mode. Accordingly, be sure to perform the releasing operation after the cylinder cutout mode
operation is finished.

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REMARK
• This operation can be performed while the engine is running.
• When F6 is pressed, if background (a) of the selected cylinder No. becomes blue, the cylinder is reset.
• If the machine monitor releases a cutout cylinder but the engine controller cannot release the cutout cyl-
inder, the background (a) of the cylinder number becomes red.
5. Each time F4 is pressed during the cylinder cutout opera-
tion, the displayed data is newly held (c) (the real-time da-
ta is kept displayed on the left side).
• Hold function can be unlocked by pressing F4 while
hold is turned on.
• The holding function is available for a cylinder regard-
less of whether it is cutout or not.
If a normally operating cylinder is cutout, the following phe-
nomena occur.
• Decrease in engine speed
• Increase in injection rate command
However, if the engine is running at around high idle, the engine speed may not decrease for the reason of
engine control. In this case, lower the engine speed with the fuel control dial and judge by increase of the
injection rate command.

METHOD FOR OPERATING TESTING MENU (REGENERATION FOR SERVICE)

(PC400_10_E-K-A9H0-252-00-B)
Use the testing menu to check the machine or to reset the settings of machine monitor.
The “Active Regeneration for Service” is a method of burning soot by performing the KDPF regeneration, re-
gardless of the soot accumulation.
1. Select “Diagnostic Tests” from the “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Diagnostic Tests” screen, select “Active Regenera-

tion for Service” with function switches or numeral input
switches.
• For selecting method, see “Operating method of serv-
ice mode” in “SERVICE MODE”.
• When the manual stationary regeneration has been
performed or stopped while the aftertreatment devices
regeneration has also been performed, “Active Regen-
eration for Service” cannot be selected.

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3. When the “Active Regeneration for Service” screen is dis-

played, the following information is displayed correspond-
ing to regeneration process. Set up the aftertreatment de-
vices regeneration according to the given messages.
a: Soot accumulation level
b: Regenerating aftertreatment devices
c: Selectable items
d: Message

1) From the “Active Regeneration for Service”screen, se-

lect “Manual Stationary Regeneration”.
F5: Returns to the “Diagnostic Tests” screen
F6: Executes manual stationary regeneration

REMARK
• The screen changes to the “Monitoring Selection
Menu” screen which enables monitoring of ma-
chine information during active regeneration by
performing the following switch operation during
Active Regeneration for Service.
• Switch operation (While pressing 4, press other
switches in order): 4 + 1 → 2 → 3
Press F6 to return from the “Self-define Monitor-
ing” screen to the “Active Regeneration for Serv-
ice” screen.
• For the monitoring operation, see “Monitoring” of
“SETTING AND OPERATION OF MACHINE MONITOR”.
• “Active Regeneration for Service” can be performed only when the lock lever is in their LOCK posi-
tion and the fuel control dial is in the MIN (Low idle) position.
• When performing the manual stationary regeneration, check that nobody is around and no combus-
tible material is around the machine. If the machine needs to be moved again to secure safety,
move it to a safe place and repeat the procedure from the first step.
• “Active Regeneration for Service” stops automatically after 40 minutes. However, if the regeneration
is started when the soot accumulation is above 4 g/ ℓ, the regeneration continues until the soot ac-
cumulation decreases to 0.99 g/ ℓ. In this case, regeneration process may take more than 40 mi-
nutes.
2) After the active regeneration for service is complete,
“Regeneration completed.” is displayed on the screen.

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REMARK
By pressing F6 during the manual stationary regener-
ation, “Stop manual stationary regeneration?” is dis-
played on the screen. The regeneration treatment can
be stopped by pressing F6.
• F5: Does not stop regeneration (manual station-
ary regeneration is continued)
• F6: Stops regeneration

METHOD FOR OPERATING TESTING MENU (KDPF MEMORY RESET)

(PC220_11_E-K-A9H0-271-00-B)
Use the testing menu to check the machine or to reset the settings of machine monitor.
“KDPF Memory Reset” resets KDPF information saved in the machine. Refer to this section and reset KDPF
information after cleaning or replacing KDOC, and cleaning or replacing KCSF.
1. Select “Diagnostic Tests” from the “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Diagnostic Tests” screen, select “KDPF Memory

Reset” with function switches or numeral input switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

3. On “KDPF Memory Reset” screen, select an item to be re-

set.
F3: Moves the selected item down by one item
F4: Moves the selected item up by one item
F5: Returns to the “Diagnostic Tests” screen
F6: Enters the selected item
• Perform both “KDPF Cleaning” reset and “KDPF
Change” reset after cleaning or replacing KCSF.
• After cleaning or replacing KDOC, perform “KDOC
Change”.
REMARK
Perform the applicable operation. For details, see TROUBLESHOOTING, “PRECAUTIONS FOR CLEAN-
ING AND REPLACING KDPF (KCSF and KDOC)”.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

4. After “Do you want to reset?” is displayed, enter the reset

with the function switch.
F5: Returns the screen to previous screen
F6: Executes resetting
When the memory has been reset successfully, “Reset
completed.” appears on the screen. If an error occurs
while resetting the memory, “Reset failed.” appears on the
screen.

METHOD FOR OPERATING TESTING MENU (SCR SERVICE TEST)

(PC400_11_E-K-AF00-100-00-B)
Use the testing menu to check the machine or to reset the settings of machine monitor.
In case of failure of devices related to SCR, you can select the test items according to the procedures in this
section.
1. Select “Diagnostic Tests” from the “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Diagnostic Tests” screen, select “SCR Service

Test” with function switches or numeral input switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

3. Select the test on “SCR Service Test”.

F3: Moves the selected item down by one item
F4: Moves the selected item up by one item
F5: Returns to the “Diagnostic Tests” screen
F6: Enters the selected item
REMARK
You may enter a 2-digit code by using numeral input
switches to directly select the item.
The selectable items are indicated in “SCR Service Test
Table”.

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SCR Service Test Table

Code Content
01 AdBlue/DEF Pump Pressure Up Test
02 AdBlue/DEF Injection Quantity Test
03 AdBlue/DEF Line Heater Relay 1 Test
04 AdBlue/DEF Line Heater Relay 2 Test
05 AdBlue/DEF Pump Heater Relay Test
06 AdBlue/DEF Tank Heater Valve Test
07 SCR Denitration Efficiency Test
To check the items listed in “SCR Service Test Table”, see the section “TEST SCR RELATED FUNCTIONS”.

METHOD FOR OPERATING TESTING MENU (ENGINE CONTROLLER ACTIVE

FAULT CLEAR) (PC400_11_E-K-AP70-271-00-B)
Use the testing menu to check the machine or to reset the settings of machine monitor.
The engine controller detects the occurred in-range error. Failure codes related to occurred error can be cleared
on the machine monitor.
The failure codes listed in “FAILURE CODES TABLE” of TROUBLESHOOTING, “PROCEDURE FOR TROU-
BLESHOOTING” cannot be cleared by “Engine Controller Active Fault Clear”.
1. Select “Diagnostic Tests” from the “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Diagnostic Tests” screen, select “Engine Controller

Active Fault Clear” with function switches or numeral input
switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

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3. On the “Engine Controller Active Fault Clear” screen, se-

lect an item to be set by using the function switches.
F5: Returns to the “Diagnostic Tests” screen
F6: Clears the failure code

METHOD FOR OPERATING TESTING MENU (ASH IN SOOT ACCUMULATION

CORRECTION) (PC400_11_E-K-A9H0-273-00-B)
Use the testing menu to check the machine or to reset the settings of machine monitor.
You can correct the ash accumulation quantity in the soot accumulation according to the procedures in this sec-
tion.
1. Perform “KDPF Cleaning”, and then perform “KDPF Change”. See “METHOD FOR OPERATING TESTING
MENU (KDPF MEMORY RESET)”.
2. Turn the starting switch to OFF position.
3. Check the system operating lamp is not lit, and turn the starting switch to ON position.
4. Select “Diagnostic Tests” from the “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

5. On the “Diagnostic Tests” screen, select “Ash in Soot Ac-

cumulation Correction” with function switches or numeral
input switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.
6. Start the engine, and turn the fuel control dial to MIN (Low
idle) position.

7. Check that “0” in the “Test State” column is flashing.

When “0” is flashing, you can perform the test.
For the display of “Test State”, see the section “TEST SCR
RELATED FUNCTIONS”.

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8. Start the calibration process by pressing F1.

REMARK
• The display of “Test State” changes to flashing of “Ash
in Soot Accumulation Correction”.
• “Ash in Soot Accumulation Correction” is completed in
approximately 2 hours.

9. When “20” in “Test State” column starts flashing, turn the

starting switch to OFF position.
REMARK
By turning the starting switch to OFF once, the correction
value is written in the engine controller.

METHOD FOR OPERATING TESTING MENU (RESET NUMBER OF ABRUPT EN-

GINE STOP BY AIS) (PC400_11_E-K-AF87-271-00-B)
Use the testing menu to check the machine or to reset the settings of machine monitor.
“Reset Number of Abrupt Engine Stop by AIS” function resets the counter of high engine speed which activates
the auto idle stop function. Use this function when VGT is replaced.
1. Select “Diagnostic Tests” from the “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Diagnostic Tests” screen, select “Reset Number of

Abrupt Engine Stop by AIS” with function switches or nu-
meral input switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

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3. On the “Reset Number of Abrupt Engine Stop by AIS”

screen, select a setting with the function switch.
F5: Returns to the “Diagnostic Tests” screen
F6: Executes resetting
REMARK
Rest the number of abrupt stop after the turbocharger is
replaced.

METHOD FOR OPERATING TESTING MENU (ENGINE STOP AdBlue/DEF INJ

OVERHEAT COUNT RESET) (PC400_11_E-K-AFJ0-271-00-B)

NOTICE
When performing this item, see TROUBLESHOOTING, Failure code [AS10NT] “AdBlue/DEF Injector
Overheat Caution” or Failure code [AS10KM] “AdBlue/DEF Injector Overheat Warning”, and instruct an
operator about operation.
Use the testing menu to check the machine or to reset the settings of machine monitor.
This function is used to reset the number saved in the machine, the number which engine stop performed when
the temperature of exhaust gas and coolant is high.
Perform “Engine Stop at AdBlue/DEF Inj Overheat Count Reset” by referring to the procedures in this section.
1. Select “Diagnostic Tests” from the “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. Enter “95” with numeral input switches after the “Diagnos-

tic Tests” screen is displayed, and press F6.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

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3. On the “Engine Stop at AdBlue/DEF Inj Overheat Count

Reset” screen, select an item to be set by using the func-
tion switches.
F5: Returns to the “Diagnostic Tests” screen
F6: Executes resetting

4. Execute the reset, then press F6. The screen returns to

“Diagnostic Tests”.

METHOD FOR OPERATING TESTING MENU (Capacitor Discharge)

(HB335_3_E-K-PQJV-100-00-B)

If the hybrid system is normal, the capacitor can be discharged by using the machine monitor. The capacitor
stores electric charge and the charge can be discharged with the motor-generator.
When the hybrid system is stopped, failure code will be generated. Depending on the types of error (See the
following table), the capacitor cannot be discharged with the machine monitor. In this case, the capacitor must
be discharged with a special capacitor discharger.
NOTICE
• Even if the capacitor cannot be discharged with the machine monitor, the monitor screen still dis-
plays the message “move to the capacitor discharge screen and discharge the capacitor”. However,
do not discharge the capacitor.
• Be alert that the work equipment can still move even when the upper structure cannot be swung
while discharging the capacitor.
1. Start the engine.
2. Set the fuel control dial to MIN (Low idle) position.
3. Select “Diagnostic Tests” from the “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

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4. On “Diagnostic Tests” screen, select “Capacitor Discharge”

with function switches or numeral input switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

5. On “Capacitor Discharge”, select an item to be performed

by using the function switches.
Select “START”, and discharge the capacitor.
F1 (“START”): Discharges the capacitor
F5: Returns the display to “Service Menu” screen

REMARK
It is normal for the engine speed to increase temporarily
because the charge in the capacitor is consumed through
the generator motor.

6. The capacitor is discharged completely when “Capacitor

Charge Ratio”“0%” is displayed approximately 20 minutes
after the start of discharge and “Completed.” message ap-
pears at last.

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REMARK
After the capacitor is discharged, when the starting switch
is turned to OFF position and then to ON position (without
starting the engine) and “Capacitor Discharge” screen is
displayed, “Capacitor Charge Ratio”“60%” is displayed.
This is not an abnormal display.

• The dummy charge ratio (*1) and the charge ratio cal-
culated from the actual voltage are compared, and the
higher ratio is displayed on the machine monitor.
*1 Dummy charge ratio: Charge ratio that decreases
from “60%” to “0%” in 20 minutes after the start of dis-
charge, regardless of the actual capacitor voltage
• The dummy charge ratio is reset and returned to
“60%” each time when the starting switch is turned to
OFF position.
• The actual capacitor voltage sharply decreases in ap-
proximately 30 seconds after the start of discharge,
and then the charge ratio decreases to “0%” in ap-
proximately 20 minutes.
• The display of charge ratio based on the actual volt-
age changes little after 30 seconds after the start of
discharge, and the operator cannot see if the capaci-
tor is being discharged normally, thus the dummy
charge ratio is used.
REMARK
If any of the following phenomena occurs, the capacitor
may not be discharged (completely). In this case, immedi-
ately stop discharging the capacitor with machine monitor,
and then discharge the capacitor with a special capacitor
discharger.
• Message of “Cannot complete.”“Please turn the key
off.” is displayed
• Capacitor charge ratio does not decrease even after 5
minutes after the start of discharge
• While capacitor charge ratio is “0%”, LED does not in-
dicate “Discharged”.
• If “Completed.” message is still not displayed after 30
minutes or more has passed since the start of dis-
charge, and LED at the top of capacitor which indicates
capacitor charge state is still not “Discharged”
7. Turn the starting switch to OFF position and stop the engine completely, and then remove the key.
NOTICE
Never operate the starting switch after the capacitor has been discharged because if the engine
runs, the capacitor will be charged again.
• Turn the starting switch to ON position again immediately after turning the switch to OFF position (be-
fore the engine stops completely)

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• Start the engine again after turning the starting switch to OFF position and stopping the engine com-
pletely
Even if the capacitor charge ratio is "0%", the capacitor voltage is not always 0 V. The voltage rises again in
the capacitor after the capacitor has discharged because of its characteristics. Take extreme care when dis-
connecting a connector for maintenance, etc.

Failure codes which prevents the capacitor from discharging with machine
monitor
When any of the failure codes shown in the table is displayed, the capacitor cannot be discharged with the ma-
chine monitor.
Even if the capacitor cannot be discharged, the monitor screen still displays the message “move to the capacitor
discharge screen and discharge the capacitor”. However, do not discharge the capacitor.

Failure codes and failures related to high voltage circuit

Failure
Failure
code
GA00NS HYB Equipment Overheat
GA01KA Power Cable Interlock Open Circuit
GA02KZ DC Line Open and Short Circuit
GA04KG DC Line HW before Booster Power Voltage High Error
GA05KG DC Line SW before Booster Power Voltage High Error
GA05KP DC Line SW before Booster Output Voltage Low Error
GA06KZ DC Line Voltage Sensor before Booster Open and Short Circuit
GA08KG DC Line Hardware after Booster Power Voltage High Error
GA09KG DC Line Software after Booster Power Voltage High Error
GA09KP DC Line SW after Booster Output Voltage Low Error
GA0AKZ DC Line Voltage Sensor after Booster Open and Short Circuit
GA10MC HYB Controller Malfunction
GA12NK HYB Controller Power Supply Voltage Not Rise
GA12NL HYB Controller Power Supply Voltage Not Drop
GA18MC Motor-Generator Driver Energizing Power Supply Malfunction
GA1SFS Contactor Sticking
GA1SMC Contactor Malfunction
GA1VMC Capacitor Contactor Malfunction
GA21KB Booster IGBT Short Circuit

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Failure codes and failures related to motor-generator

Failure
Failure
code
GA13MC HYB Controller Sensor Power Supply Malfunction
GA17KR Motor-Generator Driver Defective Communication
GA17KY Motor-Generator Driver Power Supply Line Short Circuit
GA19KR Motor-Generator Driver Sub-CPU Defective Communication
GA19KT Motor-Generator Driver Sub-CPU Controller Internal Failure
GA19MA Motor-Generator Driver Sub-CPU Malfunction
GA1BMA Motor-Generator Driver DC Voltage Sensor Defective Function
GA25MA Motor-Generator Driver IGBT 0 Error
GA26MA Motor-Generator Driver IGBT 1 Error
GA60MC Motor-Generator Malfunction
GA60N1 Motor-Generator Overrun
GA62KY Motor-Generator Phase-A Current Sensor Power Supply Line Short Circuit
GA62MA Motor-Generator Phase-A Current Sensor Defective Function
GA63KY Motor-Generator Phase-B Current Sensor Power Supply Line Short Circuit
GA63MA Motor-Generator Phase-B Current Sensor Defective Function
GA64KY Motor-Generator Phase-C Current Sensor Power Supply Line Short Circuit
GA64MA Motor-Generator Phase-C Current Sensor Defective Function

ADJUSTMENT MENU (PC400_11-K-Q170-001-03-B)

METHOD FOR ADJUSTING (Pump Absorption Torque (F)) (PC400_10_E-K-C201-27E-00-B)

Adjustment menu is used to check the various settings of the machine or to adjust the value.
The “Pump Absorption Torque (F)” finely adjusts the absorption torque of the main pump.
1. Select “Adjustment” on the “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Adjustment” screen, select “Pump Absorption Tor-

que (F)” with function switches or numeral input switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

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3. After the “Pump Absorption Torque (F)” screen is dis-

played, change the value on the right side by using the
function switches.
Set value: For the actual torque adjustment value, see the
table of relationship between set value and torque ad-
justment value.
F3: Decreases the set value
F4: Increases the set value
F6: Checks and enters setting. Returns to “Adjustment”
screen.
REMARK
The 3-digit number in the left column does not change
since it is the code of this function.

A relation as a table (set value and torque adjustment value)

Code Set value Torque adjustment value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
021 004 0 Nm {0 kgm}
005 -9.8 Nm {-1 kgm}
006 -19.6 Nm {-2 kgm}
007 -29.4 Nm {-3 kgm}
008 -39.2 Nm {-4 kgm}

METHOD FOR ADJUSTING (Pump Absorption Torque (R)) (PC400_10_E-K-C202-27E-00-B)

Adjustment menu is used to check the various settings of the machine or to adjust the value.
The “Pump Absorption Torque (R)” finely adjusts the absorption torque on the rear side of the main pump.
1. Select “Adjustment” on the “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

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2. On the “Adjustment” screen, select “Pump Absorption Tor-

que (R)” with function switches or numeral input switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

3. After the “Pump Absorption Torque (R)” screen is dis-

played, change the value by using the function switches.
Set value: For the actual torque adjustment value, see the
table of relationship between set value and torque ad-
justment value.
F3: Decreases the set value
F4: Increases the set value
F6: Checks and enters setting. Returns to “Adjustment”
screen.
REMARK
The 3-digit number in the left column does not change
since it is the code of this function.

A relation as a table (set value and torque adjustment value)

Code Set value Torque adjustment value
000 +39.2 Nm {+4 kgm}
001 +29.4 Nm {+3 kgm}
002 +19.6 Nm {+2 kgm}
003 +9.8 Nm {+1 kgm}
022 004 0 Nm {0 kgm}
005 -9.8 Nm {-1 kgm}
006 -19.6 Nm {-2 kgm}
007 -29.4 Nm {-3 kgm}
008 -39.2 Nm {-4 kgm}

METHOD FOR ADJUSTING (Low Speed) (PC300_11_E-K-C167-100-00-B)

Adjustment menu is used to check the various settings of the machine or to adjust the value.
Setting function of “Travel Low Speed” is used to finely adjust the speed at the travel Low speed.

HB365LC-3 30-229
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

1. Select “Adjustment” on the “Service Menu” screen.

REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Adjustment” screen, select “Travel Low Speed”

with function switches or numeral input switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

3. After the “Travel Low Speed” screen is displayed, change

the value on the right side by using the function switches.
Set value: For the actual speed, see the table of relation-
ship between set value and travel low speed value.
F3: Decreases the set value
F4: Increases the set value
F6: Checks and enters setting. Returns to “Adjustment”
screen.
REMARK
The 3-digit number in the left column does not change
since it is the code of this function.

Table of relationship between set value and travel Low speed value
Code Set value Travel Low speed value
000 3.2 km/h
001 2.8 km/h
020
002 3.0 km/h
003 3.4 km/h

METHOD FOR ADJUSTING (Attachment Flow Adjustment) (PC300_11_E-K-PT24-100-00-B)

Adjustment menu is used to check the various settings of the machine or to adjust the value.
“Att Flow Adjust in Combined Ope” finely adjusts the flow rate to the attachment in the combined operations.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

1. Select “Adjustment” on the “Service Menu” screen.

REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Adjustment” screen, select “Att Flow Adjust in

Combined Ope” with function switches or numeral input
switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

3. After the “Att Flow Adjust in Combined Ope” screen is dis-

played, change the value by using the function switches.
Set value: For the actual flow distribution, see “Relation-
ship between set value and distribution of oil flow to at-
tachment”.
F3: Decreases the set value
F4: Increases the set value
F6: Checks and enters setting. Returns to “Adjustment”
screen.
REMARK
The 3-digit number in the left column does not change
since it is the code of this function.

A relation as a table (set value and distribution of oil flow to attachment)

Code Set value Distribution of flow to attachment
000 50 %
001 70 %
037
002 100 %
003 40 %

METHOD FOR ADJUSTING (CAL F pump swash plate sensor) (PC400_10_E-K-C3W9-273-00-B)

Adjustment menu is used to check the various settings of the machine or to adjust the value.
“Calibrate F Pump Swash Plate Sensor” is used to calibrate the sensor installed on the actual machine to elimi-
nate deviation of the sensor signal made when the front pump swash plate sensor is removed/installed or re-
placed with new one.
The pump swash plate sensor needs to be calibrated in the following cases.

HB365LC-3 30-231
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

Calibrating front pump Calibrating rear pump

swash plate sensor swash plate sensor
Removal, installation, and replacement of front side
Required -
swash plate sensor
Removal, installation and replacement of rear side swash
- Required
plate sensor
Replacing main pump assembly Required Required
Replacing pump controller Required Required
Adjusting or disassembling front pump PC valve Required -
Adjusting or disassembling rear pump PC valve - Required

REMARK
Test the pump swash plate sensor to check that the pump swash plate sensor is normal, and then perform the
calibration of the pump swash plate sensor.
A rough flow of calibration of the pump swash plate sensor is
as follows. (In adjustment menu of the service menu)
Before starting calibration, set the machine under the following
condition.
Hydraulic oil temperature: 45 to 55 °C
Working mode: P (“Power Mode”)
Travel speed: Hi

1. Select “Adjustment” on the “Service Menu” screen.

REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

2. On the “Adjustment” screen, select “Calibrate F Pump

Swash Plate Sensor” with function switches or numeral in-
put switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

3. After “Calibrate F Pump Swash Plate Sens Max” is dis-

played, calibrate the front pump swash plate sensor for the
maximum angle by running track idle off the ground and
operating the function switches.
F1: Starts calibration
F2: Initializes calibration value
F5: Returns the screen to the “Adjustment” screen
F6: Enters the setting

4. Raise the left track off the ground by using the work equip-
ment and move the left travel lever to the stroke end to run
the left track idle off the ground.
Fuel control dial: MAX (High idle)
L.H. travel lever: Full stroke (Both forward and reverse
travel may be set.)
Swing lock switch may be set in either ON or OFF.
k Provide enough work space to run the raised track
idle off the ground for testing.
k Run the raised track idle, paying enough attention
to the surroundings for safety.
5. After the speed of track running idle off the ground be-
comes stable, hold down F1 of the machine monitor to
start calibration. The state of process is displayed as a bar
on the screen during calibration. Keep track running idle off
the ground.

6. When calibration is finished successfully, “OK” is displayed

for the State of Adjustment to show that calibration for the
maximum angle is completed. Press F6 to go to calibration
for the minimum side.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

If calibration is finished unsuccessfully, “NG” is displayed

for the State of Adjustment and the failure cause code is
displayed. Referring to the failure cause codes in Table 1,
find out and remove the cause and repeat calibration.

7. After “Calibrate F Pump Swash Plate Sens Min” is dis-

played, set the all levers in neutral and calibrate the front
pump swash plate sensor for the minimum angle with the
function switches.
F1: Starts calibration
F2: Initializes calibration value
F5: Returns the screen to the “Adjustment” screen
F6: Enters the setting
8. Wait under the following conditions.
All control levers and control pedals in NEUTRAL position
Fuel control dial may be at any position.
9. Hold down F1 of the machine monitor to start calibration.
The state of process is displayed as a bar on the screen
during calibration. Keep all control levers in NEUTRAL po-
sition until the calibration is finished.

10. When calibration is finished successfully, "OK" is displayed

for the State of Adjustment to show that calibration for the
minimum angle is completed. Press F6 and return the
screen to “Adjustment” screen.

If calibration is finished unsuccessfully, "NG" is displayed

for the State of Adjustment and the failure cause code is
displayed. Referring to the failure cause codes in Table 1,
find out and remove the cause and repeat calibration for
the minimum angle by pressing F6.
REMARK
The calibration value can be initialized by holding down
“CLEAR ”button F2. If the calibration value is initialized,
“READY” is displayed for the State of Adjustment on the
screen.

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Table 1. Failure cause codes (Displayed in descending order of priority)

Object

Cause MIN MAX

swash swash Pump IT Content Required action
code
plate cali- plate cali- calibration
bration bration
A-1 ● ● ● Engine speed signal is 0 rpm Check that engine is started
Check hydraulic oil temperature
A-2 ● ● ● Hydraulic oil temperature is low
(Max. 45 °C).
Check hydraulic oil temperature
A-3 ● ● ● Hydraulic oil temperature is high
(Min. 55 °C).
A-4 ● ● ● Overheating Check for overheating
Pump pressure sensor (F, R) is Perform troubleshooting for pump
A-6 ● ● ●
defective. pressure sensor
Pump swash plate (F, R) sensor Perform troubleshooting for pump
A-7 ● ● —
is defective swash plate sensor
Arm IN PPC pressure sensor is Perform troubleshooting for the
A—8 — — ●
defective. arm IN PPC pressure sensor
Perform troubleshooting for PC-
A-9 - — ● PC-EPC abnormality
EPC
Defective CAN communication
A-A - — ● Perform troubleshooting for CAN
(Eng, Monitor, Pump)
Perform troubleshooting for the
Bucket CURL PPC pressure sen-
A-B — — ● bucket CURL PPC pressure sen-
sor is defective
sor
Pump pressure on calibration Perform troubleshooting for relief
B-1 ● - —
side is above specified value valve and pump
B-3 ● — — Lever is not set to NEUTRAL Set the lever to NEUTRAL
Pump pressure on calibration Perform troubleshooting for relief
C-1 — ● —
side is at specified value or less valve and pump
C-2 — ● — Travel speed is not Hi Select travel Hi on monitor
Fuel control dial is not at MAX po- Check that the fuel control dial is
C-3 — ● ●
sition. in MAX position.
Check that travel lever is set to
Travel operation is not performed full stroke and work equipment
C-4 - ● —
singly control lever is in NEUTRAL posi-
tion.
Check service adjustment (Nor-
C-5 — ● — Pump is not separated mally separated while travel oper-
ation is performed singly)
Travel PPC Pressure Sensor Er- Perform troubleshooting for travel
C-6 — ● —
ror PPC
Travel PPC pressure is below Check the travel lever is set to full
C-7 — ● —
specified value stroke.
When arm IN is relieved, arm IN
PPC pressure is below specified
Check the arm IN lever is set to
E-1 — — ● value or arm IN PPC pressure
full stroke.
sensor is within the normal range.
(*1)

HB365LC-3 30-235
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

Object

Cause MIN MAX

swash swash Pump IT Content Required action
code
plate cali- plate cali- calibration
bration bration
Pump pressure (F, R) is out of Perform troubleshooting for relief
E-2 — — ●
specified range valve and pump
Engine speed is out of specified
E-3 — — ● Check the high idle engine speed
range
Engine torque is out of specified Perform troubleshooting for en-
E-4 — — ●
range gine and pump
PC-EPC current is out of speci- Perform troubleshooting for PC-
E-5 — — ●
fied range EPC current
When bucket CURL is relieved,
bucket CURL PPC pressure is
Check the bucket CURL lever is
E-6 — — ● below specified value or bucket
set to full stroke.
CURL PPC pressure is within the
normal range. (*1)
Working Mode is not set to P or
E-7 — — ● Set Working Mode to P or ATT/P
ATT/P
Check that the air conditioner is
E-A — — ● Turn on the air conditioner
turned off.
Output voltage of pump swash
Perform troubleshooting for
FF ● ● — plate sensor is out of calibration
swash plate sensor
range
G-1 — — ● KDPF is in regeneration. Finish KDPF regeneration.

*1: When the sensor voltage is out of the normal range (0.5 to 4.5 V), the pump controller recognizes the relief
pressure to be 0 MPa {0 kg/cm2} . Accordingly, perform troubleshooting, referring to Troubleshooting (Failure
codes [DHPAMA] and [DHPBMA]).

METHOD FOR ADJUSTING (CAL R pump swash plate sensor) (PC400_10_E-K-C3WB-273-00-B)

Adjustment menu is used to check the various settings of the machine or to adjust the value.
Before starting calibration, set the machine under the following condition.
Hydraulic oil temperature: 45 to 55 °C
Working mode: P (“Power Mode”)
Travel speed: Hi
1. Select “Adjustment” on the “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

2. On the “Adjustment” screen, select “Calibrate R Pump

Swash Plate Sensor” with function switches or numeral in-
put switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.
3. Perform the subsequent calibration procedure according to
“Adjustment menu (Calibrate F Pump Swash Plate Sen-
sor)”.

METHOD FOR ADJUSTING WITH ADJUSTING MENU (Swing Motor Starting Tor-
que) (HB335_3_E-K-PQJX-270-00-B)
Various adjustments related to the machine can be performed with the machine monitor.
The swing motor starting torque setting function is used to finely adjust the maximum swing motor starting tor-
que.
With this function, the acceleration time at start of swing can be adjusted finely.
1. Select “Adjustment” on the “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Adjustment” screen, select “Swing Motor Starting

Torque” with function switches or numeral input switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

3. After the “Swing Motor Starting Torque” screen is dis-

played, change the value on the right side by using the
function switches.
Set value: For the actual torque adjustment value, see “Ta-
ble of Relationship Between Set Value and Swing Motor
Starting Torque”.
F3: Increases the set value
F4: Decreases the set value
F6: Checks and enters setting. Returns to “Adjustment”
screen.
REMARK
The 3-digit number in the left column does not change
since it is the code of this function.

HB365LC-3 30-237
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

Table of Relationship Between Set Value and Swing Motor Starting Torque
Code Set value Swing motor starting torque adjustment value
000 0 Nm {0 kgm}
001 -10 Nm {-1.0 kgm}
158
002 -20 Nm {-2.0 kgm}
003 -30 Nm {-3.1 kgm}

• The default maximum starting torque is “000”.

• Since the maximum swing motor torque is finely adjusted, the swing acceleration in fine swing opera-
tion does not change.

METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (Hoist Swing Adjust-

ment) (HB335_3_E-K-PQJY-270-00-B)
Various adjustments related to the machine can be performed with the machine monitor.
The hoist swing adjustment function is used to adjust the maximum swing motor torque in combined operation
of swing and boom and to finely adjust the swing acceleration in hoist swing operation.
1. Select “Adjustment” on the “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Adjustment” screen, select “Hoist Swing Adjust-

ment” with function switches or numeral input switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

3. On “Hoist Swing Adjustment” screen, select the desired

value by using the function switches.
Set value: For the actual torque adjustment value, see “Ta-
ble of Relationship Between Set Value and Swing Motor
Starting Torque”.
F3: Increases the set value
F4: Decreases the set value
F6: Checks and enters setting. Returns to “Adjustment”
screen.
REMARK
The 3-digit number in the left column does not change
since it is the code of this function.

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Table of Relationship Between Set Value and Swing Motor Starting Torque
Code Set value Swing torque adjustment value in hoist swing operation
000 100 %
001 90 %
159
002 80 %
003 70 %

• The default value is “000”.

• The table is used to adjust the swing acceleration in hoist swing operation.

METHOD FOR ADJUSTING (Fan Rotation Mode Selection) (HB335_3_E-K-ACN3-100-00-B)

Adjustment menu is used to check the various settings of the machine or to adjust the value.
The “Fan Speed Mode Select” function is used to select the maximum speed of the cooling fan from the normal
control mode, 100 % mode or 70 % mode.
1. Select “Adjustment” on the “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Adjustment” screen, select “Fan Speed Mode Se-

lect” with function switches or numeral input switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

3. On the “Fan Speed Mode Select” screen, change the set

value by using the function switches.
Set value: For the actual torque adjustment value, see “Ta-
ble of Relationship Between Set Value and Mode
(Speed)”.
F3: Decreases the set value
F4: Increases the set value
F6: Checks and enters setting. Returns to “Adjustment”
screen.
REMARK
The 3-digit number in the left-hand box does not change
because it is function code.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

Table of relationship between set value and mode (speed)

Code Set value Mode (speed)
000 Normal control
055 001 100 %(1345 rpm)
002 70 %(940 rpm)

REMARK
• When either 001 or 002 is selected as set value, selected fan speed mode cannot be changed until the
“Fan Speed Mode Select” screen is changed to the “Adjustment” menu and the starting switch is turned
to the OFF position.
• After finishing the test, return the mode to the normal control mode. To return to the normal control
mode, change the set value to "000" or turn the starting switch to OFF position and then restart the en-
gine.

METHOD FOR ADJUSTING WITH ADJUSTMENT MENU (KomVision SETTING)

(PC128_11_E-K-K900-270-00-B)
Adjustment menu is used to check the various settings of the machine or to adjust the value.
The “KomVision Adjustment” adjusts KomVision system.
This function appears on the monitor only when KomVision is selected as “With KomVision” in “METHOD FOR
SETTING WITH DEFAULT SETTING MENU (WITH/WITHOUT KomVision)”.
Adjust each device by referring to “ADJUST KomVision RELATED DEVICES”.

METHOD FOR ADJUSTING MENU(Pump calibration: Matching speed check)

(PC400_10_E-K-C200-270-10-B)
Adjustment menu is used to check the various settings of the machine or to adjust the value.
The “Pump Calibration” function is used to check the matching speed for arm IN relief and bucket CURL relief
and to set the matching speed of the engine correctly when the pump or pump controller is replaced.

When Pump Calibration(Matching Speed Calibration) is required

Pump Calibration
Replace engine -
Replace main pump assembly Required
Replace pump controller Required
Disassemble front pump PC valve Required
Disassemble rear pump PC valve Required
Replace main valve -
Adjust and replace main relief valve -

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

The outline of flow of “Pump Calibration”:“Matching Speed

Check” is shown in the figure. (In adjustment menu of “Service
Menu”)
Before starting calibration, set the machine under the following
condition.
Perform warm-up operation for at least 30 minutes.
Hydraulic oil temperature: 45 to 55 °C
Working mode: P (“Power Mode”)
Fuel control dial: MAX (High idle) position
Air conditioner: OFF

1. Select “Adjustment” on the “Service Menu” screen.

REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. Enter “40” with numeral input switches after the “Adjust-

ment” screen is displayed, and press F6.
REMARK
Since this function is required only when the pump is re-
placed, the PC valve is adjusted or disassembled, or the
pump controller is replaced, it is not displayed in the menu
list.

HB365LC-3 30-241
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

3. On the “Pump Calibration” screen, select “Matching Speed

Check” with function switches or numeral input switches.
REMARK
Select this when it is required to check abnormality or cur-
rent condition of the machine.
Selecting method is the same as on “Service Menu”
screen.
The alphabet letter at the right top of the screen indicates
the following condition.
D: Default
F: Adjustment value at shipment from factory (Factory
shipment state (Normal))
U: User calibration value
4. On the “Matching Speed Check” screen, check the match-
ing speed by relieving the arm circuit in digging operation
and by using the function switches
F1: Starts the matching speed check
F5: Returns to the “Pump Calibration” screen

5. Operate the arm or bucket control lever under the following

condition to check the relief matching.
REMARK
• Operate according to the arm IN relief and bucket
CURL relief screen.
• Set bucket CURL relief matching after completing arm
IN relief matching.
Arm lever: IN full stroke (Operate during arm IN relief
matching)
Bucket lever: CURL full stroke (Operate during bucket
CURL relief matching)
Before starting calibration, set the machine under the following condition.
(Condition)
Hydraulic oil temperature: 45 to 55 °C
Working mode: P (“Power Mode”)
Swing emergency stop switch: ON
Fuel control dial: MAX
Swing lock switch: ON
Air conditioner: OFF
k The work equipment must be operated when checking. Secure sufficient area around the ma-
chine.
k When operating the work equipment, ensure the safety of the surroundings.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

6. Perform arm IN relief operation. When the engine speed is

stabilized, hold down F1 on the machine monitor to start
checking. During matching speed check, a bar is displayed
on the screen. Keep arm IN relief operation until the check
is finished.
REMARK
It takes approximately 10 seconds to start the bar graph
operation.

7. If the check is normally completed, the result is displayed.

Press F6 to go to bucket CURL relief.

If calibration is finished unsuccessfully, “NG” is displayed

for the State of Adjustment and the failure cause code is
displayed. Referring to the failure cause codes in Table 1,
find out and remove the cause and repeat calibration.

8. On the “Matching Speed Check” screen, check the match-

ing speed by relieving the bucket circuit in digging opera-
tion and by using the function switches
F1: Starts the matching speed check
F5: Returns to arm IN relief screen
9. Wait under the following conditions.
Hydraulic oil temperature: 45 to 55 °C
Working mode: P (“Power Mode”)
Fuel control dial: MAX
Swing lock switch: ON
Air conditioner: OFF

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

10. Hold down F1 of the machine monitor to start checking.

During matching speed check, a bar is displayed on the
screen. Keep relief operation until the check is finished.

11. If the check is normally completed, the result is displayed.

Return to “Pump Calibration” screen by pressing F6.

If calibration is finished unsuccessfully, “NG” is displayed

for the State of Adjustment and the failure cause code is
displayed. Referring to the failure cause codes in Table 1,
find out and remove the cause and repeat calibration.

METHOD FOR ADJUSTING (Pump calibration: Matching speed calibration)

(PC400_10_E-K-C200-270-20-B)
Adjustment menu is used to check the various settings of the machine or to adjust the value.
Before starting calibration, set the machine under the following condition.
• Perform warm-up operation for at least 30 minutes.
• Hydraulic oil temperature: 45 to 55 °C
• Working mode: P (“Power Mode”)
• Fuel control dial: MAX (High idle) position
• Air conditioner: OFF
The “Pump Calibration” function is used to check the matching speed for arm IN relief and bucket CURL relief
and to set the matching speed of the engine correctly when the pump or pump controller is replaced.

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30 TESTING AND ADJUSTING SET AND OPERATE MACHINE MONITOR

1. Select “Adjustment” on the “Service Menu” screen.

REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. Enter “40” with numeral input switches after the “Adjust-

ment” screen is displayed, and press F6.
REMARK
Since this function is required only when the pump is re-
placed, the PC valve is adjusted or disassembled, or the
pump controller is replaced, it is not displayed in the menu
list.

3. On the “Pump Calibration” screen, select “Matching Speed

Calibration” with function switches or numeral input
switches.
REMARK
• Select this when it is required to check abnormality or
current condition of the machine.
• For selecting method, see “Operating method of serv-
ice mode” in “SERVICE MODE”.
4. Perform the subsequent calibration procedure according to
“Matching Speed Check”.

METHOD FOR ADJUSTING MENU (RESTORE TO DEFAULT SETTING)

(PC400_11_E-K-C200-270-01-B)
Adjustment menu is used to check the various settings of the machine or to adjust the value.
The “Pump Calibration” function is used to check the matching speed for arm IN relief and bucket CURL relief
and to set the matching speed of the engine correctly when the pump or pump controller is replaced.

HB365LC-3 30-245
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

1. Select “Adjustment” on the “Service Menu” screen.

REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. Enter “40” with numeral input switches after the “Adjust-

ment” screen is displayed, and press F6.

3. On the “Pump Calibration” screen, select “Restore to De-

fault Setting” with function switches or numeral input
switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

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4. Press F6 to perform the initialization.

When F6 is pressed, the “Pump Calibration” screen ap-
pears. When “D” appears on top right corner of the screen,
the initialization is completed.

METHOD FOR PERFORMING NO-INJECTION CRANKING (PC400_10_E-K-AD00-25L-00-B)

If the engine is operated after long storage of the machine, it may be worn or damaged because of insufficient
lubrication with oil. To prevent this, the machine has a function to crank the engine without injecting fuel to lubri-
cate the engine before starting it.
Setting of No-Injection cranking to be performed while the engine is stopped.
No-Injection cranking does not function while the engine is run-
ning.
This function can be selected even when the engine is running.
However, if you execute No-Injection cranking, “Engine is run-
ning. Please turn the key off once.” is displayed on the screen.

Even if the confirmation screen is displayed and No-Injection

cranking is operated, the function does not become effective in
the following cases. Turn the starting switch OFF once to oper-
ate.
• The communication between the machine monitor and en-
gine controller is not normal.
• An engine start operation has been performed before the
message “No-injection cranking is possible” is displayed.

HB365LC-3 30-247
SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

1. Select “No-Injection Cranking” on “Service Menu” screen.

REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. When “No-Injection Cranking” screen is displayed, confir-

mation for the execution of No-Injection cranking is dis-
played. Select the action with the function switch.
F5: Does not implement (returns the screen to “Service
Menu”).
F6: Executes.

3. If no-injection cranking (no fuel injection on every cylinder)

is enabled, “No-injection cranking is possible. Please turn
the key off after no-injection ends.” is displayed on the
screen. Crank the engine with the starting motor.
NOTICE
Do not crank the engine for 20 seconds or longer to
protect the starting motor.
REMARK
While the screen is changing to the screen as shown in the
figure, the screen of “Getting Ready” is displayed.
4. After the cranking is completed, turn the starting switch to OFF position.
You cannot change the screen described above to another screen.

KOMTRAX SETTINGS MENU (PC400_11-K-Q170-001-04-B)

METHOD FOR CONFIRMING KOMTRAX SETTINGS (TERMINAL STATUS)

(PC400_10_E-K-Q210-110-00-B)
On “KOMTRAX setting display” screen, select “Terminal Status” with the function switches or numeral input
switches.
"“Terminal Status”" is used to check the setting condition of the KOMTRAX terminal.

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1. Select “KOMTRAX Settings” on “Service Menu” screen.

REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On “KOMTRAX Settings”screen, select “Terminal Status”

with the function switches or numeral input switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

3. On “Terminal Status” screen, the following items are dis-

played.
Terminal Type: Model name of the KOMTRAX communica-
tion modem
KOMTRAX Communication Inspection: State of radio sta-
tion establishment
GMT time: Greenwich Mean Time (add 9 hours to it for Ja-
pan time)
F5: Returns the screen to “KOMTRAX Settings” screen

METHOD FOR CONFIRMING KOMTRAX SETTINGS (GPS AND COMMUNICATION

STATUS) (PC400_10_E-K-Q210-110-10-B)
The setting and operating state of KOMTRAX can be checked by using “KOMTRAX Settings” screen.
“GPS & Communication State” is used to check the positioning and communication state of the KOMTRAX sys-
tem.
1. Select “KOMTRAX Settings” on “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

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SET AND OPERATE MACHINE MONITOR 30 TESTING AND ADJUSTING

2. On “KOMTRAX Settings” screen, select “GPS & Communi-

cation State” with the function switches or numeral input
switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

3. On “GPS & Communication State” screen, the following

items are displayed.
Positioning: GPS positioning state
Communication: Communication environment and connec-
tion state of the communication modem
Number of message not yet sent: Number of mails that are
saved on the machine monitor and have not yet been
transmitted
F5: Returns the screen to “KOMTRAX Settings” screen

METHOD FOR CONFIRMING KOMTRAX SETTINGS (MODEM STATUS)

(PC400_10_E-K-Q210-110-20-B)
The setting and operating state of KOMTRAX can be checked by using the menu of “KOMTRAX Settings”.
“Modem Information” is used to check the phone number and IMSI of the KOMTRAX communication modem.
1. Select “KOMTRAX Settings” on “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On “KOMTRAX Settings”screen, select “Modem Informa-

tion” with the function switches or numeral input switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

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3. Display the phone number and IMSI.

F5: Returns the screen to “KOMTRAX settings” screen.

METHOD FOR DISPLAYING SERVICE MESSAGE (PC400_10_E-K-Q210-100-00-B)

Special messages for the technician sent from the KOMTRAX base station (a distributor, etc.) can be checked
with this function.
If a received message includes a setting operation, a return mail can be sent by using the numeral input
switches as well.
1. Select “Service Message” on “Service Menu” screen.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. Displaying message
• Displaying message (read only)
If there is a message, its contents are displayed. If
there is no message, “No message.” is displayed.
F5: Returns the screen to “Service Menu” screen
REMARK
• This message is different from that sent to the op-
erator with the machine monitor in the operator
mode.
• Since this message is special for the technician,
the message monitor is not displayed as it is dis-
played in the operator mode.
• Display of message (with message return function)
If a message provides the Numeric Input line under
the text, input a proper number by using the numeral
input switches and enter it by using the function
switch, and the information is returned to the KOM-
TRAX base station.
F5: Returns the screen to “KOMTRAX Settings”
screen
F6: Enters and sends the input value.

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REMARK
• This message is different from that sent to the operator in the operator mode.
• Since this message is special for the technician, the message monitor is not displayed as it is dis-
played in the operator mode.

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METHOD FOR STARTING UP KOMTRAX TERMINAL (D155_8_E-K-Q210-110-00-B)

Method for starting-up KOMTRAX

Observe the following when using KOMTRAX.
1. KOMTRAX key person performs “Machine Registration” by using KOMTRAX client PC.
2. Perform “KOMTRAX Communication Inspection”.
• For operation procedures, see “Global KOMTRAX Web Reference Manual (For Key Person)”.
• Operating the KOMTRAX client PC requires the KOMTRAX key person authority of each distributor.
Therefore, consult the KOMTRAX key person before using it.

When KOMTRAX terminal is replaced.

Observe the following when replacing KOMTRAX terminal and using it again.
1. Our technician provides a new terminal, and records the part number and serial number.
2. Our technician replaces the terminal, and perform “KOMTRAX Communication Inspection”. Our technician
notifies KOMTRAX key person of the completion of inspection work and new terminal information.
3. KOMTRAX key person performs “Terminal Replacement” by using KOMTRAX client PC.
4. KOMTRAX key person fills in required items on “Terminal Replacement Sheet”, and send it by email to
KOMTRAX support center via KOMTRAX administrator in the subsidiary.
• For details, see “Global KOMTRAX Web Reference Manual (For Key Person)”.
• Operating the KOMTRAX client PC requires the KOMTRAX key person authority of each distributor.
Therefore, consult the KOMTRAX key person before using it.

Machine side inspection for KOMTRAX Communication opening

• KOMTRAX Communication Inspection must be done to check whether normal communication is available
from the terminal when the KOMTRAX terminal is replaced or started up.
• By performing this inspection, KOMTRAX starts communication.
• GPS and data communication are checked during the KOMTRAX Communication Inspection. Accordingly,
it is preferable to place the machine under the open sky where radio wave from the satellite is not blocked.
The opening inspection may not be completed when the machine is placed indoor where radio wave from
the satellite is blocked.
1. Check the machine for KOMTRAX Communication Inspection
Observe the following when checking if KOMTRAX Communication Inspection is required or not.
1) On “Service Menu” screen, select “KOMTRAX Set-
tings” with function switches or numeral input
switches.

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2) On “KOMTRAX Settings” screen, select “Terminal Sta-

tus” with the function switches or numeral input
switches.

3) On “Terminal Status” screen, check the state of “KOM-

TRAX Communication Inspection”.
If “KOMTRAX Communication Not Open” is displayed
on the state of “KOMTRAX Communication Inspec-
tion”, Perform step 2. If “Already Open” is displayed,
KOMTRAX Communication Inspection is not needed.
2. KOMTRAX Communication Inspection
Observe the following when performing KOMTRAX Com-
munication Inspection.

1) On “Service Menu” screen, select “KOMTRAX Set-

tings” with function switches or numeral input
switches.

2) On “KOMTRAX Settings” screen, select “GPS & Com-

munication State” with the function switches or numer-
al input switches.

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3) After “GPS & Communication State” screen is dis-

played, press the numerical switches in order while
pressing 4 as 4 + 1 → 2 → 3.

4) After “Are you sure you want to inspect?” is displayed,

execute the inspection with the function switch.
F5: Returns the screen to “GPS & Communication
State” screen
F6: Executes KOMTRAX Communication Inspection.

5) The screen displays the state of KOMTRAX Commu-

nication inspection. Check on this screen that all item
are “OK”.
“Modem”: “OK” is displayed when communication area
is confirmed.
“GPS”: “OK” is displayed when it acquires GPS data.
“Transmission”: “OK” is displayed when it transmits
data correctly.
“Inspection State”: When all items of “Modem”, “GPS”,
and “Transmission” are “OK”, “OK” is displayed on
“Inspection State”.
• It takes 90 seconds to 15 minutes for all items to be “OK”.
• While waiting for all items to be “OK”, operation such as turning the starting switch to OFF position
or starting the engine will not be a problem.
If there is nothing abnormal, KOMTRAX Communication Inspection finishes automatically. Select
“KOMTRAX Settings” → “Terminal Status” of “Service Menu” to make sure that “Already Open” is
indicated for the item in “KOMTRAX Communication Inspection”.
• KOMTRAX Communication Inspection may not be completed when the machine is placed indoor
where radio wave from the satellite is blocked.

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METHOD FOR STARTING UP KOMTRAX TERMINAL 30 TESTING AND ADJUSTING

6) When all items are “OK”, “Inspection finished normal-

ly.” screen automatically displayed.
Press ENTER switch. “GPS & Communication State”
appears, and the KOMTRAX Communication Inspec-
tion for machine side is completed.
Other than the above, perform step 3.
3. Troubleshooting when KOMTRAX Communication Inspec-
tion is finished unsuccessfully
• If any of 1) to 5) in step 2 is finished unsuccessfully,
perform inspection from 1) in step 2.
• If 6) in step 2 is finished unsuccessfully, following problems are suspected.

Troubleshooting when the failure occurs

Phenomenon Cause Required action
Something on the cab blocks off GPS sat- Remove the obstacle on the cab.
GPS does not be- ellites acquisition.
come OK. GPS antenna cable is not connected to Check for the connection. If the connection is loose,
the machine monitor, or they are loose. secure it.
The mobile phone is out of communication Check for state of in/out communication range with
range. your mobile phone.
If it is out of communication range, move into com-
munication reception range and perform inspection.
Modem does not Communication antenna cable is not con- Check for the connection. If the connection is loose,
become OK. nected to the KOMTRAX terminal, or they secure it.
are loose.
KOMTRAX terminal is not connected to Check for the connection. If the connection is loose,
machine side wiring harness, or they are secure it.
loose.
4. After troubleshooting, perform 1) in step 2 again.
When the problems are not solved, contact your KOMTRAX support center.

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HB365LC-3 30-257
ADJUST REARVIEW CAMERA ANGLE 30 TESTING AND ADJUSTING

ADJUST REARVIEW CAMERA ANGLE (PC128_11-K-Q162-304-00-B)

• For the standard machine, adjust the camera angle by referring to “METHOD FOR ADJUSTING REAR-
VIEW CAMERA ANGLE”.
• For the machine with KomVision, adjust the devices by referring to “KomVision RELATED DEVICES”.

METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE (PC300_11-K-Q162-270-00-B)

k Always adjust the camera before starting work. If it is

not adjusted properly, you cannot secure the visibility
and a serious personal injury or death may result.
k When adjusting the angle of the camera, prepare a
scaffold first in order to provide a safe working plat-
form.
If you try to work standing on the counterweight, there
is a danger of serious injury or death due to falling off
from the machine.

Adjust the angle of the rearview camera so that people within 1

m away from the machine's rear part (W) can be seen in the
machine monitor at the operator's seat.

If the image on the monitor is not aligned correctly, adjust

mounting angle (A) of the rearview camera in the following pro-
cedure.
Angle (A) can be adjusted within the range from 32 to 53°.

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1. Insert a flat-head screwdriver or the like into hole (3) of

cover (2) and push inside tooth (B) to remove the cover.
2. Remove bolts (4) (2 places).

3. Remove cover (1).

REMARK
• Shim (6) may be inserted in the cover mounting bolts to
adjust the clearance in the rim of the cover. When re-
moving cover (1), record the places and quantities of
the shims. When installing the cover, insert the shims
according to the record.
• Take care of shim (6), since it comes off together with
cover (1).

4. Loosen camera mounting bolts (5) (3 places) and adjust

camera mounting angle (A) so that corner (D) of mounting
bracket (C) is aligned with horizontal line (E).

5. After adjusting, tighten bolts (5).

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Tightening torque:11.8 to 14.7 Nm{1.2 to 1.5 kgm}

REMARK
A part of the machine is shown on the monitor screen.

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ADJUST KomVision CAMERA ANGLE (HB335-3-K-K900-304-03-B)

Tools to be used when adjusting KomVision camera angle

Symbol Part No. Part name Q'ty Remarks
Commercially Niigata Seiki bevel box: BB-180 equiva-
A Digital angle gauge 1
available lent

k Check that the visibility of KomVision camera is correct always before starting operation. Adjust it if
necessary. You cannot secure the visibility and a serious personal injury or death may occur if Kom-
Vision camera is not adjusted properly.
k Prepare a scaffold first in order to provide a safe working platform. Then, adjust the angle of KomVi-
sion camera. There is a danger of serious injury or death due to falling off from the machine if stand
on the counterweight.
k Adjust the angle of KomVision camera on a safe working platform. Measure the inclination of the
counterweight. Calculate the actual angle of KomVision camera when adjusting the camera angle on
a slope by necessity.
Adjust the mounting angle (A) of KomVision camera if the im-
age on the monitor is not reflected correctly.

Adjust the mounting angle (A) of KomVision camera according to the following procedure if objects dis-
appear or look crossing in the blend area (i) where 2 camera images are blended.
• Normal: Images match with each other on yellow reference
line (ground level)

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ADJUST KomVision CAMERA ANGLE 30 TESTING AND ADJUSTING

• Shift: Images cross each other on yellow reference line

(ground level)

METHOD FOR ADJUSTING KomVision CAMERA ANGLE (HB335_3-K-K900-270-00-B)

Angle adjustment method for front right camera, rear right camera, and rear left
camera
1. Insert a flat-head screwdriver into hole (2) of bolt cover (1)
and remove the bolt cover (1) while pressing the internal
claw.
REMARK
The bolt cover (1) is made of plastic, so be careful not to
break it when removing.

2. Remove the bolt (3).

3. Remove the cover (4).

4. Loosen the mounting bolt (5).

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5. Put the angle gauge A on the (b) surface of KomVision

camera and adjust the installed angle of the KomVision
camera (a).
Angle (a): 45(+2/0) °
6. Tighten the mounting bolt (5).
3 Mounting bolt (5):
11.8 to 14.7 Nm {1.2 to 1.5 kgm}

After finishing the adjustment, restore the machine.

Calibrate the KomVision camera after adjusting the angle of the camera by referring to “METHOD FOR SET-
TING OF KomVision (CAMERA CALIBRATION)”.

Angle adjustment method for rear camera

1. Insert a flat-head screwdriver into hole (2) of bolt cover (1)
and remove the bolt cover (1) while pressing the internal
claw.
REMARK
The bolt cover (1) is made of plastic, so be careful not to
break it when removing.

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ADJUST KomVision CAMERA ANGLE 30 TESTING AND ADJUSTING

2. Remove the bolt (3).

3. Remove the cover (4).
REMARK
• Shim (5) may be installed to the mounting bolt of cover
(4) for adjustment of clearance in cover.
• Be careful when handling the shim (5). It comes off to-
gether with cover (4).

4. Loosen the mounting bolt (6).

5. Put the angle gauge A on the (b) surface of KomVision

camera and adjust the installed angle of the KomVision
camera (a).
Angle (a): 45(+2/0) °
6. Tighten the mounting bolt (6).
3 Mounting bolt (6):
11.8 to 14.7 Nm {1.2 to 1.5 kgm}

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After finishing the adjustment, restore the machine.

Calibrate the KomVision camera after adjusting the angle of the camera by referring to “METHOD FOR SET-
TING OF KomVision (CAMERA CALIBRATION)”.

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ADJUST KomVision RELATED ITEMS 30 TESTING AND ADJUSTING

ADJUST KomVision RELATED ITEMS (HB205_3-K-K900-110-01-B)

The following items are adjustment details of KomVision related items. If you performed the target works, be
sure to perform the applicable tests and the adjusting items.

KomVision adjustment items table

Item Target work Purpose Reference page
• When the KomVision controller
is replaced Check and select the model
Setting of KomVision (main
Main Setting name and the machine
• When the set values are initial- setting)
specifications
ized
• When the set values are initial- Check and select the part
Camera Set- ized Setting of KomVision (camera
number of the KomVision
ting setting)
• When the camera is replaced camera.

• When the KomVision controller

is replaced (*1) Adjust the installed location
Camera Cali- and the angle parameter of Setting of KomVision (camera
• When the set values are initial-
bration each camera to compose calibration)
ized (*1) the camera images
• When the camera is replaced

*1: Perform “Camera Calibration” after “Main Setting” is performed.

SETTING OF KomVision (MAIN SETTING) (PC128_11-K-K900-304-00-B)

Check and select the model name and the machine specifications.

METHOD FOR SETTING KomVision (MAIN SETTING) (HB335_3_E-K-K900-110-01-B)

1. From “Service Menu” screen, select “Adjustment”.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

2. On the “Adjustment” screen, select “KomVision Adjust-

ment” with function switches or numeral input switches.
REMARK
For selecting method, see “Operating method of service
mode” in “SERVICE MODE”.

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3. On the “KomVision Adjustment Menu” screen, select “Main

Setting” with the function switch.
F1: Returns to the “Service Menu” screen
F3: Moves down the selected item
F4: Moves up the selected item
F5: Cancels the selection and returns the screen to the
“Adjustment” screen
F6: Enters the selected item

4. On “Main Setting” screen, select “Machine Model” with the

function switch.
F1: Returns to the “Service Menu” screen without entering
the selected item
F3: Moves down the selected item
F4: Moves up the selected item
F5: Returns to “KomVision Adjustment Menu” without en-
tering the selected item
F6: Enters the selected item
REMARK
When the selected item is entered, the icon (a) turns yel-
low.
5. Select the corresponding machine model code, by referring to “Machine Model Code List”.
F1: Returns to the “Service Menu” screen without entering the selected item
F3: Moves down the selected item
F4: Moves up the selected item
F5: Returns to “KomVision Adjustment Menu” without entering the selected item
F6: Enters the selected item
NOTICE
Do not change any value of “03 Front End from Cent” to “07 Number of Camera”.

Machine model code list

Machine Specifications/Optional devices
Machine
model
model With no optional device Long track specification
code
HB335/
B003 ○ ○
HB365

When the machine model code is entered, the values of the following items are updated automatically, and
the icon (a) turns black again.
“03 Front End from Cent”
“04 Rear End from Cent”
“05 Right End from Cent”
“06 Left End from Cent”
“07 Number of Camera”

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ADJUST KomVision RELATED ITEMS 30 TESTING AND ADJUSTING

6. Select “Save” with the function switch.

F1: Returns to the “Service Menu” screen without entering
the selected item
F3: Moves down the selected item
F4: Moves up the selected item
F5: Returns to “KomVision Adjustment Menu” without en-
tering the selected item
F6: Enters the selected item
• When the text color of “Save” button is green:
Settings is not changed. Restart the KomVision setting
from step 4.
• When the text color of “Save” button is orange:
Saving the new setting. Go to the next step.
7. Press F6 and save the settings.
When F6 is pressed, the text color of “Save” button is green, and the settings will be saved.

SETTING OF KomVision (CAMERA SETTING) (HB205_3-K-K900-304-00-B)

Check and select the part number of the KomVision camera.

METHOD FOR SETTING KomVision (CAMERA SETTING) (HB335_3_E-K-K900-110-20-B)

1. Select “Adjustment” on “Service Menu” screen.
REMARK
See “METHOD FOR OPERATING SERVICE MODE” in
“SERVICE MODE” for selecting method.

2. Select “KomVision Adjustment” with the function switches

or numeral input switches on the “Adjustment” screen.
REMARK
See “METHOD FOR OPERATING SERVICE MODE” in
“SERVICE MODE” for selecting method.

3. Select “Camera Setting” with the function switches on the

“KomVision Adjustment Menu” screen.
F1: The screen returns to “Service Menu” screen.
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: Selection is canceled. The screen returns to the “Ad-
justment” screen
F6: Enters the selected item.

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4. Select “05 Lens Parameter Setting” with the function

switches on the “Camera Setting” screen.
F1: The screen returns to “Service Menu” screen without
saving the setting.
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: The screen returns to “KomVision Adjustment Menu”
screen without saving the setting.
F6: Enters the selected item.
REMARK
The following menus are not used for service.
“01 Rear Camera”
“02 RH-Rear Camera”
“03 RH-Front Camera”
“04 LH-Rear Camera”
5. Select “05 Lens Parameter Default” with the function
switches on “05 Lens Parameter Setting” screen.
F1: The screen returns to “Service Menu” screen without
saving the setting.
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: The screen returns to “Camera Setting” screen without
saving the setting.
F6: Enters the selected item.
REMARK
When the selected item is entered, the back ground color
of icon (i) turns yellow.
6. Select the part number of the applicable KomVision camera by referring to “Part number list of KomVision
camera by model”.
F1: The screen returns to “Service Menu” screen without saving the setting.
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: The screen returns to “Camera Setting” screen without saving the setting.
F6: Enters the selected item.
NOTICE
Do not change the numeric value in “01 Focal Length” to “04 Strain Coefficient(Circum.)”.
REMARK
The displayed part number of the KomVision camera has (*) on its end, and (*) will show a number between
0 and 9.

Part number list of KomVision camera by model

Specifications/Optional devices
Machine model Long crawler speci- Part No.
Without option
fications
HB335/HB365 ○ ○ 7835-33-400*

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ADJUST KomVision RELATED ITEMS 30 TESTING AND ADJUSTING

The background color of the (i) part returns to black once after the part number of the KomVision camera is
confirmed.
7. Select the “Save” with the function switches.
F1: The screen returns to “Service Menu” screen without
saving the setting.
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: The screen returns to “Camera Setting” screen without
saving the setting.
F6: Enters the selected item.
• When the text color of “Save” is green:
Settings is not changed. Restart the KomVision setting
from Step 4.
• When the text color of “Save” is orange:
The new setting is going to be saved. Proceed to the next Step.
8. Press F6 and save the setting.
When F6 is pressed, the text color of “Save” turns green, and the settings is saved.

SETTING OF KomVision (CAMERA CALIBRATION) (PC128_11-K-K900-304-02-B)

Testing tools for KomVision (camera calibration)

Symbol Part No. Part name Q'ty Remarks
A - Angle setting calibration marker 1
B - Position setting calibration marker 1
Commercially
C Tripod 1
available
Commercially
D Traffic cone 2 Height : Approx. 70 cm
available

Test this item under the following conditions.

• On a flat and level ground, there are not any obstacles within 4 to 5 m of the machine
• Dust free environment (Avoid a place where the camera lens may get dirty during work).
Adjust each parameter to compose the multiple camera images.

METHOD FOR SETTING OF KomVision (CAMERA CALIBRATION)(HB335_3_E-K-K900-110-03-B)

NOTICE
Perform “angle calibration” first, then perform “position calibration”.

Operation of “angle calibration”

1. Make the angle setting calibration marker A.
REMARK
• Make an enlarged photocopy of the angle setting calibration marker A in Fig. 1 found at the end of this
section.
• Ensure the figure size to be large enough to read on the machine monitor screen. The recommended
size is A3.

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30 TESTING AND ADJUSTING ADJUST KomVision RELATED ITEMS

2. Fix the angle setting calibration marker A to the tripod C.

3. Horizontally install the angle setting calibration marker A to

the position (a) approximately 1.0 to 1.5 m apart from the
camera.
REMARK
• “Angle calibration” can be performed from any camera.
• Perform the “Angle calibration” by each camera.
• Install the angle setting calibration marker A at the front
of each camera in parallel with the machine.
• Adjust the height of angle setting calibration marker A
to the height of the center of the camera lens.
• Calibration accuracy is assured by setting the center of
the angle setting calibration marker A to the center of
the camera lens within ±40 mm.
• The angle calibration accuracy may deteriorate if the
angle calibration marker position (a) is below 1.0 m.

Camera height
Camera position Camera height (mm)
Rear camera 2206
Rear R.H. camera 2430
Front R.H. camera 2430
Rear L.H. camera 2455
4. Select “Adjustment” on “Service Menu” screen.
REMARK
See “METHOD FOR OPERATING SERVICE MODE” in
“SERVICE MODE” for selecting method.

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5. Select “KomVision Adjustment” with the function switches

or numeral input switches on “Adjustment” screen.
REMARK
See “METHOD FOR OPERATING SERVICE MODE” in
“SERVICE MODE” for selecting method.

6. Select “Camera Calibration” with the function switches on

“KomVision Adjustment Menu” screen.
F1: The screen returns to “Service Menu” screen.
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: Selection is canceled. The screen returns to “Adjust-
ment” screen.
F6: Enters the selected item.

7. Select “Angle Calibration” with the function switches on

“CAMERA CALIBRATION” screen.
F1: The screen returns to “Service Menu” screen.
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: Selection is canceled. The screen returns to “KomVi-
sion Adjustment Menu” screen.
F6: Enters the selected item.

8. Select the camera to be adjusted with the function

switches on “Camera Selection (Angle Calibration)”
screen.
F1: The screen returns to “Service Menu” screen.
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: Selection is canceled. The screen returns to “CAMERA
CALIBRATION” screen.
F6: Enters the selected item.
REMARK
“Bird's-eye Image Rate” and “Camera Image Size Rate”
can be adjusted with the function switches.

30-272 HB365LC-3
30 TESTING AND ADJUSTING ADJUST KomVision RELATED ITEMS

9. Check that the angle setting calibration marker A installed

in Step 1 is displayed in the box (b) when the angle cali-
bration screen for the selected camera is displayed.
REMARK
Adjust the position of the angle setting calibration marker A
or the angle of the camera if the angle setting calibration
marker A is not displayed.

10. Select and enter “Camera Pitch Angle” with the function
switches.
F1: The screen returns to “Service Menu” screen.
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: Selection is canceled. The screen returns to “CAMERA
CALIBRATION” screen.
F6: Enters the selected item.
The back ground color of icon (c) turns yellow when the
selected item is entered.
11. Match the center of the angle setting calibration marker A
and the vertical direction position of the camera marker
with the function switches.
A: Angle setting calibration marker A
x: Camera marker
F1: The screen returns to “Service Menu” screen.
F3: Moves the camera image downward
F4: Moves the camera image upward
F5: Cancels the calibration item / Cancels the change. The
screen returns to “KomVision Adjustment Menu” screen.
F6: Enters the calibration item/Enters the change

12. Select and enter “Camera Yaw Angle” with the function
switches.
F1: The screen returns to “Service Menu” screen.
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: Selection is canceled. The screen returns to “CAMERA
CALIBRATION” screen.
F6: Enters the selected item.
The back ground color of icon (d) turns yellow when the
selected item is entered.

HB365LC-3 30-273
ADJUST KomVision RELATED ITEMS 30 TESTING AND ADJUSTING

13. Match the center of the angle setting calibration marker A

and the lateral position of the camera marker with the func-
tion switches.
A: Angle setting calibration marker A
x: Camera marker
F1: The screen returns to “Service Menu” screen.
F3: Moves the camera image to the left
F4: Moves the camera image to the right
F5: Cancels the calibration item / Cancels the change. The
screen returns to “KomVision Adjustment Menu” screen.
F6: Enters the calibration item/Enters the change

14. Select and enter “Camera Roll Angle” with the function
switches.
F1: The screen returns to “Service Menu” screen.
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: Selection is canceled. The screen returns to “CAMERA
CALIBRATION” screen.
F6: Enters the selected item.
The back ground color of icon (e) turns yellow when the
selected item is entered.
15. Match the angle setting calibration marker A and the rota-
tion direction position of the camera marker with the func-
tion switches.
A: Angle setting calibration marker A
x: Camera marker
F1: The screen returns to “Service Menu” screen.
F3: Rotates the camera image counterclockwise
F4: Rotates the camera image clockwise
F5: Cancels the calibration item / Cancels the change. The
screen returns to “KomVision Adjustment Menu” screen.
F6: Enters the calibration item/Enters the change

30-274 HB365LC-3
30 TESTING AND ADJUSTING ADJUST KomVision RELATED ITEMS

• Example of matching
A: Angle setting calibration marker A
x: Camera marker

• Example of not matched

A: Angle setting calibration marker A
x: Camera marker
16. Select “Save” with the function switches when the angle
calibration marker A and the camera marker match. Press
F6 to save the setting.

Perform Step 1 to Step 16 for each camera.

REMARK
• Perform calibration for all cameras always when the controller is replaced or when the specification is
changed.
• Perform only the necessary calibrations relevant to the camera which has been replaced.
NOTICE
Perform "Camera Calibration" according to the table always when the camera angle, etc. is adjusted af-
ter camera image check.
Item to be performed
Adjusted camera Angle calibration
Rear camera Rear R.H. camera Front R.H. camera Rear L.H. camera
Rear camera ○ - - -
Rear R.H. camera - ○ - -
Front R.H. camera - - ○ -
Rear L.H. camera - - - ○

Operation of “position calibration”

1. Make the position setting calibration marker B.
REMARK
• Make the position setting calibration marker B accord-
ing to the figure.
• Stick some 50 mm wide black tapes on a board when
making the calibration marker.

2. Set the position setting calibration marker B according to the Table 1.

HB365LC-3 30-275
ADJUST KomVision RELATED ITEMS 30 TESTING AND ADJUSTING

NOTICE
Start with the rear R.H. camera for performing “position calibration”. Then, perform in the order of
the right rear, right front, and left rear) when 4 cameras are installed.
REMARK
Perform “Position calibration” by each camera.
B: Position setting calibration marker B
y: Machine

Table 1
Dimension, angle Positive value
a 1 to 1.5 m (From upper structure end)
b 1 to 1.5 m (From counterweight end)
c 1 to 1.5 m (From upper structure end)
d Center between 2 cameras
θ 90 °
3. Check on the machine monitor that the position setting calibration marker B is reflected in the image cap-
tured by 2 adjacent cameras.
4. Select “Adjustment” on “Service Menu” screen.
REMARK
See “METHOD FOR OPERATING SERVICE MODE” in
“SERVICE MODE” for selecting method.

5. Select “KomVision Adjustment” with the function switches

or numeral input switches on “Adjustment” screen.
REMARK
See “METHOD FOR OPERATING SERVICE MODE” in
“SERVICE MODE” for selecting method.

30-276 HB365LC-3
30 TESTING AND ADJUSTING ADJUST KomVision RELATED ITEMS

6. Select “Camera Calibration” with the function switches on

“KomVision Adjustment Menu” screen.
F1: The screen returns to “Service Menu” screen.
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: Selection is canceled. The screen returns to “Adjust-
ment” screen.
F6: Enters the selected item.

7. Select “Position Calibration” with the function switches on

“CAMERA CALIBRATION” screen.
F1: The screen returns to “Service Menu” screen.
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: Selection is canceled. The screen returns to “KomVi-
sion Adjustment Menu” screen.
F6: Enters the selected item.

8. Select the camera to be adjusted with the function

switches on “Camera Selection (Position Calibration)”
screen.
F1: The screen returns to “Service Menu” screen.
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: Selection is canceled. The screen returns to “CAMERA
CALIBRATION” screen.
F6: Enters the selected item.
REMARK
Table 2 describes the calibrations target of cameras. The
calibration target changes depending on which camera is
selected on “Camera Selection (Position Calibration)”
screen.

Table 2
Selected item Standard camera Camera to be adjusted
Rear R.H. camera Rear camera Rear R.H. camera
Front R.H. camera Rear R.H. camera Front R.H. camera
Rear L.H. camera Rear camera Rear L.H. camera
9. Check that the position setting calibration marker B instal-
led in Step 1 is displayed in the box (f) when the position
calibration screen for the selected camera is displayed.
REMARK
• Check that the calibration marker is on both rear cam-
era image and R.H. camera image.
• Adjust “Bird's-eye Image Rate” or reinstall the position
setting calibration marker B if the position setting cali-
bration marker B is not displayed.

HB365LC-3 30-277
ADJUST KomVision RELATED ITEMS 30 TESTING AND ADJUSTING

10. Select and enter “Camera Lateral Position” with the func-
tion switches.
F1: The screen returns to “Service Menu” screen.
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: Selection is canceled. The screen returns to “CAMERA
CALIBRATION” screen.
F6: Enters the selected item.
The back ground color of icon (g) turns yellow when the
selected item is entered.
11. Align the marker of the target camera and the lateral posi-
tion of the calibration marker B for position setting with the
function switches.
z: Marker of camera to be adjusted
B: Position setting calibration marker B
F1: The screen returns to “Service Menu” screen.
F3: Moves the camera image to the left
F4: Moves the camera image to the right
F5: Cancels the calibration item/the Cancels the changed
item. The screen returns to “Camera Selection (Position
Calibration)” screen.
F6: Enters the calibration item/Enters the change

12. Select and enter “Camera longitude Posit” with the func-
tion switches.
F1: The screen returns to “Service Menu” screen.
F3: Moves the selection downward.
F4: Moves the selection upward.
F5: Selection is canceled. The screen returns to “CAMERA
CALIBRATION” screen.
F6: Enters the selected item.
The back ground color of icon (h) turns yellow when the
selected item is entered.

30-278 HB365LC-3
30 TESTING AND ADJUSTING ADJUST KomVision RELATED ITEMS

13. Align the marker of the target camera and the longitudinal
position of the calibration marker B for position setting with
the function switches.
z: Marker of camera to be adjusted
B: Position setting calibration marker B
F1: The screen returns to “Service Menu” screen.
F3: Moves the camera image downward
F4: Moves the camera image upward
F5: Cancels the calibration item/the Cancels the changed
item. The screen returns to “Camera Selection (Position
Calibration)” screen.
F6: Enters the calibration item/Enters the change

• Example of matching
z: Marker of camera to be adjusted
B: Position setting calibration marker B

• Example of not matched

z: Marker of camera to be adjusted
B: Position setting calibration marker B
14. Select “Save” with the function switches when the position
calibration marker B and the camera marker match. Press
F6 to save the setting.
Return the screen to the standard screen after completing
the calibration process. Check that the failure code is not
displayed.
Perform Step 1 to Step 14 for each camera.
15. See the camera image to check the following items.
1) Check that the line (a), (b), or (c) is not displayed.
When the line (a) is displayed:
The rear R.H. camera is tilted upward out of the speci-
fied angle. Adjust the camera mounting angles to be
within the specified angle by referring to “METHOD
FOR ADJUSTING KomVision CAMERA ANGLE”.
When the line (b) is displayed:
The rear L.H. camera is tilted upward out of the speci-
fied angle. Adjust the camera mounting angles to be

HB365LC-3 30-279
ADJUST KomVision RELATED ITEMS 30 TESTING AND ADJUSTING

within the specified angle by referring to “METHOD FOR ADJUSTING KomVision CAMERA ANGLE”.
When the line (c) is displayed:
The front R.H. camera is tilted upward out of the specified angle. Adjust the camera mounting angles to
be within the specified angle by referring to “METHOD FOR ADJUSTING KomVision CAMERA AN-
GLE”.
2) Check the degree how wide the counterweight and
right side of machine are displayed (j).
REMARK
• Check the degree how wide the counterweight and
right side of machine are displayed (j) by the width
of machine displayed on the bird's-eye image on
machine monitor.
• Degree how wide counterweight and right side of
machine are displayed (j): 3 mm or less
• Degree how wide the portion is displayed: Degree
how wide the camera image of the machine body
is displayed
• When the right side of the counterweight is dis-
played largely:
The rear R.H. camera is tilted downward out of the
specified angle. Adjust the camera mounting an-
gles to be within the specified angle by referring to
“METHOD FOR ADJUSTING KomVision CAM-
ERA ANGLE”.
• When the left side of the counterweight is dis-
played largely:
The rear L.H. camera is tilted downward out of the
specified angle. Adjust the camera mounting an-
gles to be within the specified angle by referring to
“METHOD FOR ADJUSTING KomVision CAM-
ERA ANGLE”.
• When the right side of the machine is displayed
largely:
The front R.H. camera is tilted downward out of
the specified angle. Adjust the camera mounting
angles to be within the specified angle by referring
to “METHOD FOR ADJUSTING KomVision CAM-
ERA ANGLE”.

30-280 HB365LC-3
30 TESTING AND ADJUSTING ADJUST KomVision RELATED ITEMS

3) Check that the images (i) are aligned correctly.

REMARK
• Person's upper body may be doubly displayed in
blend area (i) since KomVision corrects the error
between the mounted cameras on the basis of
ground level (by position calibration).
• The targets on machine side (k) from the red refer-
ence line within the blend area (i), their images
may be doubly displayed.
• The targets out side (m) of the red reference line
within the blend area (i), images from both cam-
eras may be separately displayed.

4) Place the traffic cones D at the following positions,

and check that they can be seen in the camera image.
a: 1.0 to 1.5 m from upper structure end
b: 1.0 to 1.5 m from counterweight end
c: 1.0 to 1.5 m from upper structure end
d: Center between 2 cameras
Perform “Camera Calibration” again if the object is not
seen in the camera image by referring to “METHOD
FOR SETTING OF KomVision (CAMERA CALIBRA-
TION)”. Adjust the angles of the camera by referring to
“METHOD FOR ADJUSTING KomVision CAMERA
ANGLE” when the image quality is still poor after per-
forming “Camera Calibration”.
NOTICE
Make sure to perform “Camera Calibration” ac-
cording to the Table 3 after the camera angle, etc.
is adjusted as a result of camera image check.

Table 3
Item to be performed
“Angle Calibration” “Position Calibration”
Adjusted camera
Rear Rear R.H. Front R.H. Rear L.H. Rear R.H. Front R.H. Rear L.H.
Camera camera camera camera camera camera camera

Rear camera ○ - - - ○ ○ ○
Rear R.H. camera - ○ - - ○ ○ -
Front R.H. camera - - ○ - - ○ -
Rear L.H. camera - - - ○ - - ○

HB365LC-3 30-281
ADJUST KomVision RELATED ITEMS 30 TESTING AND ADJUSTING

Fig. 1

30-282 HB365LC-3
30 TESTING AND ADJUSTING ADJUST KomVision RELATED ITEMS

KomVision screen - Check 12 m visibility (PC200_11-K-K900-304-04-B)

Tools for testing 12 m visibility of KomVision

Symbol Part No. Part name Q'ty Remarks
Commercially Material: (Example) Wooden board, card-
A Wooden board, cardboard 1
available board
Commercially Material: (Example) Wooden board, card-
B Wooden board, cardboard 1
available board
Commercially
- Tape measure 1
available

KomVision screen - Check 12 m visibility (PC300_11-K-K900-340-00-B)

Check that the view from operator's seat is correct according to the following procedure.
1. Set the marker A on the rear of machine as shown in the
figure.
(1): Center of swing
(2): Swing radius
(3): 2000 mm
(a): 345 mm
(b): 500 mm

2. Press the button F3 (4) to enlarge the screen [1]. Check

that the marker A does not disappear from KomVision
screen.
REMARK
Perform the camera calibration if the marker disappears by
referring to Testing and adjusting, “ADJUST KomVision
RELATED DEVICES, CAMERA CALIBRATION”.

HB365LC-3 30-283
ADJUST KomVision RELATED ITEMS 30 TESTING AND ADJUSTING

3. Check that the mark is correctly seen on the screen.

REMARK
Judge according to the figure.
OK: Marker is on the line.
NG: Marker is out of the line.

1) Check that the mark A is at position [2] (rear side) on

the reference line B.
REMARK
Perform camera calibration if the judgment result is
NG by referring to Testing and adjusting, “ADJUST
KomVision RELATED DEVICES, CAMERA CALIBRA-
TION”.

2) Swing the upper structure to the left so that the marker

A is displayed at position [3] (left side). Check that the
marker A is at position [3] (left side) on the reference
line.
REMARK
Perform camera calibration if the judgment result is
NG by referring to Testing and adjusting, “ADJUST
KomVision RELATED DEVICES, CAMERA CALIBRA-
TION”.

3) Check that the marker A comes to the position [4]

(right side) on the reference line according to the
same procedure.
REMARK
Perform camera calibration if the judgment result is
NG by referring to Testing and adjusting, “ADJUST
KomVision RELATED DEVICES, CAMERA CALIBRA-
TION”.

4. Install the marker B on the ground on a circumference of

12000 mm from the center of swing.
(5): Center of swing
(6): 12000 mm
(c): 1500 mm
(d): 1500 mm

30-284 HB365LC-3
30 TESTING AND ADJUSTING ADJUST KomVision RELATED ITEMS

5. Return the screen to the standard screen [5]. Check that

the marker B does not disappear from the screen.
REMARK
Perform the camera calibration if the marker disappears by
referring to Testing and adjusting, “ADJUST KomVision
RELATED DEVICES, CAMERA CALIBRATION”.

6. Check that the mark is correctly seen on the screen.

REMARK
Judge according to the figure.
OK: Marker is seen partially.
NG: Marker is not seen.

1) Check that the marker B is at position [6] (right side)

on the screen.
REMARK
Perform camera calibration if the judgment result is
NG by referring to Testing and adjusting, “ADJUST
KomVision RELATED DEVICES, CAMERA CALIBRA-
TION”.

2) Swing the upper structure to the left so that the marker

B is displayed at position [7] (left side). Check that the
marker A is at position [7] (left side) on the screen.
REMARK
Perform camera calibration if the judgment result is
NG by referring to Testing and adjusting, “ADJUST
KomVision RELATED DEVICES, CAMERA CALIBRA-
TION”.

3) Check that the marker B comes to position [8] (right

side) on the screen according to the same procedure.
REMARK
Perform camera calibration if the judgment result is
NG by referring to Testing and adjusting, “ADJUST
KomVision RELATED DEVICES, CAMERA CALIBRA-
TION”.

HB365LC-3 30-285
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 30 TESTING AND ADJUSTING

HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER (PC400_10-K-AP40-2A4-00-B)

NOTICE
• Before connecting the wiring harness connector, be sure to completely remove sand, dust, water,
etc., inside the connector on the controller side.
• Disconnecting or connecting work of the connector between the engine controller and the engine
must be performed only when the starting switch and battery disconnect switch are in OFF position.
• Even when you perform troubleshooting, do not start the engine while a T-adapter is inserted into or
connected to the connector between the engine controller and engine.
REMARK
You may turn the starting switch to OFF or ON position but do not turn it to START position. (Do not
start the engine).

30-286 HB365LC-3
30 TESTING AND ADJUSTING HANDLE BATTERY DISCONNECT SWITCH

HANDLE BATTERY DISCONNECT SWITCH (HB335_3-K-AW1P-2A4-00-B)

k A hazard can result if an unauthorized person turns the

battery disconnect switch (1) to ON position carelessly.
(O): OFF position
(I): ON position
• Battery disconnect switch (1) is usually used in the follow-
ing cases in the same purpose of disconnecting the cable
from the negative terminal of the battery.
• When storing the machine for a long period (1 month
or longer)
• When servicing or repairing the electrical system
• When performing electric welding
• When handling the battery
• When replacing the fuse, etc.
• When battery disconnect switch (1) is turned to OFF posi-
tion (the contact is opened), all the continuous power sup-
plies for the components including the starting switch B
terminal and controllers are all cut out. It is the same state
as the time when the battery is not connected, and all the
electrical system of the machine are out of operation.
NOTICE
When turning the battery disconnect switch (1) to OFF position, always remove the key.
• The operating condition of each controller can be checked with the system operating lamp (2) to prevent
the abnormal end of the disconnection of the battery power supply circuit while the controllers are in opera-
tion.
• Before shutting off the battery power supply circuit, turn the starting switch to OFF position, and check that
the system operating lamp (2) goes out, then turn the battery disconnect switch (1) to OFF position.
• If the battery disconnect switch (1) is turned to OFF position (battery power supply circuit is OFF) while the
system operating lamp (2) is lit, data loss error of controller may occur. Never operate the battery discon-
nect switch (1) while the system operating lamp (2) is lit.
• The system operating lamp (2) goes out in maximum 2 minutes after the starting switch is turned to OFF
position.
• The system operating lamp (2) may sometimes light up while the starting switch is turned to OFF position
because KOMTRAX terminal may maintain its communication under this condition.
• Even if the system operating lamp (2) is off, it may seem to be lighting slightly because of a very little cur-
rent inside the controller. This phenomenon does not indicate abnormality.
• The KOMTRAX terminal performs communication periodically during the starting switch is in OFF posi-
tion, thus it repeats starting and stopping.
• The start and stop cycle (sleep cycle) of KOMTRAX terminal varies depending on the factors including
the communication state and machine stop time. It may be lit for a maximum of approximately 1 hour.
• When you want to open the battery circuit for maintenance but the system operating lamp (2) is lit, turn the
starting switch to ON position once, turn it to OFF position, and then the lamp goes out in maximum 2 mi-
nutes. After system operating lamp (2) goes out, turn the battery disconnect switch (1) to OFF position im-
mediately.

HB365LC-3 30-287
TEST DIODES 30 TESTING AND ADJUSTING

TEST DIODES (PC400_10-P-E300-304-00-B)

Test the diode array (8-pin) and the single diode (2-pin) accord-
ing to the following procedure.
The continuity directions of the diode array are as shown in the
figure.
REMARK
The continuity direction of the single diode is indicated on the
surface of the diode.

METHOD FOR TESTING DIODE USING DIGITAL TESTER (PC400_10-P-E300-36J-10-B)

1. Select the screen to the diode range to check the dis-
played values.
REMARK
When an ordinary circuit multimeter is used, the voltage of
the internal battery is indicated.
2. Apply the red (+) lead of the multimeter to the anode (P)
side of the diode and apply the black (-) lead to the cath-
ode (N) side, and check the indicated value.
3. Evaluate the condition of the diode by the indicated value.
Indicated value does not change: No continuity (defective)
Indicated value changes: Continuity (normal) (*)
In the case of a silicon diode, a value in the range between 460 to 600 mV is indicated.

METHOD FOR TESTING DIODE USING ANALOG TESTER (PC400_10-P-E300-36J-20-B)

1. Selects the screen for resistance range.
2. Apply the red (+) lead of the multimeter to the anode (P) side of the diode and apply the black (-) lead to the
cathode (N) side, and check that the pointer moves.
3. Apply the red (+) lead of the multimeter to the cathode (N) side of the diode and apply the black (-) lead to
the anode (P) side, and check that the pointer moves.
4. Evaluate the condition of the diode by the movement of the pointer.
Result of movement of the pointer
Judgment
Step 2 Step 3
Normal (however, the movement of
the pointer (resistance) varies by type
Moves Does not move
of tester, or selection of measuring
range).
Moves Moves Defective (internal short circuit)
Does not move Does not move Defective (internal open circuit)

30-288 HB365LC-3
30 TESTING AND ADJUSTING Pm CLINIC SERVICE

Pm CLINIC (PC400_10-A-2160-001-00-B)

Pm CLINIC SERVICE (HB335_3-A-2160-209-10-B)

Machine model Serial No. Service meter

□ HB365LC-3 h
User name Date of inspection Inspector

SPECIFICATIONS
Main parts Attachment Shoe width
□ Boom, standard □ ( ) □ Breaker □ 600mm □()
□ Arm, standard □ ( ) □() □ 700mm
□ Bucket, standard □ ( ) □() □ 850mm
Check of oil and coolant levels
□ Radiator coolant When necessary
□ Engine oil □ Damper case oil □ Machinery case oil
□ Hydraulic oil □ Final drive case oil □()
Ambient temperature Altitude
°C m
Operator's comment

Result of visual inspection

Mechanic Sys Error Record Electric Sys Error Record

A900NR Times/First time h/Latest h Times/First time h/Latest h
A900N6 Times/First time h/Latest h Times/First time h/Latest h
A900NY Times/First time h/Latest h Times/First time h/Latest h
AA10NX Times/First time h/Latest h Times/First time h/Latest h
AB00KE Times/First time h/Latest h Times/First time h/Latest h
B@BAZG Times/First time h/Latest h Times/First time h/Latest h
B@BAZK Times/First time h/Latest h Times/First time h/Latest h
B@BCNS Times/First time h/Latest h Times/First time h/Latest h
B@BCZK Times/First time h/Latest h Times/First time h/Latest h
B@HANS Times/First time h/Latest h Times/First time h/Latest h
CA234 Times/First time h/Latest h Times/First time h/Latest h

HB365LC-3 30-289
Pm CLINIC SERVICE 30 TESTING AND ADJUSTING

Max. range of engine coolant temperature gauge

Coolant temperature Color of monitor light
Coolant temperature
gauge level (a)
6 105 °C
Red
5 102 °C
4 100 °C
3 85 °C Blue
2 60 °C
1 30 °C White

Max. range of hydraulic oil temperature gauge

Hydraulic oil temper- Color of monitor light
Oil temperature level
ature (a)
6 105 °C
Red
5 102 °C
4 100 °C
3 85 °C Blue
2 40 °C
1 20 °C White

Pm CLINIC CHECK SHEET:HB365LC-3 (HB335_3-A-2160-033-03-B)

HB365LC-3
k Perform the checks after warming up the engine sufficiently.
Machine model Serial number Service meter User name Date of inspection Inspector
HB365LC-3

30-290 HB365LC-3
30 TESTING AND ADJUSTING Pm CLINIC SERVICE

Engine
Machine model HB365LC-3
Engine SAA6D114E-6
Goo No
Standard
Meas- d good
value for Repair
Item Testing conditions Unit ured
new ma- limit
value
chine
• Engine coolant temperature: Working
60 to 100 °C mode: P 1096 to 1096 to
• Hydraulic oil temperature: 45 (Power 1236 1236
to 55 °C Mode)

Engine • Auto-deceleration switch:

speed at OFF
rpm
high idle • Swing lock switch: ON Working
(*1) mode: B Refer-
• Fuel control dial: MAX (High (1950) ence
idle) position (Breaker value
Mode)
• Work equipment control lev-
er, control pedal: NEUTRAL
position
• Engine coolant temperature: 60 to 100 °C
• Hydraulic oil temperature: 45 to 55 °C
Engine • Working mode: P (Power Mode)
speed at 650 to 650 to
• Swing lock switch: OFF rpm
low idle 750 750
(*1) • Fuel control dial: MIN (Low idle) position
• All control levers and control pedals in
NEUTRAL position
• Engine coolant temperature: 60 to 100 °C
• Hydraulic oil temperature: 45 to 55 °C
Engine • Working mode: P (Power Mode)
speed at 1280 to 1280 to
• Auto-deceleration switch: OFF rpm
2-pump 1480 1480
relief (*1) • Swing lock switch: OFF
• Fuel control dial: MAX (High idle) position
• Work equipment control: Arm IN relief
Engine
speed
when oil • Engine coolant temperature: 60 to 100 °C
pressure • Hydraulic oil temperature: 45 to 55 °C
of 2
pumps
• Working mode: P (Power Mode)
are re- • Auto-deceleration switch: OFF
1428 to 1428 to
lieved + • Swing lock switch: OFF rpm
1628 1628
One-
touch • Fuel control dial: MAX (High idle) position
power • Operation of work equipment: Relief the
maximiz- pressure at arm IN and actuate one-touch
ing is ac- power maximizing
tuated
(*1)

HB365LC-3 30-291
Pm CLINIC SERVICE 30 TESTING AND ADJUSTING

Machine model HB365LC-3

Engine SAA6D114E-6
Goo No
Standard
Meas- d good
value for Repair
Item Testing conditions Unit ured
new ma- limit
value
chine
• Engine coolant temperature: 60 to 100 °C
Engine • Hydraulic oil temperature: 45 to 55 °C
speed • Working mode: P (Power Mode)
when au-
• Auto-deceleration switch: ON 650 to 650 to
to-decel- rpm
• Swing lock switch: OFF 750 750
eration is
actuated • Fuel control dial: MAX (High idle) position
(*1)
• Work equipment control lever, control
pedal: NEUTRAL position
• Engine coolant tem- 0.34 to Min.
perature: 60 to 100 °C Fuel control dial: 0.59 0.21
MAX (High idle)
• Working mode: position {3.5 to {Min.
B(Breaker Mode) 6.0} 2.1}

Engine • Work equipment con-

trol lever, control ped- MPa
oil pres-
sure al: NEUTRAL position { kg/cm2} Min.
Fuel control dial: Min. 0.15 0.08
• Engine oil (*2) MIN (Low idle) po-
EO10W30-LA sition {Min. 1.5} {Min.
EO15W40-LA 0.8}
EOS5W30-LA
EOS5W40-LA
• Engine coolant temperature: 60 to 100 °C
• Hydraulic oil temperature: 45 to 55 °C
• Working mode: P (Power Mode)
Max. Max.
• Auto-deceleration switch: OFF kPa 1.96 2.94
Blowby
pressure • Swing lock switch: ON { mmH2O} {Max. {Max.
• Fuel control dial: MAX (High idle) position 200} 300}
• Operation of work equipment: Relief the
pressure at arm IN and actuate one-touch
power maximizing

*1: Item that can be checked in monitoring function on the machine monitor.
*2: KES diesel engine oil

30-292 HB365LC-3
30 TESTING AND ADJUSTING Pm CLINIC SERVICE

Work equipment speed

Machine model HB365LC-3
Engine SAA6D114E-6 No
Goo
goo
Standard val- Meas- d
d
Item Testing conditions Unit ue for new Repair limit ured val-
machine ue
• Hydraulic oil temperature: 45 to
55 °C
• Working mode: P (Power
Mode)
• Fuel control dial: MAX (High
idle) position
Boom • Time required for the boom to
be raised from the point the Sec. 3.3 to 4.1 Max. 4.5
RAISE
bucket is at the ground to the
boom RAISE stroke end (just
before cushion)
• Measuring posture: See “MA-
CHINE POSTURE AND PRO-
CEDURE FOR MEASURING
PERFORMANCE”, “Fig. 9”.
• Hydraulic oil temperature: 45 to
55 °C
• Working mode: P (Power
Mode)
• Fuel control dial: MAX (High
idle) position
Arm IN • Time required for the arm to be Sec. 3.4 to 4.2 Max. 4.4
operated from the arm OUT
stroke end (just before cush-
ion) to the arm IN stroke end
• Measuring posture: See “MA-
CHINE POSTURE AND PRO-
CEDURE FOR MEASURING
PERFORMANCE”, “Fig. 10”.
• Hydraulic oil temperature: 45 to
55 °C
• Working mode: P (Power
Mode)
• Fuel control dial: MAX (High
idle) position
Arm OUT • Time required for the arm to be Sec. 2.8 to 3.4 Max. 3.5
operated from the arm OUT
stroke end (just before cush-
ion) to the arm IN stroke end
• Measuring posture: See “MA-
CHINE POSTURE AND PRO-
CEDURE FOR MEASURING
PERFORMANCE”, “Fig. 10”.

HB365LC-3 30-293
Pm CLINIC SERVICE 30 TESTING AND ADJUSTING

Machine model HB365LC-3

Engine SAA6D114E-6 No
Goo
goo
Standard val- Meas- d
d
Item Testing conditions Unit ue for new Repair limit ured val-
machine ue
• Hydraulic oil temperature: 45 to
55 °C
• Working mode: P (Power
Mode)
• Fuel control dial: MAX (High
idle) position
Bucket
• Time required to operate the Sec. 2.9 to 3.5 Max. 3.8
CURL
bucket from the DUMP stroke
end to the CURL stroke end
• Measuring posture: See “MA-
CHINE POSTURE AND PRO-
CEDURE FOR MEASURING
PERFORMANCE”, “Fig. 11”.

Swing speed
Machine model HB365LC-3
Engine SAA6D114E-6 No
Goo
goo
Standard val- Meas- d
d
Item Testing conditions Unit ue for new Repair limit ured val-
machine ue
• Hydraulic oil temperature:
Swing RIGHT

45 to 55 °C
30.7 to 32.5 Max. 38
• Working mode: P (Power
Mode)
• Fuel control dial: MAX
Time re- (High idle) position
quired for • Time required to complete Sec.
swinging
Swing LEFT

5 swings after 1 swing

• Measuring posture: See 30.7 to 32.5 Max. 38
“MACHINE POSTURE
AND PROCEDURE FOR
MEASURING PERFORM-
ANCE”, “Fig. 2”.

30-294 HB365LC-3
30 TESTING AND ADJUSTING Pm CLINIC SERVICE

Travel speed
Machine model HB365LC-3
Engine SAA6D114E-6
Go No
Standard
Meas- od good
value for
Item Testing conditions Unit Repair limit ured val-
new ma-
ue
chine

Reverse Forward Reverse Forward Reverse Forward

• Hydraulic oil tempera-
ture: 45 to 55 °C
• Working mode:
B(Breaker Mode)
47.0 to 69.0 45.0 to 74.5
Lo
47.0 to 69.0 45.0 to 74.5

• Fuel control dial: MAX

(High idle) position
36.0 to 47.0 34.0 to 51.5
Travel • Time required to com-
speed (idle plete 5 idle turns of Mi Sec.
running) track off ground after 1
idle turn 36.0 to 47.0 34.0 to 51.5
• Measuring posture:
See “MACHINE POS-
TURE AND PROCE- 32.0 to 36.0 32.0 to 41.5
DURE FOR MEASUR-
ING PERFORMANCE”, Hi
“Fig. 4”.
32.0 to 36.0 32.0 to 41.5

HB365LC-3 30-295
Pm CLINIC SERVICE 30 TESTING AND ADJUSTING

Hydraulic drift of work equipment

Machine model HB365LC-3
Engine SAA6D114E-6 No
Goo
goo
Standard val- Meas- d
d
Item Testing conditions Unit ue for new Repair limit ured val-
machine ue
• Hydraulic oil temperature: 45 to
55 °C
• Level and flat ground
• Bucket filled up with dirt and
sand, or at the rated load
(21170 N {2160 kg} )
Whole work • Engine: Stopped
equipment
• Work equipment control lever,
(Hydraulic control pedal: NEUTRAL posi- mm Max. 450 Max. 675
drift meas- tion
ured at tooth
tip) • Hydraulic drift for 15 minutes,
measure it every 5 minutes
from immediately after initial
setting
• Measuring posture: See “MA-
CHINE POSTURE AND PRO-
CEDURE FOR MEASURING
PERFORMANCE”, “Fig. 8”.

30-296 HB365LC-3
30 TESTING AND ADJUSTING Pm CLINIC SERVICE

Hydraulic circuit
Machine model HB365LC-3
Engine SAA6D114E-6 No
Goo
goo
Standard val- Meas- d
d
Item Testing conditions Unit ue for new Repair limit ured val-
machine ue
• Hydraulic oil temperature: 45 to
55 °C
• Working mode: P (Power
Mode)
Control cir- MPa 3.04 to 3.44 2.84 to 3.43
• Auto-deceleration switch: OFF
cuit oil pres-
sure • Fuel control dial: MAX (High { kg/cm2} {31 to 35} {29 to 35}
idle) position
• Work equipment control lever,
control pedal: NEUTRAL posi-
tion
• Hydraulic oil temperature: 45 to
55 °C
• Working mode: P (Power
Mode)
Unload
pressure • Auto-deceleration switch: OFF
MPa 2.9 to 4.9 2.9 to 4.9
(pump outlet • Swing lock switch: OFF
pressure) { kg/cm2} {30 to 50} {30 to 50}
(*1)
• Fuel control dial: MAX (High
idle) position
• Work equipment control lever,
control pedal: NEUTRAL posi-
tion

HB365LC-3 30-297
Pm CLINIC SERVICE 30 TESTING AND ADJUSTING

Machine model HB365LC-3

Engine SAA6D114E-6 No
Goo
goo
Standard val- Meas- d
d
Item Testing conditions Unit ue for new Repair limit ured val-
machine ue
• Hydraulic oil temperature: 45 to
55 °C
• Working mode: P (Power
Mode)
33.42 to 33.15 to
• Auto-deceleration switch: OFF
36.07 36.77
• Swing lock switch: OFF
{341 to 368} {338 to 375}
• Fuel control dial: MAX (High
idle) position
• Work equipment control: Arm
IN relief
Work equip- (When one-touch power maximizing
ment (arm) function is actuated) MPa
relief pres- • Hydraulic oil temperature: 45 to { kg/cm2}
sure (*1) 55 °C
• Working mode: P (Power
Mode)
36.07 to
• Auto-deceleration switch: OFF 35.6 to 39.2
38.74
• Swing lock switch: OFF {363 to 400}
{368 to 395}
• Fuel control dial: MAX (High
idle) position
• Operation of work equipment:
Relief the pressure at arm IN
and actuate one-touch power
maximizing

30-298 HB365LC-3
30 TESTING AND ADJUSTING Pm CLINIC SERVICE

Machine model HB365LC-3

Engine SAA6D114E-6 No
Goo
goo
Standard val- Meas- d
d
Item Testing conditions Unit ue for new Repair limit ured val-
machine ue
• R.H.
Travel
locked
• Relief
the oil
pres- 36.32 to
35.6 to 40.7
sure at 40.24
{363 to 415}
• Hydraulic oil tem- right {370 to 410}
perature: 45 to FOR-
55 °C WARD
or RE-
• Working mode: P
VERS
Travel relief (Power Mode)
E MPa
pressure • Auto-deceleration
(*1) switch: OFF • L.H. { kg/cm2}
Travel
• Fuel control dial:
locked
MAX (High idle)
position • Relief
the oil
• Travel speed: Hi 36.28 to 35.60 to
pres-
sure at 40.21 40.70
left {370 to 410} {363 to 415}
FOR-
WARD
or RE-
VERS
E
• Hydraulic oil tem- Running
perature: 45 to L.H. track
55 °C idle off the 2.35 to 2.55 2.35 to 2.55
ground {24 to 26} {24 to 26}
• Working mode: P
(Power Mode) (Front
pump)
• Travel speed: Hi

LS differen- • Fuel control dial:

MAX (High idle) MPa
tial pressure
(*1) position Running { kg/cm2}
• Travel operation: R.H. track
Travel control lev- idle off the 2.35 to 2.55 2.35 to 2.55
ground {24 to 26} {24 to 26}
er: Half stroke
(Rear
• LS differential
pump)
pressure = Pump
discharge pres-
sure - LS pressure

HB365LC-3 30-299
Pm CLINIC SERVICE 30 TESTING AND ADJUSTING

Machine model HB365LC-3

Engine SAA6D114E-6 No
Goo
goo
Standard val- Meas- d
d
Item Testing conditions Unit ue for new Repair limit ured val-
machine ue
• Hydraulic oil tem- Front pump 33.42 to 33.15 to
perature: 45 to discharged 36.07 36.77
55 °C pressure {341 to 368} {338 to 375}
• Working mode: P Servo pis-
(Power Mode) Above value Above value
PC valve ton inlet
x approx. 0.6 x approx. 0.6
outlet pres- • Swing lock switch: pressure MPa
sure (servo ON 33.42 to 33.15 to
piston inlet
Rear pump { kg/cm2}
• Fuel control dial: discharged 36.07 36.77
pressure)
MAX (High idle) pressure {341 to 368} {338 to 375}
position
• Work equipment Servo pis-
Above value Above value
control: Arm IN re- ton inlet x approx. 0.6 x approx. 0.6
lief pressure

• Hydraulic oil tem- Approx. 1.74 Approx. 1.74

Fuel control {Approx. {Approx.
perature: 45 to
dial: MIN 17.7} 17.7}
55 °C
(Low idle)
PC-EPC • Working mode: P position (Reference (Reference
valve outlet (Power Mode) value) value)
MPa
pressure • Swing lock switch:
{ kg/cm2}
(Front OFF Fuel control Approx. 0.22 Approx. 0.22
pump) dial: MAX {Approx. 2.2} {Approx. 2.2}
• Work equipment
control lever, con- (High idle) (Reference (Reference
trol pedal: NEU- position value) value)
TRAL position
• Hydraulic oil tem- Approx. 1.74 Approx. 1.74
Fuel control {Approx. {Approx.
perature: 45 to
dial: MIN 17.7} 17.7}
55 °C
(Low idle)
• Working mode: P position (Reference (Reference
PC-EPC value) value)
(Power Mode)
valve outlet MPa
pressure • Swing lock switch:
{ kg/cm2}
(Rear pump)
OFF Fuel control Approx. 0.22 Approx. 0.22
• Work equipment dial: MAX {Approx. 2.2} {Approx. 2.2}
control lever, con- (High idle) (Reference (Reference
trol pedal: NEU- position value) value)
TRAL position
• Hydraulic oil tem- Approx. 1.45 Approx. 1.45
Travel
perature: 45 to {Approx. {Approx.
speed: Lo
55 °C 14.8} 14.8}
• Working mode:
Outlet pres- P(Power Mode) MPa
sure of LS-
EPC valve • Fuel control dial: { kg/cm2}
Travel
MAX (High idle) 0{0} 0{0}
speed: Hi
position
• Travel control:
Fine control

30-300 HB365LC-3
30 TESTING AND ADJUSTING Pm CLINIC SERVICE

*1: Item that can be checked in monitoring function on the machine monitor.

HB365LC-3 30-301
 40 TROUBLESHOOTING

HB365LC-3 40-1
CONTENTS 40 TROUBLESHOOTING

CONTENTS (ALL-A-0310-002-00-B)
ABBREVIATION LIST .................................................................................................................................. 40-15
RELATED INFORMATION ON TROUBLESHOOTING ................................................................................ 40-21
GENERAL TROUBLESHOOTING POINTS .......................................................................................... 40-21
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM................................................................. 40-23
SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................ 40-35
PRECAUTIONS FOR USING HYBRID SYSTEMS, TROUBLESHOOTING FOR HIGH-VOLTAGE EQUIP-
MENT ................................................................................................................................................ 40-37
TABLE OF SELF-DEFINE MONITORING ITEMS AND CHECK SHEET FOR HYBRID COMPONENTS........
.......................................................................................................................................................... 40-44
CHECKS BEFORE TROUBLESHOOTING ........................................................................................... 40-50
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING ............................................................ 40-52
WALK-AROUND CHECK............................................................................................................... 40-52
TESTING IN ACCORDANCE WITH TESTING PROCEDURE.............................................................. 40-54
CHECK FUEL LEVEL AND TYPE.................................................................................................. 40-54
CHECK IMPURE INGREDIENT IN FUEL ...................................................................................... 40-54
CHECK FUEL PREFILTER ............................................................................................................ 40-55
WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT.............................................. 40-55
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE...................................................... 40-56
CHECK MAIN FILTER ................................................................................................................... 40-59
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN)............................................................. 40-61
CHECK OIL LEVEL IN MOTOR-GENERATOR CASE ................................................................... 40-62
CHECK COOLANT LEVEL (RESERVOIR TANK) .......................................................................... 40-63
CHECK CLOGGING OF AIR CLEANER........................................................................................ 40-64
OUTER ELEMENT - CLEAN.......................................................................................................... 40-65
ELEMENTS - REPLACE ................................................................................................................ 40-67
CHECK HYDRAULIC OIL LEVEL .................................................................................................. 40-69
CHECK HYDRAULIC OIL STRAINER ........................................................................................... 40-70
CHECK HYDRAULIC FILTER ........................................................................................................ 40-70
CHECK CAPACITOR ..................................................................................................................... 40-72
CHECK OIL LEVEL IN ELECTRIC SWING MOTOR CASE ........................................................... 40-72
CHECK OIL LEVEL IN SWING MACHINERY CASE ..................................................................... 40-73
CHECK OIL LEVEL IN FINAL DRIVE CASE.................................................................................. 40-74
BLEED AIR FROM FUEL SYSTEM .............................................................................................. 40-75
BLEED AIR FROM HYDRAULIC SYSTEM .................................................................................... 40-75
METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod ....................................................... 40-75
AUTOMATIC GREASE SYSTEM .......................................................................................................... 40-80
FINDING MALFUNCTIONS ........................................................................................................... 40-80
MALFUNCTION FINDING PROCEDURES.................................................................................... 40-82
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM............................................ 40-84
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR ........................................ 40-84
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER ................................... 40-84
PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER....................................... 40-85
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL...................................... 40-85
PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER ................................ 40-85
PREPARATION FOR TROUBLESHOOTING OF INVERTER (HYBRID CONTROLLER) .............. 40-86
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH SPECIAL LOCK ... 40-86
PROCEDURE FOR TESTING AND TROUBLESHOOTING ................................................................. 40-90
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS .................................................... 40-93
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE........................................................... 40-97
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR
SYSTEM ........................................................................................................................................... 40-99
CONNECTOR LIST AND LAYOUT ......................................................................................................40-102
CONNECTOR CONTACT IDENTIFICATION .......................................................................................40-116
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE .........................................................................40-156
FUSE LOCATION TABLE ....................................................................................................................40-162
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC).................................40-164

40-2 HB365LC-3
40 TROUBLESHOOTING CONTENTS

PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883]

AND [CA3135]).................................................................................................................................40-168
FAILURE CODES TABLE ....................................................................................................................40-170
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) ............................................................40-191
FAILURE CODE [879AKA]...................................................................................................................40-191
FAILURE CODE [879AKB]...................................................................................................................40-192
FAILURE CODE [879BKA]...................................................................................................................40-193
FAILURE CODE [879BKB]...................................................................................................................40-195
FAILURE CODE [879CKA]...................................................................................................................40-197
FAILURE CODE [879CKB]...................................................................................................................40-198
FAILURE CODE [879DKZ]...................................................................................................................40-199
FAILURE CODE [879EMC] ..................................................................................................................40-201
FAILURE CODE [879FMC] ..................................................................................................................40-202
FAILURE CODE [879GKX] ..................................................................................................................40-203
FAILURE CODE [989L00] ....................................................................................................................40-205
FAILURE CODE [989M00] ...................................................................................................................40-206
FAILURE CODE [989N00] ...................................................................................................................40-207
FAILURE CODE [A1U0N3] ..................................................................................................................40-208
FAILURE CODE [A1U0N4] ..................................................................................................................40-210
FAILURE CODE [A900FR]...................................................................................................................40-212
FAILURE CODE [A900N6] ...................................................................................................................40-213
FAILURE CODE [A900NY]...................................................................................................................40-214
FAILURE CODE [AA10NX] ..................................................................................................................40-215
FAILURE CODE [AB00KE] ..................................................................................................................40-217
FAILURE CODE [AQ10N3] ..................................................................................................................40-219
FAILURE CODE [AS00N3]...................................................................................................................40-221
FAILURE CODE [AS00R2]...................................................................................................................40-223
FAILURE CODE [AS00R3]...................................................................................................................40-224
FAILURE CODE [AS00R4]...................................................................................................................40-225
FAILURE CODE [AS00R5]...................................................................................................................40-226
FAILURE CODE [AS00R6]...................................................................................................................40-227
FAILURE CODE [AS00ZK]...................................................................................................................40-228
FAILURE CODE [AS10KM]..................................................................................................................40-229
FAILURE CODE [AS10NR] ..................................................................................................................40-230
FAILURE CODE [AS10NT] ..................................................................................................................40-231
FAILURE CODE [B@BAZG] ................................................................................................................40-232
FAILURE CODE [B@BAZK].................................................................................................................40-233
FAILURE CODE [B@BCNS] ................................................................................................................40-235
FAILURE CODE [B@BCZK] ................................................................................................................40-236
FAILURE CODE [B@HANS] ................................................................................................................40-237
FAILURE CODE [CA115] .....................................................................................................................40-238
FAILURE CODE [CA122] .....................................................................................................................40-239
FAILURE CODE [CA123] .....................................................................................................................40-241
FAILURE CODE [CA131] .....................................................................................................................40-243
FAILURE CODE [CA132] .....................................................................................................................40-245
FAILURE CODE [CA144] .....................................................................................................................40-247
FAILURE CODE [CA145] .....................................................................................................................40-249
FAILURE CODE [CA153] .....................................................................................................................40-251
FAILURE CODE [CA154] .....................................................................................................................40-254
FAILURE CODE [CA187] .....................................................................................................................40-257
FAILURE CODE [CA221] .....................................................................................................................40-259
FAILURE CODE [CA222] .....................................................................................................................40-261
FAILURE CODE [CA227] .....................................................................................................................40-263
FAILURE CODE [CA234] .....................................................................................................................40-264
FAILURE CODE [CA238] .....................................................................................................................40-265
FAILURE CODE [CA239] .....................................................................................................................40-267
FAILURE CODE [CA249] .....................................................................................................................40-269
FAILURE CODE [CA256] .....................................................................................................................40-271

HB365LC-3 40-3
CONTENTS 40 TROUBLESHOOTING

FAILURE CODE [CA271] .....................................................................................................................40-273

FAILURE CODE [CA272] .....................................................................................................................40-275
FAILURE CODE [CA281] .....................................................................................................................40-277
FAILURE CODE [CA322] .....................................................................................................................40-278
FAILURE CODE [CA323] .....................................................................................................................40-280
FAILURE CODE [CA324] .....................................................................................................................40-282
FAILURE CODE [CA325] .....................................................................................................................40-284
FAILURE CODE [CA331] .....................................................................................................................40-286
FAILURE CODE [CA332] .....................................................................................................................40-288
FAILURE CODE [CA343] .....................................................................................................................40-290
FAILURE CODE [CA351] .....................................................................................................................40-291
FAILURE CODE [CA352] .....................................................................................................................40-292
FAILURE CODE [CA356] .....................................................................................................................40-295
FAILURE CODE [CA357] .....................................................................................................................40-297
FAILURE CODE [CA386] .....................................................................................................................40-299
FAILURE CODE [CA428] .....................................................................................................................40-300
FAILURE CODE [CA429] .....................................................................................................................40-302
FAILURE CODE [CA435] .....................................................................................................................40-304
FAILURE CODE [CA441] .....................................................................................................................40-306
FAILURE CODE [CA442] .....................................................................................................................40-308
FAILURE CODE [CA449] .....................................................................................................................40-309
FAILURE CODE [CA451] .....................................................................................................................40-312
FAILURE CODE [CA452] .....................................................................................................................40-315
FAILURE CODE [CA488] .....................................................................................................................40-317
FAILURE CODE [CA515] .....................................................................................................................40-318
FAILURE CODE [CA516] .....................................................................................................................40-320
FAILURE CODE [CA553] .....................................................................................................................40-322
FAILURE CODE [CA555] .....................................................................................................................40-323
FAILURE CODE [CA556] .....................................................................................................................40-324
FAILURE CODE [CA559] .....................................................................................................................40-325
FAILURE CODE [CA595] .....................................................................................................................40-329
FAILURE CODE [CA687] .....................................................................................................................40-330
FAILURE CODE [CA689] .....................................................................................................................40-332
FAILURE CODE [CA691] .....................................................................................................................40-337
FAILURE CODE [CA692] .....................................................................................................................40-339
FAILURE CODE [CA697] .....................................................................................................................40-341
FAILURE CODE [CA698] .....................................................................................................................40-342
FAILURE CODE [CA731] .....................................................................................................................40-343
FAILURE CODE [CA778] .....................................................................................................................40-345
FAILURE CODE [CA1117] ...................................................................................................................40-350
FAILURE CODE [CA1664] ...................................................................................................................40-351
FAILURE CODE [CA1669] ...................................................................................................................40-353
FAILURE CODE [CA1673] ...................................................................................................................40-354
FAILURE CODE [CA1677] ...................................................................................................................40-355
FAILURE CODE [CA1678] ...................................................................................................................40-356
FAILURE CODE [CA1682] ...................................................................................................................40-357
FAILURE CODE [CA1683] ...................................................................................................................40-359
FAILURE CODE [CA1684] ...................................................................................................................40-361
FAILURE CODE [CA1686] ...................................................................................................................40-363
FAILURE CODE [CA1691] ...................................................................................................................40-364
FAILURE CODE [CA1694] ...................................................................................................................40-367
FAILURE CODE [CA1695] ...................................................................................................................40-370
FAILURE CODE [CA1696] ...................................................................................................................40-371
FAILURE CODE [CA1712] ...................................................................................................................40-373
FAILURE CODE [CA1713] ...................................................................................................................40-376
FAILURE CODE [CA1714] ...................................................................................................................40-378
FAILURE CODE [CA1715] ...................................................................................................................40-379
FAILURE CODE [CA1776] ...................................................................................................................40-380

40-4 HB365LC-3
40 TROUBLESHOOTING CONTENTS

FAILURE CODE [CA1777] ...................................................................................................................40-383

FAILURE CODE [CA1843] ...................................................................................................................40-386
FAILURE CODE [CA1844] ...................................................................................................................40-388
FAILURE CODE [CA1879] ...................................................................................................................40-390
FAILURE CODE [CA1881] ...................................................................................................................40-393
FAILURE CODE [CA1883] ...................................................................................................................40-395
FAILURE CODE [CA1885] ...................................................................................................................40-398
FAILURE CODE [CA1887] ...................................................................................................................40-400
FAILURE CODE [CA1921] ...................................................................................................................40-402
FAILURE CODE [CA1922] ...................................................................................................................40-405
FAILURE CODE [CA1942] ...................................................................................................................40-410
FAILURE CODE [CA1993] ...................................................................................................................40-411
FAILURE CODE [CA2185] ...................................................................................................................40-414
FAILURE CODE [CA2186] ...................................................................................................................40-415
FAILURE CODE [CA2249] ...................................................................................................................40-417
FAILURE CODE [CA2265] ...................................................................................................................40-418
FAILURE CODE [CA2266] ...................................................................................................................40-420
FAILURE CODE [CA2271] ...................................................................................................................40-422
FAILURE CODE [CA2272] ...................................................................................................................40-424
FAILURE CODE [CA2288] ...................................................................................................................40-427
FAILURE CODE [CA2311] ...................................................................................................................40-428
FAILURE CODE [CA2349] ...................................................................................................................40-429
FAILURE CODE [CA2353] ...................................................................................................................40-432
FAILURE CODE [CA2357] ...................................................................................................................40-434
FAILURE CODE [CA2381] ...................................................................................................................40-435
FAILURE CODE [CA2382] ...................................................................................................................40-437
FAILURE CODE [CA2383] ...................................................................................................................40-440
FAILURE CODE [CA2386] ...................................................................................................................40-443
FAILURE CODE [CA2387] ...................................................................................................................40-445
FAILURE CODE [CA2555] ...................................................................................................................40-446
FAILURE CODE [CA2556] ...................................................................................................................40-449
FAILURE CODE [CA2637] ...................................................................................................................40-452
FAILURE CODE [CA2639] ...................................................................................................................40-454
FAILURE CODE [CA2771] ...................................................................................................................40-457
FAILURE CODE [CA2777] ...................................................................................................................40-463
FAILURE CODE [CA2976] ...................................................................................................................40-466
FAILURE CODE [CA3133] ...................................................................................................................40-468
FAILURE CODE [CA3134] ...................................................................................................................40-470
FAILURE CODE [CA3135] ...................................................................................................................40-472
FAILURE CODE [CA3142] ...................................................................................................................40-475
FAILURE CODE [CA3143] ...................................................................................................................40-476
FAILURE CODE [CA3144] ...................................................................................................................40-477
FAILURE CODE [CA3146] ...................................................................................................................40-479
FAILURE CODE [CA3147] ...................................................................................................................40-480
FAILURE CODE [CA3148] ...................................................................................................................40-481
FAILURE CODE [CA3151] ...................................................................................................................40-483
FAILURE CODE [CA3165] ...................................................................................................................40-489
FAILURE CODE [CA3229] ...................................................................................................................40-491
FAILURE CODE [CA3231] ...................................................................................................................40-493
FAILURE CODE [CA3232] ...................................................................................................................40-495
FAILURE CODE [CA3235] ...................................................................................................................40-499
FAILURE CODE [CA3239] ...................................................................................................................40-501
FAILURE CODE [CA3241] ...................................................................................................................40-504
FAILURE CODE [CA3242] ...................................................................................................................40-507
FAILURE CODE [CA3251] ...................................................................................................................40-510
FAILURE CODE [CA3253] ...................................................................................................................40-512
FAILURE CODE [CA3254] ...................................................................................................................40-515
FAILURE CODE [CA3255] ...................................................................................................................40-518

HB365LC-3 40-5
CONTENTS 40 TROUBLESHOOTING

FAILURE CODE [CA3256] ...................................................................................................................40-522

FAILURE CODE [CA3311] ...................................................................................................................40-524
FAILURE CODE [CA3312] ...................................................................................................................40-526
FAILURE CODE [CA3313] ...................................................................................................................40-529
FAILURE CODE [CA3314] ...................................................................................................................40-530
FAILURE CODE [CA3315] ...................................................................................................................40-531
FAILURE CODE [CA3316] ...................................................................................................................40-533
FAILURE CODE [CA3317] ...................................................................................................................40-534
FAILURE CODE [CA3318] ...................................................................................................................40-535
FAILURE CODE [CA3319] ...................................................................................................................40-537
FAILURE CODE [CA3321] ...................................................................................................................40-538
FAILURE CODE [CA3322] ...................................................................................................................40-540
FAILURE CODE [CA3419] ...................................................................................................................40-542
FAILURE CODE [CA3421] ...................................................................................................................40-544
FAILURE CODE [CA3497] ...................................................................................................................40-546
FAILURE CODE [CA3498] ...................................................................................................................40-547
FAILURE CODE [CA3543] ...................................................................................................................40-548
FAILURE CODE [CA3545] ...................................................................................................................40-554
FAILURE CODE [CA3547] ...................................................................................................................40-556
FAILURE CODE [CA3558] ...................................................................................................................40-557
FAILURE CODE [CA3559] ...................................................................................................................40-559
FAILURE CODE [CA3562] ...................................................................................................................40-561
FAILURE CODE [CA3563] ...................................................................................................................40-563
FAILURE CODE [CA3567] ...................................................................................................................40-566
FAILURE CODE [CA3568] ...................................................................................................................40-569
FAILURE CODE [CA3571] ...................................................................................................................40-573
FAILURE CODE [CA3572] ...................................................................................................................40-575
FAILURE CODE [CA3574] ...................................................................................................................40-577
FAILURE CODE [CA3575] ...................................................................................................................40-579
FAILURE CODE [CA3577] ...................................................................................................................40-581
FAILURE CODE [CA3578] ...................................................................................................................40-583
FAILURE CODE [CA3582] ...................................................................................................................40-585
FAILURE CODE [CA3583] ...................................................................................................................40-591
FAILURE CODE [CA3596] ...................................................................................................................40-593
FAILURE CODE [CA3649] ...................................................................................................................40-596
FAILURE CODE [CA3681] ...................................................................................................................40-598
FAILURE CODE [CA3682] ...................................................................................................................40-603
FAILURE CODE [CA3713] ...................................................................................................................40-608
FAILURE CODE [CA3717] ...................................................................................................................40-611
FAILURE CODE [CA3718] ...................................................................................................................40-612
FAILURE CODE [CA3725] ...................................................................................................................40-613
FAILURE CODE [CA3741] ...................................................................................................................40-616
FAILURE CODE [CA3748] ...................................................................................................................40-617
FAILURE CODE [CA3751] ...................................................................................................................40-620
FAILURE CODE [CA3755] ...................................................................................................................40-622
FAILURE CODE [CA3866] ...................................................................................................................40-624
FAILURE CODE [CA3867] ...................................................................................................................40-628
FAILURE CODE [CA3868] ...................................................................................................................40-631
FAILURE CODE [CA3899] ...................................................................................................................40-635
FAILURE CODE [CA3911] ...................................................................................................................40-637
FAILURE CODE [CA3912] ...................................................................................................................40-641
FAILURE CODE [CA3932] ...................................................................................................................40-643
FAILURE CODE [CA3933] ...................................................................................................................40-645
FAILURE CODE [CA3934] ...................................................................................................................40-647
FAILURE CODE [CA3935] ...................................................................................................................40-650
FAILURE CODE [CA3936] ...................................................................................................................40-652
FAILURE CODE [CA4151] ...................................................................................................................40-654
FAILURE CODE [CA4152] ...................................................................................................................40-658

40-6 HB365LC-3
40 TROUBLESHOOTING CONTENTS

FAILURE CODE [CA4155] ...................................................................................................................40-662

FAILURE CODE [CA4156] ...................................................................................................................40-664
FAILURE CODE [CA4157] ...................................................................................................................40-667
FAILURE CODE [CA4158] ...................................................................................................................40-669
FAILURE CODE [CA4159] ...................................................................................................................40-670
FAILURE CODE [CA4161] ...................................................................................................................40-671
FAILURE CODE [CA4162] ...................................................................................................................40-674
FAILURE CODE [CA4163] ...................................................................................................................40-677
FAILURE CODE [CA4164] ...................................................................................................................40-679
FAILURE CODE [CA4165] ...................................................................................................................40-681
FAILURE CODE [CA4166] ...................................................................................................................40-683
FAILURE CODE [CA4168] ...................................................................................................................40-685
FAILURE CODE [CA4169] ...................................................................................................................40-688
FAILURE CODE [CA4171] ...................................................................................................................40-690
FAILURE CODE [CA4249] ...................................................................................................................40-693
FAILURE CODE [CA4251] ...................................................................................................................40-695
FAILURE CODE [CA4259] ...................................................................................................................40-697
FAILURE CODE [CA4261] ...................................................................................................................40-700
FAILURE CODE [CA4277] ...................................................................................................................40-703
FAILURE CODE [CA4281] ...................................................................................................................40-707
FAILURE CODE [CA4459] ...................................................................................................................40-711
FAILURE CODE [CA4461] ...................................................................................................................40-714
FAILURE CODE [CA4658] ...................................................................................................................40-717
FAILURE CODE [CA4731] ...................................................................................................................40-721
FAILURE CODE [CA4732] ...................................................................................................................40-722
FAILURE CODE [CA4739] ...................................................................................................................40-723
FAILURE CODE [CA4768] ...................................................................................................................40-724
FAILURE CODE [CA4769] ...................................................................................................................40-726
FAILURE CODE [CA4842] ...................................................................................................................40-728
FAILURE CODE [CA4952] ...................................................................................................................40-732
FAILURE CODE [CA5115] ...................................................................................................................40-734
FAILURE CODE [CA5179] ...................................................................................................................40-737
FAILURE CODE [CA5181] ...................................................................................................................40-739
FAILURE CODE [CA5383] ...................................................................................................................40-741
FAILURE CODE [D110KB]...................................................................................................................40-743
FAILURE CODE [D19JKZ] ...................................................................................................................40-745
FAILURE CODE [D811MC] ..................................................................................................................40-748
FAILURE CODE [D862KA]...................................................................................................................40-749
FAILURE CODE [D8ALKA] ..................................................................................................................40-750
FAILURE CODE [D8ALKB] ..................................................................................................................40-752
FAILURE CODE [D8AQKR] .................................................................................................................40-754
FAILURE CODE [DA20MC] .................................................................................................................40-759
FAILURE CODE [DA22KK] ..................................................................................................................40-760
FAILURE CODE [DA25KP] ..................................................................................................................40-763
FAILURE CODE [DA26KP] ..................................................................................................................40-765
FAILURE CODE [DA29KQ]..................................................................................................................40-768
FAILURE CODE [DA2LKA] ..................................................................................................................40-770
FAILURE CODE [DA2LKB] ..................................................................................................................40-772
FAILURE CODE [DA2QKR] .................................................................................................................40-774
FAILURE CODE [DA2RKR] .................................................................................................................40-779
FAILURE CODE [DAF0KM] .................................................................................................................40-784
FAILURE CODE [DAF0MB] .................................................................................................................40-785
FAILURE CODE [DAF0MC] .................................................................................................................40-786
FAILURE CODE [DAF8KB] ..................................................................................................................40-787
FAILURE CODE [DAF9KQ]..................................................................................................................40-789
FAILURE CODE [DAFGMC] ................................................................................................................40-790
FAILURE CODE [DAFLKA] ..................................................................................................................40-791
FAILURE CODE [DAFLKB] ..................................................................................................................40-793

HB365LC-3 40-7
CONTENTS 40 TROUBLESHOOTING

FAILURE CODE [DAFQKR] .................................................................................................................40-795

FAILURE CODE [DAZ9KQ]..................................................................................................................40-799
FAILURE CODE [DAZQKR] .................................................................................................................40-800
FAILURE CODE [DB2QKR] .................................................................................................................40-804
FAILURE CODE [DB2RKR] .................................................................................................................40-809
FAILURE CODE [DBP0KM] .................................................................................................................40-814
FAILURE CODE [DBP0KT] ..................................................................................................................40-815
FAILURE CODE [DBPQKR].................................................................................................................40-816
FAILURE CODE [DDNRKA].................................................................................................................40-821
FAILURE CODE [DDNRKY].................................................................................................................40-823
FAILURE CODE [DDNS00]..................................................................................................................40-825
FAILURE CODE [DGH2KA] .................................................................................................................40-827
FAILURE CODE [DGH2KB] .................................................................................................................40-829
FAILURE CODE [DHA4KA]..................................................................................................................40-831
FAILURE CODE [DHAAMA].................................................................................................................40-833
FAILURE CODE [DHACMA] ................................................................................................................40-835
FAILURE CODE [DHPAMA].................................................................................................................40-837
FAILURE CODE [DHPBMA].................................................................................................................40-839
FAILURE CODE [DHS3MA] .................................................................................................................40-841
FAILURE CODE [DHS4MA] .................................................................................................................40-843
FAILURE CODE [DHS8MA] .................................................................................................................40-845
FAILURE CODE [DHS9MA] .................................................................................................................40-847
FAILURE CODE [DHSAKZ] .................................................................................................................40-849
FAILURE CODE [DHSBKZ] .................................................................................................................40-851
FAILURE CODE [DHSCMA] ................................................................................................................40-853
FAILURE CODE [DHSDMA] ................................................................................................................40-855
FAILURE CODE [DHSFMA].................................................................................................................40-857
FAILURE CODE [DHSGMA] ................................................................................................................40-859
FAILURE CODE [DHSHMA] ................................................................................................................40-861
FAILURE CODE [DHSJMA] .................................................................................................................40-863
FAILURE CODE [DHVAKZ]..................................................................................................................40-865
FAILURE CODE [DHVAL8] ..................................................................................................................40-867
FAILURE CODE [DHVAMA] .................................................................................................................40-869
FAILURE CODE [DHVBKZ] .................................................................................................................40-870
FAILURE CODE [DHVBL8] ..................................................................................................................40-872
FAILURE CODE [DHVBMA].................................................................................................................40-874
FAILURE CODE [DKR0MA] .................................................................................................................40-875
FAILURE CODE [DKR1MA] .................................................................................................................40-877
FAILURE CODE [DKULKA]..................................................................................................................40-879
FAILURE CODE [DKULKB]..................................................................................................................40-881
FAILURE CODE [DKULKY]..................................................................................................................40-883
FAILURE CODE [DLM5KA]..................................................................................................................40-884
FAILURE CODE [DLM5MB] .................................................................................................................40-886
FAILURE CODE [DR10KA] ..................................................................................................................40-888
FAILURE CODE [DR21KX] ..................................................................................................................40-891
FAILURE CODE [DUMBKA].................................................................................................................40-893
FAILURE CODE [DUMBKB].................................................................................................................40-895
FAILURE CODE [DV20KB] ..................................................................................................................40-897
FAILURE CODE [DW43KA] .................................................................................................................40-899
FAILURE CODE [DW43KB] .................................................................................................................40-901
FAILURE CODE [DW43KY] .................................................................................................................40-902
FAILURE CODE [DW45KA] .................................................................................................................40-903
FAILURE CODE [DW45KB] .................................................................................................................40-906
FAILURE CODE [DW45KK] .................................................................................................................40-909
FAILURE CODE [DW45KY] .................................................................................................................40-911
FAILURE CODE [DW4CKY].................................................................................................................40-913
FAILURE CODE [DW91KA] .................................................................................................................40-914
FAILURE CODE [DW91KB] .................................................................................................................40-916

40-8 HB365LC-3
40 TROUBLESHOOTING CONTENTS

FAILURE CODE [DW91KY] .................................................................................................................40-917

FAILURE CODE [DWA2KA] .................................................................................................................40-918
FAILURE CODE [DWA2KB] .................................................................................................................40-920
FAILURE CODE [DWA2KY] .................................................................................................................40-921
FAILURE CODE [DWK0KA].................................................................................................................40-922
FAILURE CODE [DWK0KB].................................................................................................................40-924
FAILURE CODE [DWK0KY].................................................................................................................40-926
FAILURE CODE [DWK2KA].................................................................................................................40-927
FAILURE CODE [DWK2KB].................................................................................................................40-929
FAILURE CODE [DWK2KY].................................................................................................................40-931
FAILURE CODE [DWN5KA].................................................................................................................40-932
FAILURE CODE [DWN5KB].................................................................................................................40-934
FAILURE CODE [DWN5KY].................................................................................................................40-935
FAILURE CODE [DXA8KA]..................................................................................................................40-936
FAILURE CODE [DXA8KB]..................................................................................................................40-939
FAILURE CODE [DXA9KA]..................................................................................................................40-941
FAILURE CODE [DXA9KB]..................................................................................................................40-944
FAILURE CODE [DXE0KA]..................................................................................................................40-946
FAILURE CODE [DXE0KB]..................................................................................................................40-948
FAILURE CODE [DXE4KA]..................................................................................................................40-949
FAILURE CODE [DXE4KB]..................................................................................................................40-951
FAILURE CODE [DXE4KY]..................................................................................................................40-952
FAILURE CODE [DXE5KA]..................................................................................................................40-953
FAILURE CODE [DXE5KB]..................................................................................................................40-955
FAILURE CODE [DXE6KA]..................................................................................................................40-957
FAILURE CODE [DXE6KB]..................................................................................................................40-959
FAILURE CODE [DXE7KA]..................................................................................................................40-961
FAILURE CODE [DXE7KB]..................................................................................................................40-963
FAILURE CODE [DXE7KY]..................................................................................................................40-965
FAILURE CODE [DXE8KA]..................................................................................................................40-967
FAILURE CODE [DXE8KB]..................................................................................................................40-969
FAILURE CODE [DXE8KY]..................................................................................................................40-971
FAILURE CODE [DXE9KA]..................................................................................................................40-973
FAILURE CODE [DXE9KB]..................................................................................................................40-975
FAILURE CODE [DXE9KY]..................................................................................................................40-977
FAILURE CODE [DXEAKA] .................................................................................................................40-979
FAILURE CODE [DXEAKB] .................................................................................................................40-981
FAILURE CODE [DXEAKY] .................................................................................................................40-983
FAILURE CODE [DY20KA] ..................................................................................................................40-985
FAILURE CODE [DY20MA]..................................................................................................................40-987
FAILURE CODE [DY2CKB]..................................................................................................................40-989
FAILURE CODE [DY2DKB]..................................................................................................................40-991
FAILURE CODE [DY2EKB]..................................................................................................................40-993
FAILURE CODE [GA00NS]..................................................................................................................40-995
FAILURE CODE [GA01KA] ..................................................................................................................40-996
FAILURE CODE [GA02KZ] ..................................................................................................................40-998
FAILURE CODE [GA04KG]................................................................................................................40-1001
FAILURE CODE [GA05KG]................................................................................................................40-1004
FAILURE CODE [GA05KP] ................................................................................................................40-1007
FAILURE CODE [GA06KZ] ................................................................................................................40-1010
FAILURE CODE [GA08KG]................................................................................................................40-1011
FAILURE CODE [GA09KG]................................................................................................................40-1019
FAILURE CODE [GA09KP] ................................................................................................................40-1027
FAILURE CODE [GA0AKZ]................................................................................................................40-1028
FAILURE CODE [GA0BKZ]................................................................................................................40-1029
FAILURE CODE [GA10MA] ...............................................................................................................40-1036
FAILURE CODE [GA10MC] ...............................................................................................................40-1043
FAILURE CODE [GA12NK]................................................................................................................40-1044

HB365LC-3 40-9
CONTENTS 40 TROUBLESHOOTING

FAILURE CODE [GA13KP] ................................................................................................................40-1050

FAILURE CODE [GA13KY] ................................................................................................................40-1052
FAILURE CODE [GA15KZ] ................................................................................................................40-1054
FAILURE CODE [GA17KR]................................................................................................................40-1062
FAILURE CODE [GA17MB] ...............................................................................................................40-1063
FAILURE CODE [GA18MC] ...............................................................................................................40-1064
FAILURE CODE [GA19KR]................................................................................................................40-1069
FAILURE CODE [GA19KT] ................................................................................................................40-1070
FAILURE CODE [GA1BMA] ...............................................................................................................40-1071
FAILURE CODE [GA1FKR]................................................................................................................40-1073
FAILURE CODE [GA1FMA] ...............................................................................................................40-1074
FAILURE CODE [GA1GKR] ...............................................................................................................40-1077
FAILURE CODE [GA1GKT] ...............................................................................................................40-1078
FAILURE CODE [GA1GMB]...............................................................................................................40-1079
FAILURE CODE [GA1HKZ]................................................................................................................40-1080
FAILURE CODE [GA1JKZ] ................................................................................................................40-1081
FAILURE CODE [GA1KKZ]................................................................................................................40-1082
FAILURE CODE [GA1LKZ] ................................................................................................................40-1083
FAILURE CODE [GA1MKZ] ...............................................................................................................40-1084
FAILURE CODE [GA1NNS] ...............................................................................................................40-1085
FAILURE CODE [GA1SFS]................................................................................................................40-1086
FAILURE CODE [GA1SMC]...............................................................................................................40-1087
FAILURE CODE [GA1TKP]................................................................................................................40-1088
FAILURE CODE [GA1TNS]................................................................................................................40-1091
FAILURE CODE [GA1UKZ]................................................................................................................40-1094
FAILURE CODE [GA1VFS]................................................................................................................40-1097
FAILURE CODE [GA1VMC]...............................................................................................................40-1098
FAILURE CODE [GA1XKZ]................................................................................................................40-1099
FAILURE CODE [GA1YNS] ...............................................................................................................40-1100
FAILURE CODE [GA1ZKZ] ................................................................................................................40-1101
FAILURE CODE [GA1ZNS]................................................................................................................40-1102
FAILURE CODE [GA22NS]................................................................................................................40-1103
FAILURE CODE [GA23KZ] ................................................................................................................40-1104
FAILURE CODE [GA24KZ] ................................................................................................................40-1105
FAILURE CODE [GA25MA] ...............................................................................................................40-1106
FAILURE CODE [GA25NS]................................................................................................................ 40-1110
FAILURE CODE [GA26MA] ............................................................................................................... 40-1111
FAILURE CODE [GA26NS]................................................................................................................ 40-1115
FAILURE CODE [GA27KZ] ................................................................................................................ 40-1116
FAILURE CODE [GA2QKR] ............................................................................................................... 40-1117
FAILURE CODE [GA2RKR] ...............................................................................................................40-1122
FAILURE CODE [GA60MC] ...............................................................................................................40-1127
FAILURE CODE [GA60N1] ................................................................................................................40-1129
FAILURE CODE [GA61KZ] ................................................................................................................40-1131
FAILURE CODE [GA61NS]................................................................................................................40-1133
FAILURE CODE [GA62KY] ................................................................................................................40-1134
FAILURE CODE [GA62KZ] ................................................................................................................40-1139
FAILURE CODE [GA62MA] ...............................................................................................................40-1143
FAILURE CODE [GA63KY] ................................................................................................................40-1144
FAILURE CODE [GA63KZ] ................................................................................................................40-1149
FAILURE CODE [GA63MA] ...............................................................................................................40-1153
FAILURE CODE [GA64KY] ................................................................................................................40-1154
FAILURE CODE [GA64KZ] ................................................................................................................40-1159
FAILURE CODE [GA64MA] ...............................................................................................................40-1163
FAILURE CODE [GA70KB] ................................................................................................................40-1164
FAILURE CODE [GA70MD] ...............................................................................................................40-1167
FAILURE CODE [GA70NS]................................................................................................................40-1169
FAILURE CODE [GA71KZ] ................................................................................................................40-1170

40-10 HB365LC-3
40 TROUBLESHOOTING CONTENTS

FAILURE CODE [GA72MA] ...............................................................................................................40-1172

FAILURE CODE [GA72MC] ...............................................................................................................40-1174
FAILURE CODE [GA81KZ] ................................................................................................................40-1176
FAILURE CODE [GAA0KB]................................................................................................................40-1179
FAILURE CODE [GAA2KB]................................................................................................................40-1181
FAILURE CODE [GAA6KP]................................................................................................................40-1183
FAILURE CODE [GAA6KY]................................................................................................................40-1185
FAILURE CODE [GACA00]................................................................................................................40-1187
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) ................................................................40-1188
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .....................................................40-1188
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK...............................................................40-1194
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .........................................................40-1197
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP............40-1199
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTH-
ING.................................................................................................................................................40-1201
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL
LEVEL MONITOR LIGHTS UP IN YELLOW...................................................................................40-1204
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR
COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW.................................................................40-1205
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING
.......................................................................................................................................................40-1206
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING ....
.......................................................................................................................................................40-1207
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING..........
.......................................................................................................................................................40-1208
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.....................40-1209
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...........................40-1210
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .............40-1211
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..
.......................................................................................................................................................40-1212
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .......40-1213
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING ......
.......................................................................................................................................................40-1214
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM ........................40-1215
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL......................................40-1217
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR
MAXIMUM ......................................................................................................................................40-1218
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT
TEMPERATURE.............................................................................................................................40-1219
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAX-
IMUM..............................................................................................................................................40-1220
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERA-
TURE .............................................................................................................................................40-1222
E-23 MONITOR TEMPERATURE GAUGE OF HYBRID SYSTEMS DOES NOT INDICATE CORRECT
TEMPERATURE.............................................................................................................................40-1223
E-24 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .............................40-1224
E-25 FUNCTION SWITCH DOES NOT OPERATE ............................................................................40-1225
E-26 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER).........................40-1226
E-27 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES
NOT LIGHT UP OR DOES NOT GO OFF ......................................................................................40-1227
E-28 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER ...........................40-1228
E-29 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS
NOT DISPLAYED ...........................................................................................................................40-1229
E-30 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT
CHANGED .....................................................................................................................................40-1230
E-31 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE
.......................................................................................................................................................40-1231

HB365LC-3 40-11
CONTENTS 40 TROUBLESHOOTING

E-32 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT
CHANGE ........................................................................................................................................40-1232
E-33 ALARM BUZZER CANNOT BE CANCELED .............................................................................40-1233
E-34 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION...40-1234
E-35 SERVICE MODE CANNOT BE SELECTED ..............................................................................40-1235
E-36 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE ...........40-1236
E-37 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK...............40-1238
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT
SWING ...........................................................................................................................................40-1239
E-39 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING
BRAKE DOES NOT OPERATE ......................................................................................................40-1242
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICA-
TOR NOT DISPLAYED ON MONITOR...........................................................................................40-1244
E-41 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED ..................................40-1246
E-42 ALARM DOES NOT SOUND DURING TRAVEL .......................................................................40-1247
E-43 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED.................................40-1249
E-44 HORN DOES NOT SOUND.......................................................................................................40-1250
E-45 HORN DOES NOT STOP SOUNDING......................................................................................40-1253
E-46 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF ........
.......................................................................................................................................................40-1255
E-47 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE..........40-1256
E-48 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE .....
.......................................................................................................................................................40-1258
E-49 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ..........
.......................................................................................................................................................40-1259
E-50 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ........
.......................................................................................................................................................40-1260
E-51 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION....40-1261
E-52 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .......40-1262
E-53 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .......
.......................................................................................................................................................40-1263
E-54 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ........
.......................................................................................................................................................40-1264
E-55 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........40-1265
E-56 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ......40-1266
E-57 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION ....40-1267
E-58 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED..............................................40-1269
E-59 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY ........................................................40-1270
E-60 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED ....................................................40-1271
E-61 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE.........................................................40-1273
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) ............................40-1274
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)......................................40-1274
FAILURE MODE AND CAUSE TABLE...............................................................................................40-1275
H-1 ALL WORK EQUIPMENTS OR TRAVEL DOES NOT OPERATE................................................40-1285
H-2 ALL WORK EQUIPMENT AND TRAVEL SPEED OR POWER IS LOW ......................................40-1286
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR...................................................40-1288
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .........................................40-1289
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS .........................................................40-1290
H-6 SPEED OR POWER OF BOOM IS LOW ....................................................................................40-1292
H-7 ARM SPEED OR POWER IS LOW .............................................................................................40-1298
H-8 BUCKET SPEED OR POWER IS LOW.......................................................................................40-1303
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION ............................................40-1306
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE ...............................................................................40-1307
H-11 HYDRAULIC DRIFT OF ARM IS LARGE ..................................................................................40-1309
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE............................................................................40-1311
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT
MOVES ..........................................................................................................................................40-1312
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE ........................................................................40-1313

40-12 HB365LC-3
40 TROUBLESHOOTING CONTENTS

H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE ................................40-1314

H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE.........................................................40-1315
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED...................................................................40-1316
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED ............................................40-1317
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD
MOVES SLOWER ..........................................................................................................................40-1318
H-20 MACHINE DOES NOT TRAVEL STRAIGHT .............................................................................40-1319
H-21 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW....................................40-1321
H-22 TRAVEL SPEED IS LOW ..........................................................................................................40-1324
H-23 ONE OF TRACKS DOES NOT RUN .........................................................................................40-1326
H-24 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST .........40-1328
H-25 FAN SPEED IS ABNORMAL (TOO HIGH OR LOW, OR STATIONARY) ...................................40-1329
H-26 UNUSUAL NOISE IS HEARD FROM AROUND FAN ................................................................40-1330
H-27 Quick coupler cylinder will not extend........................................................................................40-1331
H-28 Quick coupler cylinder will not retract (but buzzer doesnot sound) ............................................40-1333
H-29 Buzzer does not sound (but quick coupler cylinder doesretract) ................................................40-1335
H-30 Quick coupler cylinder extends and retracts slowly....................................................................40-1337
TROUBLESHOOTING OF ENGINE (S-MODE) ........................................................................................40-1338
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)......................................40-1338
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION.40-1339
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT ........................................................40-1340
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT
DOES NOT START) .......................................................................................................................40-1341
S-4 ENGINE STARTABILITY IS POOR..............................................................................................40-1343
S-5 ENGINE DOES NOT PICK UP SMOOTHLY ...............................................................................40-1345
S-6 ENGINE STOPS DURING OPERATION .....................................................................................40-1347
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE ...............................................................................40-1349
S-8 ENGINE LACKS POWER............................................................................................................40-1350
S-9 KDPF GETS CLOGGED IN A SHORT TIME ...............................................................................40-1352
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE .........................................................................40-1354
S-11 OIL BECOMES CONTAMINATED QUICKLY .............................................................................40-1355
S-12 FUEL CONSUMPTION IS EXCESSIVE ....................................................................................40-1356
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) .40-1357
S-14 OIL PRESSURE DROPS ..........................................................................................................40-1358
S-15 FUEL MIXES INTO ENGINE OIL...............................................................................................40-1360
S-16 WATER MIXES INTO ENGINE OIL (MILKY) .............................................................................40-1361
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) ...........................................40-1362
S-18 UNUSUAL NOISE IS HEARD....................................................................................................40-1364
S-19 VIBRATION IS EXCESSIVE ......................................................................................................40-1365
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT........................................................................40-1366
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .......................................................40-1367
S-22 ACTIVE REGENERATION TAKES TIME...................................................................................40-1369
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION.....................................40-1370
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE ..........................................................................40-1371
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .................................................................40-1373
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)................................40-1374
TROUBLESHOOTING FOR HYBRID SYSTEMS (Y MODE) ....................................................................40-1375
PRECAUTIONS FOR USING HYBRID SYSTEMS ............................................................................40-1375
Y-1 HYBRID MONITOR DOES NOT GO OUT ...................................................................................40-1376
Y-2 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT...........................40-1378
Y-3 UPPER STRUCTURE SWINGS ONLY TO THE RIGHT OR LEFT ..............................................40-1379
Y-4 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS LOW IN BOTH DIREC-
TIONS (RIGHT AND LEFT)............................................................................................................40-1380
Y-5 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS LOW IN ONLY ONE DI-
RECTION .......................................................................................................................................40-1381
Y-6 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND
LEFT) .............................................................................................................................................40-1382

HB365LC-3 40-13
CONTENTS 40 TROUBLESHOOTING

Y-7 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (EITHER RIGHT
OR LEFT) .......................................................................................................................................40-1383
Y-8 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING.......................................40-1384
Y-9 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .........40-1385
Y-10 SWING DRIFT ON A SLOPE IS LARGE (WHILE PARKING BRAKE IS APPLIED) ...................40-1386
Y-11 SWING DRIFT ON A SLOPE IS LARGE (WHILE PARKING BRAKE IS RELEASED)................40-1387
Y-12 ELECTRIC SWING MOTOR TEMPERATURE INCREASES ABNORMALLY ............................40-1388
Y-13 MOTOR-GENERATOR TEMPERATURE INCREASES ABNORMALLY.....................................40-1391
Y-14 INVERTER TEMPERATURE INCREASES ABNORMALLY .......................................................40-1393
Y-15 CAPACITOR TEMPERATURE INCREASES ABNORMALLY.....................................................40-1395

40-14 HB365LC-3
40 TROUBLESHOOTING ABBREVIATION LIST

ABBREVIATION LIST (ALL-A-0360-005-00-B)

• This list of abbreviations includes the abbreviations used in the text of the shop manual for parts, compo-
nents, and functions whose meaning is not immediately clear. The spelling is given in full with an outline of
the meaning.
• Abbreviations that are used in general society may not be included.
• Special abbreviations which appear infrequently are noted in the text.
• This list of abbreviations consists of two parts. The first part is a list of the abbreviations used in the text of
the manual, and the second part is a list of the abbreviations used in the circuit diagrams.
List of abbreviations used in the text
Purpose of use (major ap-
Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
Travel and brake This is a function that releases the brake when
ABS Antilock Brake System the tires skid (tires are not rotated). This function
(HD, HM) applies the brake again when the tires rotate.
Automatic Idling Setting This is a function that automatically sets the idle
AISS Engine
System speed.
Steering This is a function that performs the steering oper-
Advanced Joystick ations with a lever instead of using a steering
AJSS
Steering System (WA) wheel. This function performs gear shifting and
changing forward and reverse direction.
Travel and brake This is a function that automatically operates the
Automatic Retarder Ac-
ARAC retarder with a constant braking force when let-
celerator Control (HD, HM) ting go of the accelerator pedal on the downhill.
Travel and brake This is a function that automatically operates the
retarder to ensure that the machine speed does
Automatic Retarder
ARSC not accelerate above the speed set by the opera-
Speed Control (HD, HM) tor when letting go of the accelerator pedal on
the downhill.
Travel and brake This is a function that drives both wheels auto-
Automatic Spin Regula- matically using the optimum braking force when
ASR
tor (HD, HM) the tire on one side spins on the soft ground sur-
faces.
A function or component that can be added to the
ATT Attachment Work equipment
standard specification.
BRAKE This is a valve that bypasses a part of the brake
Brake cooling oil control cooling oil to reduce the load applied to the hy-
BCV
valve (HD) draulic pump when the retarder is not being
used.
Communication and elec- This is one of communication standards that are
CAN Controller Area Network
tronic control used in the network on the machine.
This is a regulator valve that is installed to KCCV
Crankcase Depression
CDR Engine ventilator. It is written as CDR valve and is not
Regulator
used independently.
This is a system that can actuate multiple actua-
Closed-center Load
CLSS Hydraulic system tors simultaneously regardless of the load (pro-
Sensing System
vides better combined operation than OLSS).

HB365LC-3 40-15
ABBREVIATION LIST 40 TROUBLESHOOTING

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a function that maintains optimum fuel in-
jection amount and fuel injection timing. This is
CRI Common Rail Injection Engine performed the engine controller which electroni-
cally controls supply pump, common rail, and in-
jector.
This is an electronic control device that send the
Electronic Control Mod- command to actuators using the signals from the
ECM Electronic control system
ule sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECU)
Transmission This is a proportional electromagnetic valve that
Electronic Control Mod-
ECMV decreases the transmission shock by gradually
ulation Valve (D, HD, WA, etc) increasing oil pressure for engaging clutch.
Travel This is a device that ensures smooth high-speed
Electronically Controlled
ECSS travel by absorbing vibration of machine during
Suspension System (WA) travel with hydraulic spring effect of accumulator.
This is an electronic control device that send the
command to actuators using the signals from the
ECU Electronic Control Unit Electronic control system
sensors on the machine so that the optimum ac-
tuation is performed. (Same as ECM)
This is a function that recirculates a part of ex-
Exhaust Gas Recircula- haust gas to combustion chamber, so that it re-
EGR Engine
tion duces combustion temperature, and reduces
emission of NOx.
This is a function with which operator can check
Equipment Manage- information from each sensor on the machine (fil-
EMMS Machine monitor
ment Monitoring System ter, oil replacement interval, malfunctions on ma-
chine, failure code, and failure history).
Electromagnetic proportional control This is a
Electromagnetic Propor-
EPC Hydraulic system mechanism with which actuators operate in pro-
tional Control
portion to the current.
This structure protects the operator's head from
Falling Object Protective falling objects. (Falling object protective struc-
FOPS Cab and canopy ture)
Structure
This performance is standardized as ISO 3449.
Forward-Neutral-Re-
F-N-R Operation Forward - Neutral - Reverse
verse
Communication
Global Positioning Sys- This system uses satellites to determine the cur-
GPS (KOMTRAX, KOMTRAX
tem rent location on the earth.
Plus)
Communication
Global Navigation Satel- This is a general term for system uses satellites
GNSS (KOMTRAX, KOMTRAX
lite System such as GPS, GALILEO, etc.
Plus)
Steering This is a function that enables the machine to
Hydrostatic Steering turn without steering clutch by controlling a differ-
HSS
System (D Series) ence in travel speed of right and left tracks with a
combination of hydraulic motor and bevel shaft.
Transmission Hydraulic transmission system that uses a com-
Hydro Static Transmis-
HST bination of hydraulic pump and hydraulic motor
sion (D, WA) without using gears for stepless gear shifting.

40-16 HB365LC-3
40 TROUBLESHOOTING ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
A general term for the engineering and its social-
Information and Com- Communication and elec-
ICT ly applied technology of information processing
munication Technology tronic control
and communication.
This is a valve that adjusts the fuel intake amount
IMA Inlet Metering Actuator Engine at the pump inlet in order to control the supply
pump fuel discharged volume. (Same as IMV)
This is a device to detect the angle (or angular
Inertial Measurement
IMU Engine velocity) and acceleration of the 3 axes that con-
Unit
trol motions.
This is a valve that adjusts the fuel intake amount
at the pump inlet in order to control the supply
IMV Inlet Metering Valve Engine
pump combustion discharged volume. (Same as
IMA)
This is a mechanism that burns the blowby gas
Komatsu Closed Crank- again by separating oil from blowby gas and re-
KCCV Engine
case Ventilation turning it to the intake side. It primarily consists of
filters.

Komatsu Catalyzed This is a filter that captures soot in exhaust gas.

KCSF Engine
Soot Filter It is built in to KDPF.
This is a catalyst that is used for purifying ex-
Komatsu Diesel Oxida- haust gas.
KDOC Engine
tion Catalyst It is built in to KDPF or assembled with the muf-
fler.
This is a component that is used to purify the ex-
Komatsu Diesel Particu- haust gas. KDOC (catalyst) and KCSF (filter to
KDPF Engine capture soot) are built-in it.
late Filter
It is installed instead of the conventional muffler.
Travel and brake This is a function that performs braking with the
optimum force and recovers the driving force of
Komatsu Traction Con-
KTCS the wheels by actuating the inter-axle differential
trol System (HM) lock when the wheels runs idle while the machine
travels on the soft ground.
This is an image display equipment such as a
LCD Liquid Crystal Display Machine monitor monitor in which the liquid crystal elements are
assembled.
This is a semiconductor element that emits light
LED Light Emitting Diode Electronic parts
when the voltage is applied in forward direction.
Local Interconnect Net- Communication and elec- This is one of communication standards that are
LIN
work tronic control used in the network on the machine.
This is a function that detects differential pres-
LS Load Sensing Hydraulic system sure of pump, and controls discharged volume
corresponding to load.
Low Voltage Differential Communication and elec- This is one of communication standards that are
LVDS
Signaling tronic control used in the network on the machine.
This indicates engine intake air flow. This is not
used independently but is used as combined with
MAF Mass Air Flow Engine
sensor. Mass air flow sensor can be called as
MAF sensor.

HB365LC-3 40-17
ABBREVIATION LIST 40 TROUBLESHOOTING

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a service that allows transmission and re-
Multimedia Messaging
MMS Communication ception of short messages consisting of charac-
Service
ters or voice or images between cell phones.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NC Normally Closed circuits. Circuit is normally closed if it is not actu-
system
ated, and it opens when it is actuated.
This is a characteristic of electrical or hydraulic
Electrical system, hydraulic
NO Normally Open circuits. Circuit is normally open if it is not actuat-
system
ed, and it closes when it is actuated.
This is a hydraulic system that can operate multi-
Open-center Load
OLSS Hydraulic system ple actuators at the same time regardless of the
Sensing System
load.
PC Pressure Compensation Hydraulic system This is a function that corrects the oil pressure.
Steering This is a function that electrically controls the en-
Palm command control gine and transmission in an optimal way with the
PCCS
system (D Series) controller instantly analyzing data from levers,
pedals, and dials.
This is a valve that adjusts the fuel intake amount
PCV Pre-stroke Control Valve Engine at the pump inlet in order to control fuel dis-
charged volume of supply pump.
Proportional Pressure This is a system that operates actuators in pro-
PPC Hydraulic system
Control portion to the oil pressure.
Hydraulic system
PPM Piston Pump and Motor Piston type hydraulic pump and motor.
(D, PC, etc)
PTO Power Take Off Power train system Power take-off mechanism
Work equipment This is a function that performs hydraulic control
Power Tilt and power
PTP of the tilt and pitch of the dozer blade of the bull-
Pitch dozer (D Series) dozer.
ROPS is a protective structure that intended to
protect the operator wearing seat belt from suffer-
ing injury which may be caused if the cab is
Roll-Over Protective crushed when the machine rolls over. (Roll-over
ROPS Cab and canopy
Structure protective structure)
This performance is standardized as ISO 3471 or
ISO 12117-2.
This is an exhaust gas purifier using urea water
that converts nitrogen oxides (NOx) into harm-
Selective Catalytic Re- less nitrogen and water by oxidation-reduction re-
SCR Urea SCR system
duction action. It may also be mentioned as exhaust gas
purification catalyst or part of the name of related
devices.
Le Systeme Internation- Abbreviation for "International System of Units" It
SI al d' Unites (Internation- Unit is the universal unit system and "a single unit for
al unit system) a single quantity" is the basic principle applied.
This is an actuator that consists of a solenoid and
SOL Solenoid Electrical system an iron core that is operated by the magnetic
force when the solenoid is energized.

40-18 HB365LC-3
40 TROUBLESHOOTING ABBREVIATION LIST

Purpose of use (major ap-

Abbrevia-
Actual word spelled out plicable machine (*1), or Explanation
tion
component/system)
This is a protective structure that intended to pro-
tect the operator wearing seat belt from suffering
Tip-Over Protective injury which may be caused if the cab is crushed
TOPS Cab and canopy when the machine tips over. (Roll-over protective
Structure
structure of hydraulic excavator)
This performance is standardized as ISO 12117.
This is a solenoid valve that switches over direc-
TWV 2-Way Valve Hydraulic system
tion of flow.
Variable Geometry Tur- This is a turbocharger on which the cross-section
VGT Engine
bocharger area of the exhaust passage is variable.
This is a function that finely controls the maxi-
Variable Horse Power mum output of the machine so that high work effi-
VHPC Engine control
Control ciency and low fuel consumption rate are both
achieved.

*1: Code for applicable machine model

D: Bulldozer
HD: Dump truck
HM: Articulate dump truck
PC: Hydraulic excavator
WA: Wheel loader
List of abbreviations used in the circuit diagrams
Abbreviation Actual word spelled out
A/C Air Conditioner
A/D Analogue-to-Digital
A/M Air Mix Damper
ACC Accessory
ADD Additional
AUX Auxiliary
BR Battery Relay
CW Clockwise
CCW Counter Clockwise
ECU Electronic Control Unit
ECM Electronic Control Module
ENG Engine
EXGND External Ground
F.G. Frame Ground
GND Ground
IMA Inlet Metering Actuator
NC No Connection

HB365LC-3 40-19
ABBREVIATION LIST 40 TROUBLESHOOTING

Abbreviation Actual word spelled out

S/T
Steering
STRG
SIG Signal
SOL Solenoid
STD Standard
OPT
Option
OP
PRESS Pressure
SPEC Specification
SW Switch
TEMP Temperature
T/C Torque Converter
T/M Transmission

40-20 HB365LC-3
40 TROUBLESHOOTING GENERAL TROUBLESHOOTING POINTS

RELATED INFORMATION ON TROUBLESHOOTING

(ALL-A-5100-001-00-B)

GENERAL TROUBLESHOOTING POINTS (PC400_10-A-5130-42A-00-B)

k If you remove the radiator cap while the engine is still hot, hot coolant may spout out and can scald
you. Wait until the engine cools down.
k Take extreme care not to touch a hot portion or not to be wound in a turning portion.
k Before removing a plug or a cap of a portion where oil pressure, hydraulic pressure, or air pressure
is applied, release the internal pressure first, then connect the measuring tool securely.
k When disconnecting wiring, remove the key and turn the battery disconnect switch to OFF position.
k Park the machine on a level place and check the frame lock bar, chocks, parking brake, etc.
k When working in a group, make signs and allow only the persons concerned to approach the ma-
chine.
• Troubleshooting means to investigate the root cause of a failure, repair immediately, and prevent recur-
rence of the failure.
• One important thing when you perform troubleshooting is to understand the structure and operation.
• It is important to have an interview with the operator and set up an aim of failure cause for performing a
troubleshooting effectively.
• If you disassembly the machine hastily when it has a failure, you may disassemble unrelated portions and
may not be able to find the cause. As a result, the costs of the man-hours, parts, oil, or grease may in-
crease, and you may lose the confidence of the users and operators. Accordingly, sufficient advance check
and proper procedure are necessary for troubleshooting.
1. Ask users or operators the following questions.
1) Have any other problems occurred apart from the problem that has been reported?
2) Is there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there problems with the machine condition before this?
4) Under what conditions did the failure occur?
5) Had any repairs been performed before the failure? When were these repairs performed?
6) Has the same kind of failure occurred before?
2. Perform the following checks before troubleshooting.
1) Check the machine for a symptom of abnormality.
2) Perform the Check before starting items.
3) Check the other check items.
4) Check other maintenance matters which can be checked externally and are considered to be necessa-
ry.
3. Check the degree of the trouble by yourself and judge if it is a real failure or it is a problem of handling or
operation.
When reproducing the trouble phenomenon by operating the machine, do not perform check or measure-
ment that can increase the failure.
4. Use the results of the investigation and inspection to narrow down the probable causes of the failure, then
use the troubleshooting flow chart (matrix) to locate the failure exactly.
The basic troubleshooting procedure is as follows.
• Start from the simple points.
• Start from the most likely points.
• Investigate other related parts or information.

HB365LC-3 40-21
GENERAL TROUBLESHOOTING POINTS 40 TROUBLESHOOTING

5. If the root cause is not corrected, a similar failure may occur again even if the apparent failure has been
repaired. Always find out the cause of a failure first and remove the root cause of each failure.

40-22 HB365LC-3
40 TROUBLESHOOTING TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM

TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM (PC400_11-A-5130-42A-20-B)

The followings are troubleshooting related cautions and changes for the newly installed Urea SCR system for
the Tier4 Final specification.
Engine controller shut down
• When the starting switch is turned to the OFF position, the engine controller starts the shutdown process-
ing. After the shutdown processing is completed, the action of turning off the engine controller's power is
referred to as “Engine controller shut down”.
• On machines with the Urea SCR system, the engine controller's shutdown process now includes purging of
AdBlue/DEF from devices or hoses to the tank. This increases average shutdown time from 2 minutes in
former models to maximum 7 minutes in Tier4 Final Specification models. (Described as 2 to 6 minutes in
the description of “Troubleshooting by failure code”).
• If the starting switch is turned OFF and ON before the engine controller is shut down, the information in the
engine controller which should be updated will not be updated, and the troubleshooting of the device may
not function properly. If this happens, it becomes necessary to shut down the engine controller. Completion
of engine controller shut down can be confirmed when the system operating lamp goes out.
Loaded Diagnostics Operation To Confirm Failure Correction and Loaded Diag-
nostics Operation To Clear Failure Code in the troubleshooting procedure
k Since the aftertreatment devices and their temperature sensor, pressure sensor, NOx sensor, ammo-
nia sensor, AdBlue/DEF injector, etc. are heated to a high temperature after “Loaded Diagnostics Op-
eration To Confirm Failure Correction” or “Loaded Diagnostics Operation To Clear Failure Code”,
take care not to get burned. Perform troubleshooting or repair after letting the devices cool down.
NOTICE
The operations for “Operation for judging the repair result” and “Machine operation for clearing the fail-
ure code” to apply a load to the engine are special operations to be performed only in a procedure for
trobleshooting.
Peroform stall operatoin, etc . to implement normal check according to the procedure described in
TESTING AND ADJUSTING.
NOTICE
Check the fuel and AdBlue/DEF level before the operation for “Operation for judging the repair result”
or “Machine operation for clearing the failure code”.
For checking the fuel and AdBlue/DEF level, see TESTING AND ADJUSTING, “SET AND OPERATE MA-
CHINE MONITOR”, “SERVICE MODE", "METHOD FOR OPERATING TESTING MENU (SCR SERVICE
TEST)”.
1. Tips
• The engine controller monitors the operation of engine related components (including aftertreatment
devices), and displays a failure code on the monitor when an abnormality is detected, and clears the
failure code after the failure is corrected. The monitored items include: sensors, actuators, electric wir-
ing, catalyzer, etc.
• The engine controller clears the failure code when it performs troubleshooting and the failure is correct-
ed. However, the failure code may be cleared when the engine controller is shut down even if the fail-
ure still exists. It may be necessary to apply load to the engine to activate the troubleshooting. Open
circuits and short circuits can be diagnosed by turning the starting switch to ON position after complet-
ing the repair. The engine controller determines if the failure, and displays a failure code on the monitor
when an abnormality is detected.
• However, the engine controller may not activate troubleshooting of the aftertreatment devices or other
functions if the exhaust gas temperature or flow rate is below the specified value. “Loaded Diagnostics
Operation To Confirm Failure Correction” or “Loaded Diagnostics Operation To Clear Failure Code”
should always be performed after the repair. These operations mean to run the engine, and rev up or
load the engine to meet the conditions for activating troubleshooting.
2. Loaded Diagnostics Operation To Confirm Failure Correction

HB365LC-3 40-23
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 40 TROUBLESHOOTING

• This operation is performed to confirm if a failure is corrected when the failure code is already cleared
(described later) or has been cleared before the failure was corrected.
• After the repair is completed, run the engine and the machine until the exhaust gas temperature and
flow rate exceed the specified value. Let the engine controller to activate troubleshooting of the after-
treatment devices to determine if the failure is corrected. If the failure is corrected, the failure code will
not be displayed.
REMARK
• For failure codes that require “Loaded Diagnostics Operation To Confirm Failure Correction” or “Loaded
Diagnostics Operation To Clear Failure Code” after repairing, a “Notice” mark is described in the related
information column of each failure code description, and the procedure will be given at the end of each
failure code description.
• When performing “Loaded Diagnostics Operation To Confirm Failure Correction” or “Loaded Diagnostics
Operation To Clear Failure Code”, confirm that the level of AdBlue/DEF and fuel in the tank are enough
to perform. To check the level of AdBlue/DEF and fuel, see to Testing and adjusting chapter, “SETTING
AND OPERATING MACHINE MONITOR”, “SERVICE MODE”, “METHOD FOR OPERATING TESTING
MENU (SCR SERVICE TEST)”.
3. Loaded Diagnostics Operation To Clear Failure Code
• This operation is performed to clear a failure code which is not cleared by turning the starting switch to
ON position after the failure is corrected.
• After the repair is completed, run the engine and the machine until the exhaust gas temperature and
flow rate exceed the specified value. Let the engine controller to activate troubleshooting of the after-
treatment devices to determine if the failure is corrected. If the failure is corrected, the displayed failure
code will go out.
4. SCR Service Test
• This is a function for determining whether there is a failure in the Urea SCR system. Perform this test
from the machine monitor.
REMARK
If instructed to perform a “SCR Service Test” in the troubleshooting procedure or somewhere else, see Test-
ing and adjusting chapter, “SETTING AND OPERATING MACHINE MONITOR”, “SERVICE MODE”,
“METHOD FOR OPERATING TESTING MENU (SCR SERVICE TEST)” and perform “SCR Service Test”.
Clearing Failure Code
“Clearing failure code” refers to manually deleting an “active” failure code from the engine controller. The follow-
ing two “Clearing Failure Code” functions have been added for Tier4 Final specification.
1. “Engine Controller Active Fault Clear”
• It is now possible to clear the failure code from the machine monitor without using INSITE.
• This function is provided as a means to perform troubleshooting when operating conditions for normally
activating the troubleshooting cannot be met after the cause of the failure is repaired. If the machine
can be operated, always clear failure codes by performing “Loaded Diagnostics Operation To Confirm
Failure Correction” or “Loaded Diagnostics Operation To Clear Failure Code”.
• For details, refer to Testing and adjusting chapter “SETTING AND OPERATING MACHINE MONITOR”,
“SERVICE MODE”, “METHOD FOR SETTING WITH TESTING MENU (ENGINE CONTROLLER AC-
TIVE FAULT CLEAR)”.However, if a failure code that relates to the “Inducement strategies” is displayed
(see separated list of failure code), failure codes will not be able to be cleared by this function.
• In this case, the failure code is cleared by using the “Engine Controller Active Fault Clear”, described
below, or by using INSITE.
2. “Engine Con Inducement Fault Clear”
• This is a function for clearing failure code caused by the Urea SCR system “Inducement”.
• For the failure code relating to the “Inducement strategy” of the Urea SCR system, which cannot be
cleared by “Engine Controller Active Fault Clear”, these can now be cleared from the machine monitor
by using a one-time password issued by Komatsu. Also, INSITE can be used for clearing.

40-24 HB365LC-3
40 TROUBLESHOOTING TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM

In case failure codes cannot be cleared

• The relevant failure code may not be able to clear due to derated engine power caused by “Inducement
strategy”, environmental conditions or other functional restrictions. Details and the measures to be taken
are as shown below.
Case 1 : Derated engine power caused by “Inducement strategy”
• The failure code may not be able to be cleared because it is a failure code caused by an “Inducement strat-
egy”, which derates the engine power. (Detail of “Inducement strategy”, see Structure and function chapter
“UREA SCR SYSTEM”.)
• Failure codes, which are caused by “Inducement strategy”, and be cleared by turning the starting switch to
ON position or operating the engine at low idle, are cleared in the same manner as before.
• However, some failure codes caused by “Inducement strategy” and require “Loaded Diagnostics Operation
To Clear Failure Code” may not let the machine move to activate troubleshooting. (The “Inducement status”
advances to derate engine power.) For the applicable codes, see separate sheet. Applicable codes are also
identified at their descriptions of “Troubleshooting by failure code”.
• Measures to be taken:
When the repair is completed, perform “Engine Con Inducement Fault Clear” and then “Loaded Diagnostics
Operation To Confirm Failure Correction” or “Loaded Diagnostics Operation To Clear Failure Code” to con-
firm that the failure code is cleared.
Case 2 : Environmental conditions
• Depending on environmental conditions (altitude, ambient temperature and etc.) when performing “Loaded
Diagnostics Operation To Confirm Failure Correction” or “Loaded Diagnostics Operation To Clear Failure
Code”, or when AdBlue/DEF freeze prevention mode is activated, the failure code may not be able to be
cleared.
(Applicable codes are identified by including the conditions that prevent clearing in “Related information” of
each “Troubleshooting by failure code”.)
• Measures to be taken:
1. When the repair is completed, perform “Loaded Diagnostics Operation To Confirm Failure Correction”
or “Loaded Diagnostics Operation To Clear Failure Code” under appropriate environmental conditions.
(See the description of each “Troubleshooting by failure code”.)
2. If the measure mentioned above is difficult to take after the repair is completed, perform “Engine Con-
troller Active Fault Clear”, or “Engine Con Inducement Fault Clear” and then confirm that the failure
code is cleared.
• Examples:
• Some failure codes cannot be cleared under certain environmental conditions (altitude, ambient tem-
perature, etc.)
1. Some failure codes cannot be cleared at high altitudes (ambient pressure 80 kPa or less).
2. Some failure codes cannot be cleared at low temperatures (ambient temperature -7 °C or below).
3. Some failure codes indicate failures only when AdBlue/DEF freeze prevention mode is activated.
4. Some failure codes do not indicate a failure when AdBlue/DEF freeze prevention mode is activat-
ed.
• Code cannot be cleared because AdBlue/DEF pump stops or AdBlue/DEF injection stops
• Condition that stops the AdBlue/DEF pump or AdBlue/DEF injection is shown below.
1. Ambient temperature: -24 °C or below
2. Thaw mode activated
Case 3 : Functional restrictions caused by other failures
• The failure code may not be able to clear due to functional restrictions (Regeneration control stops, Stops
AdBlue/DEF injection, etc.) caused by other failures. Operation and procedure required for clearing the
code are given under “Troubleshooting by each failure code”.

HB365LC-3 40-25
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 40 TROUBLESHOOTING

• Measures to be taken:
By following the clearing procedure, clear the failure code.
• Examples:
1. The failure code cannot be cleared because an abnormal high voltage, abnormal low voltage, or com-
munication error (open or short circuit) of failure code is displayed for a related component.
2. The failure code cannot be cleared because correct values are not input from a sensor (a failure code
for a related sensor is displayed).
3. The failure code cannot be cleared because a failure code that disables auto regeneration or manual
stationary regeneration of the aftertreatment devices is displayed.
4. The failure code cannot be cleared because a failure code that stops the AdBlue/DEF pump or disa-
bles AdBlue/DEF injection is displayed.
How to identify the failure code to be repaired
Among failure codes displayed on “Abnormality Record” screen of the machine monitor, identify failure codes
that have following conditions as a code to be repaired
1. Failure codes displayed with “E” (“E” is displayed on the left of failure code. See the following figure.)
• Check the “Abnormality Record” screen and identify all failure codes that “E” is currently displayed as a
code to be repaired.
• The failure codes are displayed in the upper row from the “E” on the “Abnormality Record” screen.
2. Failure codes displayed without “E” and their service meter reading (SMR) at last occurrence (at previous
working time, etc.) become the most recent time.
• The failure codes that have detected records most recently and are displayed without “E” may be in the
state that their abnormalities are not cleared (*1). Due to that, check the description of “Troubleshoot-
ing by failure code” and identify them as a code to be repaired.
• The failure codes are displayed on “Abnormality Record” screen in ascending order. (See the following
figure.)
*1: It corresponds to a failure code that is cleared by turning the starting switch to OFF position, or by stop-
ping the engine though the repair is not completed. Due to this kind of failure code, the failure code to be
repaired is not determined only by the existence of “E”. (Failure C pattern in the following REMARK “Dis-
play of “E” on the “Abnormality Record” screen”.)
1: Area where “E” is displayed
2: Area where the most recent SMR is displayed

REMARK
Display of “E” on the “abnormality record” screen
1. Transition of “E” displayed with failure code has a following pattern.
The table is shown the display of “E” on “Abnormality Record” screen of the machine monitor when turning
the starting switch to O N position after turning the starting switch to OFF position and shutting down the
engine controller.
Occurrence of failure code (with or without “E”)
Transition Before re- Determination of the repair completion
pattern pair (under After repair Remarks
failure)

40-26 HB365LC-3
40 TROUBLESHOOTING TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM

The “E” is not displayed To determine if the repair is completed suc-

Failure A “E” No display after the repair is complet- cessfully enables to turn the starting switch to
ed. ON position.
It is necessary to perform “Loaded Diagnos-
The “E” doses not go out
tics Operation To Clear Failure Code” to de-
Failure B “E” “E” only by the repair is com-
termine if the repair is completed successful-
pleted.
ly.
• See the most recent SMR on Abnor-
mality Record screen and determine if
it is to be repaired because only the
Once the engine controller “E” cannot determine if the failure is
shuts down, the “E” goes cleared.
Failure C No display No display
out even if the repair is not
completed. • It is necessary to perform “Loaded Di-
agnostics Operation To Confirm Fail-
ure Correction” to determine if the re-
pair is completed successfully.
2. Unless clearing the “E” of failure code, a number of occurrences increase every time when turning the start-
ing switch to ON position.

HB365LC-3 40-27
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 40 TROUBLESHOOTING

Troubleshooting Flow

40-28 HB365LC-3
40 TROUBLESHOOTING TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM

HB365LC-3 40-29
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 40 TROUBLESHOOTING

40-30 HB365LC-3
40 TROUBLESHOOTING TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM

List of failure codes related to Inducement

• “●” mark shown in the following list means failure codes related to Inducement in each territory.
• When activating Inducement strategy, the following failure code is displayed with one of “AdBlue/DEF level
Low Error”, or “Urea SCR system devices abnormality” on “Current Abnormality” screen of the machine
monitor.
• “Urea SCR system devices abnormality” is displayed as Urea SCR System Abnormality on the Abnormali-
ty Record screen.

North America EU
Urea Urea
AdBlue/ AdBlue/
Failure SCR SCR
Detail of failure DEF DEF
code system system
level level
devices devices
Low Er- Low Er-
abnor- abnor-
ror ror
mality mality
AS00ZK AdBlue/DEF Level Low Error 5 ● - - -
CA249 Ambient Air Temp Sensor High Error - - - ●
CA256 Ambient Air Temp Sensor Low Error - - - ●
CA1669 AdBlue/DEF Level Sensor Voltage High Error - - - ●
CA1673 AdBlue/DEF Level Low Error 3 ● - ● -
CA1677 AdBlue/DEF Temperature Sensor Low Error - - - ●
CA1678 AdBlue/DEF Temperature Sensor High Error - - - ●
CA1682 AdBlue/DEF Pump Priming Error - ● - ●
CA1683 AdBlue/DEF Tank Heating Valve Voltage High Error - ● - ●
CA1684 AdBlue/DEF Tank Heating Valve Voltage Low Error - ● - ●
CA1686 AdBlue/DEF Quality Sensor Voltage High Error - - - ●
CA1714 AdBlue/DEF Quality Sensor Out of Calibration Error - - - ●
CA1715 AdBlue/DEF Quality Sensor Internal Circuit Error - - - ●
CA1885 Turbo Outlet NOx Sensor Circuit Error - - - ●
CA1887 SCR Outlet NOx Sensor Circuit Error - - - ●
CA2271 EGR Valve Position Sensor High Error - - - ●
CA2272 EGR Valve Position Sensor Low Error - - - ●
CA2349 EGR Valve Solenoid Open Circuit Error - - - ●
CA2353 EGR Valve Solenoid Short Circuit Error - - - ●
CA2357 EGR Valve Servo Error - - - ●
CA2771 SCR Outlet NOx Sensor Datalink Timeout Error - ● - ●
CA2976 AdBlue/DEF Pump Temperature Sensor Signal Error - ● - ●
CA3142 SCR Temperature Sensor High Error - ● - ●
CA3143 SCR Temperature Sensor Low Error - ● - ●
CA3144 SCR Temperature Sensor In Range Error - ● - ●
CA3146 SCR Outlet Temperature Sensor High Error - ● - ●
CA3147 SCR Outlet Temperature Sensor Low Error - ● - ●
CA3148 SCR Outlet Temperature Sensor In Range Error - ● - ●

HB365LC-3 40-31
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 40 TROUBLESHOOTING

North America EU
Urea Urea
AdBlue/ AdBlue/
Failure SCR SCR
Detail of failure DEF DEF
code system system
level level
devices devices
Low Er- Low Er-
abnor- abnor-
ror ror
mality mality
CA3151 SCR Catalyst Efficiency Low Error 2 - ● - ●
CA3165 SCR Outlet Temperature High Error - ● - ●
CA3229 SCR Temperature High Error - ● - ●
CA3231 SCR Temperature High Error - Non Regeneration - ● - ●
CA3232 Turbo Outlet NOx Sensor Datalink Timeout Error - ● - ●
CA3235 SCR Outlet Temperature High Error - Non Regeneration - ● - ●
CA3319 KDPF Outlet Temperature Sensor High Error - ● - ●
CA3321 KDPF Outlet Temperature Sensor Low Error - ● - ●
CA3322 KDPF Outlet Temperature Sensor In Range Error - ● - ●
CA3497 AdBlue/DEF Level Low Error 1 ● - ● -
CA3498 AdBlue/DEF Level Low Error 2 ● - ● -
CA3543 AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low) - ● - -
CA3545 SCR Outlet NOx Sensor Unstable Error - - - ●
CA3558 AdBlue/DEF Pump Voltage High Error - ● - ●
CA3559 AdBlue/DEF Pump Voltage Low Error - ● - ●
CA3563 AdBlue/DEF LineHeater Relay 1 Voltage Low Error - ● - ●
CA3567 AdBlue/DEF Injector Open Circuit Error or Short Circuit Error - ● - ●
CA3568 AdBlue/DEF Injector Malfunction - ● - ●
CA3571 AdBlue/DEF Pump Pressure Sensor High Error - ● - ●
CA3572 AdBlue/DEF Pump Pressure Sensor Low Error - ● - ●
CA3574 AdBlue/DEF Pump Pressure Too Low Error - ● - ●
CA3575 AdBlue/DEF Pump Pressure Too High Error - ● - ●
CA3577 AdBlue/DEF FCV Voltage High Error - ● - ●
CA3578 AdBlue/DEF FCV Voltage Low Error - ● - ●
CA3583 SCR Outlet NOx Sensor Heater Warming up Error - - - ●
CA3596 AdBlue/DEF Pump Pressure Unstable Error - ● - ●
CA3649 Turbo Outlet NOx Sensor Heater Warming up Error - - - ●
CA3681 SCR Outlet NOx Sensor Power Voltage Error - - - ●
CA3682 Turbo Outlet NOx Sensor Power Voltage Error - - - ●
CA3717 SCR Outlet NOx Sensor Voltage Mismatch Error - - - ●
CA3718 Turbo Outlet NOx Sensor Voltage Mismatch Error - - - ●
CA3725 Turbo Outlet NOx Sensor Unstable Error - - - ●
CA3866 AdBlue/DEF Low Concentration Error 2 - ● - ●
CA3868 AdBlue/DEF Tank Sensor Datalink Timeout Error - ● - ●

40-32 HB365LC-3
40 TROUBLESHOOTING TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM

North America EU
Urea Urea
AdBlue/ AdBlue/
Failure SCR SCR
Detail of failure DEF DEF
code system system
level level
devices devices
Low Er- Low Er-
abnor- abnor-
ror ror
mality mality
CA3899 SCR NH3 Sensor Circuit Error - - - ●
CA3911 SCR NH3 Sensor Datalink Timeout Error - ● - ●
CA3912 SCR NH3 Sensor Heater Warming up Error - - - ●
CA3932 SCR NH3 Sensor Heater Voltage High Error - - - ●
CA3933 SCR NH3 Sensor Heater Voltage Low Error - - - ●
CA3934 SCR NH3 Sensor Power Interrupt Error - - - ●
CA3935 SCR NH3 Sensor Trim Resistance Error - - - ●
CA3936 SCR NH3 Sensor Internal Circuit Error - - - ●
CA4151 KDOC and KDPF Temperature Sensor Datalink Timeout Error - ● - ●
CA4152 SCR Temperature Sensor Datalink Timeout Error - ● - ●
CA4155 AdBlue/DEF Pump Heater Relay Voltage High Error - ● - ●
CA4158 KDOC and KDPF Temperature Sensor Internal Circuit Error - ● - ●
CA4159 SCR Temperature Sensor Internal Circuit Error - ● - ●
KDOC and KDPF Temperature Sensor ECU Voltage High Er-
CA4161 - ● - ●
ror
KDOC and KDPF Temperature Sensor ECU Voltage Low Er-
CA4162 - ● - ●
ror
CA4164 SCR Temperature Sensor ECU Voltage High Error - ● - ●
CA4165 SCR Temperature Sensor ECU Voltage Low Error - ● - ●
CA4259 KDOC and KDPF Temperature Sensor Power Interrupt Error - ● - ●
CA4261 SCR Temperature Sensor Power Interrupt Error - ● - ●
AdBlue/DEF Quality Sensor Liquid Distinction Impossible Er-
CA4277 - ● - -
ror
CA4461 AdBlue/DEF LineHeater Relay 2 Voltage Low Error - ● - ●
CA4731 AdBlue/DEF Temperature Sensor Transmission Data Error - - - ●
CA4732 AdBlue/DEF Level Sensor Transmission Data Error - - - ●
CA4739 AdBlue/DEF Level Sensor Internal Circuit Error - - - ●
CA4769 AdBlue/DEF Level Measurement Impossible - ● - ●
CA4842 AdBlue/DEF High Concentration Error - ● - ●

HB365LC-3 40-33
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 40 TROUBLESHOOTING

List of failure codes that are related to Inducement and cannot be cleared at engine power deration
Failure
Detail of failure North America EU
code
CA1885 Turbo Outlet NOx Sensor Circuit Error - ●
CA1887 SCR Outlet NOx Sensor Circuit Error - ●
CA3144 SCR Temperature Sensor In Range Error ● ●
CA3148 SCR Outlet Temperature Sensor In Range Error ● ●
CA3151 SCR Catalyst Efficiency Low Error 2 ● ●
CA3322 KDPF Outlet Temperature Sensor In Range Error ● ●
CA3543 AdBlue/DEF Quality Error (SCR Catalyst Efficiency Low) ● -
CA3545 SCR Outlet NOx Sensor Unstable Error - ●
CA3568 AdBlue/DEF Injector Malfunction ● ●
CA3583 SCR Outlet NOx Sensor Heater Warming up Error - ●
CA3649 Turbo Outlet NOx Sensor Heater Warming up Error - ●
CA3681 SCR Outlet NOx Sensor Power Voltage Error - ●
CA3682 Turbo Outlet NOx Sensor Power Voltage Error - ●
CA3725 Turbo Outlet NOx Sensor Unstable Error - ●
CA3899 SCR NH3 Sensor Circuit Error - ●
CA3912 SCR NH3 Sensor Heater Warming up Error - ●
CA3932 SCR NH3 Sensor Heater Voltage High Error - ●
CA3933 SCR NH3 Sensor Heater Voltage Low Error - ●
CA3934 SCR NH3 Sensor Power Interrupt Error - ●
CA3935 SCR NH3 Sensor Trim Resistance Error - ●
CA3936 SCR NH3 Sensor Internal Circuit Error - ●

List of failure codes is related to Inducement and cannot be cleared when freezing AdBlue/DEF (All terri-
tory)
Failure Detail of failure
code
CA1673 AdBlue/DEF Level Low Error 3
CA1682 AdBlue/DEF Pump Priming Error
CA3567 AdBlue/DEF Injector Open Circuit Error or Short Circuit Error
CA3574 AdBlue/DEF Pump Pressure Too Low Error
CA3575 AdBlue/DEF Pump Pressure Too High Error
CA3578 AdBlue/DEF FCV Voltage Low Error
CA3596 AdBlue/DEF Pump Pressure Unstable Error
CA3866 AdBlue/DEF Low Concentration Error 2
CA4277 AdBlue/DEF Quality Sensor Liquid Distinction Impossible Error
CA4768 Fuel in AdBlue/DEF Tank Error
CA4769 AdBlue/DEF Level Measurement Impossible
CA4842 AdBlue/DEF High Concentration Error

40-34 HB365LC-3
40 TROUBLESHOOTING SEQUENCE OF EVENTS IN TROUBLESHOOTING

SEQUENCE OF EVENTS IN TROUBLESHOOTING (PC400_10-A-5130-42A-10-B)

HB365LC-3 40-35
SEQUENCE OF EVENTS IN TROUBLESHOOTING 40 TROUBLESHOOTING

40-36 HB365LC-3
 PRECAUTIONS FOR USING HYBRID SYSTEMS, TROUBLESHOOT-
40 TROUBLESHOOTING ING FOR HIGH-VOLTAGE EQUIPMENT

PRECAUTIONS FOR USING HYBRID SYSTEMS, TROUBLESHOOTING FOR

HIGH-VOLTAGE EQUIPMENT (HB335_3-K-PQG9-010-20-B)

Precautions for hybrid system

This machine is equipped with the hybrid system which combines the electrical motor and diesel engine.
Before starting work, see the Operation and Maintenance Manual, FOREWORD, SAFETY, BASIC INFORMA-
TION, “HANDLING HYBRID COMPONENT AND HIGH VOLTAGE WIRING”.
NOTICE
When performing testing and adjusting of hybrid system, understand the followings thoroughly before
starting.
• Only qualified person who has finished the special course for handling low-voltage electricity can
perform removal of hybrid component (motor-generator, capacitor, inverter, electric swing motor)
and high-voltage wiring (conduit wiring in orange color).
• Even for the qualified person, do not disassemble the hybrid component (motor-generator, capacitor,
inverter, electric swing motor).
• When replacing the hybrid component and high-voltage wiring (conduit wiring in orange color), re-
place it as a unit.
• Before handling the hybrid component, see TESTING AND ADJUSTING, “SETTING AND OPERATION
OF MACHINE MONITOR”, “METHOD FOR SETTING WITH TESTING MENU (CAPACITOR DIS-
CHARGE )”, and perform the "Capacitor Discharge".
Depending on the failure code displayed, capacitor discharge with machine monitor may not be
available.
• If the failure code is displayed (to indicate abnormality of the hybrid system), discharging cannot be
conducted even if discharging instructions are displayed on the machine monitor and operated as
instructed. Conditions that can consume the electric charge of the capacitor is not satisfied, so use
a dedicated generator for capacitor discharge: 796-426-1800.
• Even if the capacitor charge ratio is 0 %, the capacitor voltage is not necessarily to be completely
0 V. With the nature of a capacitor, the voltage tends to recover after discharging. Accordingly, take
care when disconnecting the power cable connector.
• A voltage of 50 % or less will still remain in the capacitor after the discharging process is completed.
Do not work with bare hands. Be sure to insulate your hands before work.
• After discharging, check that both capacitor charge LED (1) are not lit.
Both right and left LED are lit: High voltage is being output
Only right LED is lit: Charged with high voltage
Both right and left LED are not lit: Uncharged
• After the discharging is completed, do not operate the
following. Otherwise, the capacitor may be recharged.
1. Do not turn the starting switch to ON position be-
fore the engine completely stops after the starting
switch has been turned to OFF position.
2. After the discharging is completed, do not start the
engine.
• When the connector at capacitor side is removed, cov-
er the connector halves (on the harness and capacitor)
with a plastic bag, etc. to prevent entry of foreign mate-
rial.
• When performing this, stop the engine. Do not connect the multimeter directly to the capacitor side
connector (female side).
• For the monitoring item related to the hybrid component, see the “TABLE OF SELF-DEFINE MONI-
TORING FOR HYBRID COMPONENT AND CHECK SHEET”.

HB365LC-3 40-37
PRECAUTIONS FOR USING HYBRID SYSTEMS, TROUBLESHOOT-
ING FOR HIGH-VOLTAGE EQUIPMENT 40 TROUBLESHOOTING

• When the hybrid component has trouble, check it and write down the check result. See the “TABLE
OF SELF-DEFINE MONITORING FOR HYBRID COMPONENT AND CHECK SHEET”.
Failure code that does not allow the discharge with the machine monitor
Failure code related to high-voltage circuit
Failure code Failure (displayed on screen)
[GA00NS] HYB Equipment Overheat
[GA01KA] Power Cable Interlock Open Circuit
[GA02KZ] DC Line Open and Short Circuit
[GA04KG] DC Line HW before Booster Power Voltage High Error
[GA05KG] DC Line SW before Booster Power Voltage High Error
[GA05KP] DC Line SW before Booster Output Voltage Low Error
[GA06KZ] DC Line Voltage Sensor before Booster Open and Short Circuit
[GA08KG] DC Line HW before Booster Power Voltage High Error
[GA09KG] DC Line Software after Booster Power Voltage High Error
[GA09KP] DC Line SW after Booster Output Voltage Low Error
[GA0AKZ] DC Line Voltage Sensor after Booster Open and Short Circuit
[GA10MA] HYB Controller Malfunction
[GA10MC] HYB Controller Malfunction
[GA12NK] HYB Controller Power Supply Voltage Not Rise
[GA13KP] HYB Controller Sensor Power Supply Output Voltage Low Error
[GA13KY] HYB Controller Sensor Power Supply Short Circuit
[GA18MC] Motor-Generator Driver Energizing Power Supply Malfunction
[GA1SFS] Contactor Sticking
[GA1SMC] Contactor Malfunction
[GA1VFS] Capacitor Contactor Sticking
[GA1VMC] Capacitor Contactor Malfunction

Failure code related to motor-generator and swing motor

Failure code Failure (displayed on screen)
[GA17KR] Motor-Generator Driver Defective Communication
[GA19KR] Motor-Generator Driver Sub-CPU Defective Communication
[GA19KT] Motor-Generator Driver Sub-CPU Controller Internal Failure
[GA1BMA] Motor-Generator Driver DC Voltage Sensor Defective Function
[GA25MA] Motor-Generator Driver IGBT 0 Error
[GA26MA] Motor-Generator Driver IGBT 1 Error
[GA60MC] Motor-Generator Malfunction
[GA60N1] Motor-Generator Overrun
[GA62KY] Motor-Generator Phase-A Current Sensor Power Supply Line Short Circuit
[GA62MA] Motor-Generator Phase-A Current Sensor Defective Function
[GA63KY] Motor-Generator Phase-B Current Sensor Power Supply Line Short Circuit

40-38 HB365LC-3
 PRECAUTIONS FOR USING HYBRID SYSTEMS, TROUBLESHOOT-
40 TROUBLESHOOTING ING FOR HIGH-VOLTAGE EQUIPMENT

Failure code Failure (displayed on screen)

[GA63MA] Motor-Generator Phase-B Current Sensor Defective Function
[GA64KY] Motor-Generator Phase-C Current Sensor Power Supply Line Short Circuit
[GA64MA] Motor-Generator Phase-C Current Sensor Defective Function

Troubleshooting of high-voltage equipment

HB365LC-3 40-39
PRECAUTIONS FOR USING HYBRID SYSTEMS, TROUBLESHOOT-
ING FOR HIGH-VOLTAGE EQUIPMENT 40 TROUBLESHOOTING

1: Capacitor 5: High-voltage wiring (motor-generator)

2: Inverter A: Motor-generator
3: High-voltage wiring (electric swing motor) B: Electric control unit
4: High-voltage wiring (capacitor) C: Electric swing motor
Precautions for connecting the power cable

40-40 HB365LC-3
 PRECAUTIONS FOR USING HYBRID SYSTEMS, TROUBLESHOOT-
40 TROUBLESHOOTING ING FOR HIGH-VOLTAGE EQUIPMENT

• The power cable connector is asymmetrical and has different upper and lower sides. The marks (I, II or III)
on the power cable side and body side must be matched.
• Marks on the motor-generator (connectors: GM02 and GM03) are as follows:
Connectors on motor-generator side

HB365LC-3 40-41
PRECAUTIONS FOR USING HYBRID SYSTEMS, TROUBLESHOOT-
ING FOR HIGH-VOLTAGE EQUIPMENT 40 TROUBLESHOOTING

Connectors on wiring harness side

Troubleshooting flow

40-42 HB365LC-3
 PRECAUTIONS FOR USING HYBRID SYSTEMS, TROUBLESHOOT-
40 TROUBLESHOOTING ING FOR HIGH-VOLTAGE EQUIPMENT

HB365LC-3 40-43
TABLE OF SELF-DEFINE MONITORING ITEMS AND CHECK SHEET
FOR HYBRID COMPONENTS 40 TROUBLESHOOTING

TABLE OF SELF-DEFINE MONITORING ITEMS AND CHECK SHEET FOR

HYBRID COMPONENTS (HB335_3-K-PQG9-010-30-B)

Table of self-define monitoring

Elect
Mo-
ric
tor- In- Ca- Unit, Re-
swin
No. Monitoring item Code gen- ver- paci- Monitoring item rang mar
g
era- ter tor e ks
mo-
tor
tor
Swing RIGHT PPC Pres-
1 09008 MPa
sure #2
Swing LEFT PPC Pres- 09009 MPa
2
sure #2
Swing LEFT PPC Press 09006 mV
3
Sens 2 Volt
Swing RIGHT PPC Pres
4 09007 mV
Sens 2 Volt
5 Swing Motor DC Current 09100 A A A
High-voltage Side DC
6 09200 V V V
Voltage
7 Capacitor Voltage 09300 V
Booster Low-voltage Side
8 09400 V
Voltage
Capacitor Base Tempera-
9 09304 °C
ture
Capacitor Bus Bar Tem-
10 09305 °C
perature
Capacitor Cell Tempera-
11 09306 °C
ture
Booster IGBT Base Tem-
12 09403 °C
perature
Booster IGBT Junction
13 09404 °C
Temp
Booster Inductor Temper-
14 09402 °C
ature
Swing Motor Coil Temper-
15 09101 °C
ature
Swing Driver Ph-U IGBT
16 09504 °C
Base Temp
Swing Driver Ph-V IGBT
17 09505 °C
Base Temp
Swing Driver Ph-W IGBT
18 09506 °C
Base Temp
Motor-Generator Temper-
19 09600 °C
ature
Motor-Generator Driver
20 09607 °C
IGBT Base Temp #0

40-44 HB365LC-3
 TABLE OF SELF-DEFINE MONITORING ITEMS AND CHECK SHEET
40 TROUBLESHOOTING FOR HYBRID COMPONENTS

Elect
Mo-
ric
tor- In- Ca- Unit, Re-
swin
No. Monitoring item Code gen- ver- paci- Monitoring item rang mar
g
era- ter tor e ks
mo-
tor
tor
Motor-Generator Driver
21 09608 °C
IGBT Base Temp #1
Swing Driver IGBT Junc-
22 09507 °C
tion Temp
ON,
Booster Not Started
OFF
23 HYB Controller Warning 09703
ON,
Emergency Stop Input
OFF
HYB Swing Parking ON,
24 HYB Controller Solenoid 09700
Brake OFF
Battery Relay ON,
25 HYB Controller Output 09705
Drive(HYB) OFF
26 Motor-Generator Speed 09602 r/min
27 Motor-Generator Torque 09603 Nm
Motor-Generator Shaft
28 09604 kW
Output
Motor-Generator Target
29 09605 r/min
Speed
Motor-Generator Target
30 09606 Nm
Torque
31 Capacitor Target Voltage 09303 V
32 Capacitor Current 09307 A
33 Swing Lever Stroke 42103 %
34 Boom Lever Stroke 42104 %
35 Arm Lever Stroke 42105 %
36 Bucket Lever Stroke 42106 %
Motor-Gene Speed ON,
Control OFF
Motor-Gen Torque Con- ON,
trol OFF
HYB Controller Control Motor-Generator Servo ON,
37 09701
Output ON OFF
ON,
Swing Motor Servo ON
OFF
Low-Speed Matching ON,
ON OFF

HB365LC-3 40-45
TABLE OF SELF-DEFINE MONITORING ITEMS AND CHECK SHEET
FOR HYBRID COMPONENTS 40 TROUBLESHOOTING

Elect
Mo-
ric
tor- In- Ca- Unit, Re-
swin
No. Monitoring item Code gen- ver- paci- Monitoring item rang mar
g
era- ter tor e ks
mo-
tor
tor
Key SW (HYB Control- ON,
ler) OFF
ON,
Emergency Stop Input
OFF
ON,
38 HYB Controller SW Input 09702 Operation Lock Lever
OFF
Swing Brake Release ON,
SW OFF
Swing Parking Brake ON,
SW OFF
39 Swing Motor Speed 09102 r/min
40 Swing Motor Torque 09103 Nm
41 Swing Motor Shaft Output 09104 kW
Swing Motor Target
42 09105 r/min
Speed
Swing Motor Torque Limit
43 09106 Nm
Value
Insulation Deteriorati Sens
44 09900 mV
Volt
HYB Controller Assembly
45 20255
P/N
HYB Controller Serial
46 20417
Number
HYB Controller Program
47 20256
P/N
HYB Controller Program
48 20257
Version
HYB Controller Swing
49 20269
Program P/N
HYB Controller Swing
50 20270
Program Ver
HYB Cont Motor-Gene
51 20271
Program P/N
HYB Cont Motor-Gene
52 20272
Program Ver

Check sheet
Machine model HB335-3 Work No.
Model and serial
# Date inspected
No.

40-46 HB365LC-3
 TABLE OF SELF-DEFINE MONITORING ITEMS AND CHECK SHEET
40 TROUBLESHOOTING FOR HYBRID COMPONENTS

Machine model HB335-3 Work No.

Komatsu
Engine SAA6D114E-6 diesel Service meter
engine
Engine serial No. # Name of worker

Failure

No
Goo
Visual check goo
d
d
1 Damage on wiring
2 Connector out of place

No
Goo
Check with machine monitor (Abnormality Record, Self-define Monitoring) goo
d
d
Check of error and failure
3
code

HB365LC-3 40-47
TABLE OF SELF-DEFINE MONITORING ITEMS AND CHECK SHEET
FOR HYBRID COMPONENTS 40 TROUBLESHOOTING

No
Goo
Check with machine monitor (Abnormality Record, Self-define Monitoring) goo
d
d
Check of monitoring information
No
Testing con- Measured val- Goo
Item to be displayed Code Reference value goo
ditions ue d
d
Engine speed 01002 600 to 2200 r/min
Throttle Position 31701 0 to 100 %
Swing Motor DC Current 09100 ±400 A
Capacitor Voltage 09300 190 to 400 V
Booster Low-voltage Side Voltage 09400 190 to 400 V
Capacitor Base Temperature 09304 -30 to 65 °C
Capacitor Bus Bar Temperature 09305 -30 to 65 °C
Capacitor Cell Temperature 09306 -30 to 65 °C
Booster IGBT Base Temperature 09403 -30 to 100 °C
Booster IGBT Junction Temp 09404 -30 to 135 °C
Booster Inductor Temperature 09402 -30 to 130 °C
Swing Motor Coil Temperature 09101 -30 to 160 °C
4
Swing Driver Ph-U IGBT Base Temp 09504 -30 to 85 °C
Swing Driver Ph-V IGBT Base Temp 09505 -30 to 85 °C
Swing Driver Ph-W IGBT Base Temp 09506 -30 to 85 °C
Motor-Generator Temperature 09600 -30 to 190 °C
Motor-Generator Driver IGBT Base
09607 -30 to 100 °C
Temp #0
Motor-Generator Driver IGBT Base
09608 -30 to 100 °C
Temp #1
Swing Driver IGBT Junction Temp 09507 -30 to 135 °C
HYB Controller Solenoid 09700
Same as engine
Motor-Generator Speed 09602
speed
Motor-Generator Target Speed 09605 600 to 2500 r/min
Capacitor Target Voltage 09303 280 to 375 V
-100 to 100 %
Swing Lever Stroke 42103 (When lever in
NEUTRAL: 0)

40-48 HB365LC-3
 TABLE OF SELF-DEFINE MONITORING ITEMS AND CHECK SHEET
40 TROUBLESHOOTING FOR HYBRID COMPONENTS

Check of monitoring information

No
Testing con- Measured val- Goo
Item to be displayed Code Reference value goo
ditions ue d
d
-100 to 100 %
Boom Lever Stroke 42104 (When lever in
NEUTRAL: 0)
-100 to 100 %
Arm Lever Stroke 42105 (When lever in
NEUTRAL: 0)
-100 to 100 %
Bucket Lever Stroke 42106 (When lever in
NEUTRAL: 0)
HYB Controller Control Output 09701
4
HYB Controller SW Input 09702
Swing Motor Speed 09102 ±5686 r/min
Swing Motor Target Speed 09105 ±5686 r/min
Turn the
starting
switch to ON
Insulation Deterioration Sens Volt 09900 up to 4650 mV
position and
start the en-
gine.
HYB Controller Assembly P/N 20255
HYB Controller Serial Number 20417
HYB Controller Program P/N 20256
HYB Controller Program Version 20257

HB365LC-3 40-49
CHECKS BEFORE TROUBLESHOOTING 40 TROUBLESHOOTING

CHECKS BEFORE TROUBLESHOOTING (HB335_3-A-5150-208-00-B)

Engine, lubricating oil, coolant, and AdBlue/DEF

No. Item Criteria Remedy
1 Check for unusual noise and smell - Repair
2 Check around engine and removal of dirt - Remove
3 Check around engine for water leakage - Repair
4 Check around engine for oil leakage - Repair
5 Check of fuel line for leakage - Repair
6 Check of radiator for clogging - Remove
7 Check of fuel level and type - Add fuel
8 Check of foreign material in fuel - Clean and drain
9 Check of fuel prefilter - Replace
10 Check of fuel main filter - Replace
11 Check of engine oil level (oil amount in oil pan) and type Between H and L Add engine oil
12 Check oil level in motor-generator case Between H and L Refill with oil
12 Check of coolant level (in reservoir tank) Between H and L Add coolant
Air cleaner clogging
caution lamp is not dis-
13 Check of air cleaner for clogging Clean or replace
played on the machine
monitor.
14 Check around aftertreatment devices and removal of dirt - Remove
15 Check around the aftertreatment device for gas leakage - Repair
16 Check of AdBlue/DEF line for leakage - Repair or replace
17 Check of AdBlue/DEF level and type - Add AdBlue/DEF
18 Check of AdBlue/DEF tank breather element - Replace

Hydraulic and mechanical equipment

No. Item Criteria Remedy
1 Check for unusual noise and smell - Repair
2 Check for oil leakage - Repair
3 Check of hydraulic oil level Between H and L Refill with oil
4 Check of hydraulic oil strainer - Clean or replace
5 Check of hydraulic oil filter - Replace
6 Check of oil level in swing machinery case Between H and L Refill with oil
7 Check of oil level in electric swing motor case Between H and L Refill with oil
8 Check of oil level in final drive case - Refill with oil
9 Bleeding air from fuel system - Bleed air
10 Bleeding air from hydraulic circuit - Bleed air

40-50 HB365LC-3
40 TROUBLESHOOTING CHECKS BEFORE TROUBLESHOOTING

Electric equipment
No. Item Criteria Remedy
1 Check of battery terminal for looseness and corrosion - Retighten or replace
2 Check of alternator terminal for looseness and corrosion - Retighten or replace
Check of starting motor terminal for looseness and corro-
3 - Retighten or replace
sion
4 Check of battery voltage (with engine stopped) 20 to 30 V Charge or replace
5 Check of battery electrolyte level Between H and L Refill or replace
Check of wiring harness for discoloration, burn and cover
6 - Repair or replace
peeling
Check for coming off of wiring harness clamp and sagging
7 - Repair
of wiring harness
8 Check of grounding - Repair
9 Check of connector for looseness and lock for damage - Repair or replace
Check of connector pin for corrosion, bends and deforma-
10 - Repair or replace
tion
Check of connector for entering of water and foreign materi-
11 - Dry, clean or replace
al
12 Check of wiring harness for open or short circuit - Repair or replace
13 Check of fuse for blowing out and corrosion - Replace
Check of alternator voltage (when engine speed is medium 27.5 to 29.5 V after few
14 Replace
or higher) minutes of operation
Check of battery relay for operation sound (when turning
15 - Replace
the starting switch to ON or OFF position)
16 Check and cleaning of camera - Clean or repair

Exterior
No.
1 Check of undercarriage
2 Check of handrail and step
3 Check of mirror
Item Criteria Remedy
- Repair
- Repair
- Clean or repair

Interior
No. Item Criteria Remedy
1 Check of gauge and monitor - Clean or replace
2 Check of seat belt - Repair

HB365LC-3 40-51
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 40 TROUBLESHOOTING

INSPECTION PROCEDURE BEFORE TROUBLESHOOTING (PC400_11-A-5150-001-00-B)

WALK-AROUND CHECK (PC400_11-A-5150-289-00-B)

Before starting the engine, look around and under the machine to check for any loose nuts or bolts, leakages of
oil, fuel, or coolant, and check the condition of the work equipment and hydraulic system.
Check the connectors for looseness, wiring harnesses for play, and accumulation of dust in places that reach
high temperatures.
k Accumulated combustibles around hot engine parts such as the engine, after-treatment devices, tur-
bocharger, etc. and fuel or oil leakages may cause a machine fire. Be sure to check thoroughly and
repair any failures.
• Check for unusual sounds and smells
Check for unusual sounds or smells.
If the machine is operated under the unusual sounds or smells, the cause of it may damage the machine,
so stop the operation immediately once you recognize it.
• Check around engine and removal of dirt
Check and remove any accumulated dirt around the engine and any combustibles (dead leaves, twigs, etc.)
on hot engine parts such as the after-treatment devices, turbocharger, etc.
• Check for water leakage around engine
• Check for oil leakage around engine
Check for oil leakage from engine and coolant leakage from cooling system. If any abnormality is found,
repair it.
• Check for leakage from fuel line
Check for fuel leakage, check hoses and pipes for damage. If any abnormality is found, repair it.
• Check of radiator and removal of dirt
Check if there is any accumulated dirt and any combustibles (dead leaves, twigs, etc.) around the radiator.
If any, remove them.
For removal of dirt from the radiator, see the Operation and Maintenance Manual, “Method for checking and
cleaning radiator fins, oil cooler fins, aftercooler fins, and air conditioner condenser fins”.
• Check around aftertreatment devices and dirt removal
Check and remove any accumulated dirt and combustibles (dead leaves, twigs, etc.) around aftertreatment
devices.
• Check around aftertreatment devices for gas leakage
Check piping between the turbocharger and KDPF and joints of aftertreatment devices for gas leakage
(sticking soot, etc.) If any abnormality is found, repair.
• Check of work equipment, cylinders, linkage and hoses for breakage, wear and clearance
Check the work equipment, cylinders, linkage, and hoses for breakage, wear, and clearance. If any abnor-
mality is found, repair it.
• Check of hydraulic equipment, hydraulic tank, hoses, and joints for oil leakage
Check for oil leaks. If any abnormality is found, repair it.
• Bleeding air
For the bleeding air from the fuel system, see Testing and adjusting, “BLEEDING AIR FROM FUEL SYS-
TEM”.
For the bleeding air from the hydraulic system, see Testing and adjusting, “BLEED AIR FROM HYDRAULIC
DEVICES”.
• Check and cleaning of rearview camera
Check the rearview camera for abnormality. If any abnormality is found, repair it
• Check the undercarriage (track, sprocket, idler, guard) for damage, wear, loose bolts, or leakage of oil from
rollers
If any abnormality is found, repair it.
• Check of handrails and steps for abnormality and looseness of bolts
If any abnormality is found, repair it and tighten any loose bolts.
• Check and clean rearview mirrors

40-52 HB365LC-3
40 TROUBLESHOOTING INSPECTION PROCEDURE BEFORE TROUBLESHOOTING

Check rearview mirror for abnormality. If any, repair it.

Clean the mirror surface and adjust the mirror angle so that the rear of the machine can be seen from the
operator's seat.
• Check of gauges and monitors for abnormality
Check gauges and monitors in the operator's cab for abnormality. If any abnormality is found, replace it with
a new one.
Clean up the surfaces.
• Check of seat belt and mounting hardware
Check the hook, the lock, and hook mounting part for damage. If any abnormality is found, repair it.

HB365LC-3 40-53
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

TESTING IN ACCORDANCE WITH TESTING PROCEDURE (PC400_11-A-5150-001-01-B)

CHECK FUEL LEVEL AND TYPE (HB335_3-K-AD00-289-00-B S)

k Fuel is highly flammable and dangerous. Keep the open flame away.
k When adding fuel, be careful not to overflow it. It may cause the fire.
k If any fuel has spilled, wipe it up completely. Also, if fuel has spilled over soil or sand, remove all the
fuel and soil or sand together.
1. Turn the starting switch to ON position. If the fuel level
caution lamp (1) lights up in red, check the remaining fuel
amount with fuel gauge on monitor panel.
If the pointer of fuel gauge indicates the red range, remain-
ing fuel is 56 ℓ or less.
Remaining fuel is low, so add the fuel.
2. After checking, return the starting switch to OFF position.

3. Open the fuel filler cap (F) of the fuel tank, and add fuel
through the fuel filler port until float gauge (G) rises to the
highest position.
Fuel tank capacity: 605 ℓ
Tip position (a) of float gauge (G) when the fuel tank is full
with fuel: Approximately 50 mm

REMARK
If breather hole (3) in the cap is clogged, the pressure in
the tank decreases and fuel may not be supplied. To pre-
vent this, clean the breather hole occasionally.
4. After adding fuel, push the float gauge (G) straight down
with fuel filler cap (F), and tighten the fuel filler cap (F) se-
curely while taking care float gauge (G) is not caught in tab
(2) of the fuel filler cap.

CHECK IMPURE INGREDIENT IN FUEL (HB335_3-K-AD00-289-01-B S)

1. Prepare a container below drain hose (1) to receive drained fuel.

40-54 HB365LC-3
40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

2. Turn the drain valve (2) to OPEN position (O) to discharge

the sediment and water in the bottom together with the
fuel.
3. When only the clean fuel flows out, turn the drain valve (2)
to CLOSE position (S).
4. Close the door on the right side of machine.

CHECK FUEL PREFILTER (HB335_3-K-AEA0-289-00-B)

k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Wait until all parts have cooled down before starting the work.
k High pressure is generated inside the engine fuel piping system when the engine is running. Stop
the engine and wait at least 30 seconds until the inner pressure is released and then replace the fil-
ter.
k Keep the open flame away.
NOTICE
• Komatsu genuine fuel filter cartridges use a special filter that has highly efficient filtering ability.
When replacing it, Komatsu recommends using Komatsu genuine parts.
• The common rail fuel injection system used on this machine consists of more precise parts than
those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genuine
fuel filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Never use a substitute.
• During testing or maintenance of the fuel system, take extreme care that any foreign material does
not enter the fuel system. If any dust or other material sticks to any part, wash the part thoroughly
with clean fuel.
• Prepare a container to receive oil.
• Prepare a filter wrench.

WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT (HB335_3-K-AEB0-289-00-B)

1. Open the door on the right side of machine.
The water separator is integrated with fuel prefilter (1).
2. You can judge the water amount and sediment through
transparent cup (2). If water or sediment is accumulated,
place a container to receive it under drain hose (3).
• This machine is equipped with sensor which detects
water accumulated in transparent cup (2).
• When the water separator caution lamp lights up in
red on machine monitor, water is accumulated in
transparency cup (2). Drain the water.
• If the water accumulated in transparency cup (2) is
frozen, water separator caution lamp may not light up. Also, after starting the engine, when tempera-
ture around fuel prefilter (1) rises and frozen water melts and changes to water, water separator cau-
tion lamp may suddenly light up. Drain the water frequently at cold weather even when the water sepa-
rator caution lamp is not lit.
• If water in transparent cup (2) is frozen, drain the water only after confirming that it has completely
melted.
• If you cannot visually identify the presence of water due to stains on transparent cup (2), clean trans-
parent cup (2) when replacing fuel prefilter cartridge (1).
3. Loosen drain valve (4) and drain the water.

HB365LC-3 40-55
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

4. When the fuel starts to drain from drain hose (3), tighten drain valve (4) immediately.
REMARK
When you have removed drain valve (4) while cleaning, coat the O-ring with grease and tighten drain valve
until it touches the bottom.

METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE (HB335_3-K-AEA0-289-01-B)

k Immediately after the engine is stopped, the parts are still very hot. Accordingly, do not replace the
filter immediately. Wait for all of parts to cool down before starting the work.
k High pressure is generated inside the engine fuel piping system when the engine is running.
When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal
pressure go down before replacing the filter.
k Keep the open flame away.
NOTICE
• Komatsu genuine fuel filter cartridges use a special filter that has highly efficient filtering ability.
When replacing it, Komatsu recommends using Komatsu genuine parts.
• The common rail fuel injection system used on this machine consists of more precise parts than
those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genuine
fuel filter cartridge is used, dust or dirt may get in and cause problems with the injection system.
Never use a substitute.
• When performing inspection and maintenance of the fuel system, be careful not to let any foreign
material get in, more than ever before. If dust sticks to the fuel system, wash it off thoroughly with
fuel.
Items to be prepared
• Container to receive the drained oil.
• Filter wrench
1. Remove the cover (8) at the bottom of the fuel tank. (only
for the machine equipped with this)

40-56 HB365LC-3
40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

2. Turn the valve (1) at the bottom of the fuel tank to CLOSE
position (S).

3. Open the door on the right side of machine.

4. Place a container under the fuel prefilter cartridge (4) to re-
ceive the fuel.
5. Loosen the drain valve (2) and drain the water and sedi-
ments from transparent cup (3), and also drain all the fuel
from filter cartridge (4).
6. Disconnect the connector (5).
7. Wrap the removed connector with a plastic bag to prevent
it from being splashed with fuel, oil or water.
8. Turn the transparent cup (3) counterclockwise to remove it
by using the filter wrench. The transparent cup (3) will be used again.
9. Turn the filter cartridge (4) counterclockwise to remove it by using the filter wrench.
10. Install the currently removed transparent cup (3) to the bottom of the new fuel prefilter cartridge.
At this time, replace the O-ring (6) with a new one.
REMARK
• When installing the transparent cup, spread the oil thinly over the packing surface, contact it to the seal-
ing surface of filter cartridge (4), and then tighten it by 1/4 to 1/2 turn.
• If the transparent cup is fastened too much, the O-ring will be damaged and this leads to leakage of
fuel. If it is too loose, fuel will also leak from gaps of the O-ring. Therefore, be sure to observe the fas-
tening angle.
11. Clean the filter holder, fill the new filter cartridge with clean fuel, spread the oil thinly over the packing sur-
face, then install it to the filter holder.

HB365LC-3 40-57
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

NOTICE
• When adding fuel, do not remove the cap (B) at the
center. Always fill the fuel from the dirty side (8 pla-
ces) of small holes (A).
• After adding fuel, remove the cap (B) at the center
and install the fuel filter.
• Always fill with clean fuel. Be careful not to let any
dirt or dust get into the fuel. In particular, center
part is the clean side, so do not remove the cap (B)
when adding fuel. Be careful to prevent dirt or dust
from entering the center clean side part.
12. When installing the cartridge, tighten it until the packing surface contacts the sealing surface of the filter
head, and then further tighten it by 1/2 to 3/4 turns.
REMARK
If the filter cartridge is fastened too much, the packing will be damaged and this leads to leakage of fuel. If
the filter cartridge is too loose, fuel will also leak from the packing. Be sure to observe the tightening angle.
When using a filter wrench for tightening, take care not to leave flaws or dents on the filter.
13. Check that the drain valve (2) is closed securely.
14. Remove the plastic bag wrapping the connector (5), then connect the connector (5).
REMARK
• If water gets on the connector (5), the sensor may mal-
function and the water separator caution lamp may
light up. When removing the connector (5), be extreme-
ly careful that water does not attach to the connector.
• If water gets on the connector (5), dry it completely be-
fore connecting it.

15. Set the valve (1) at the bottom of fuel tank to OPEN posi-
tion (O).

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40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

16. Install the cover (8) at the bottom of the fuel tank. (only for
the machine equipped with this)
17. After completing the replacement of filter cartridge (4),
bleed the air from the fuel line.
REMARK
For the bleeding air from the fuel system, see TESTING
AND ADJUSTING, “BLEED AIR FROM FUEL SYSTEM”.

If there is still fuel leakage, repeat steps 1 to 9 to remove the filter cartridge, and if any damage or pinched for-
eign material on the packing surface is found, replace it with a new cartridge and then perform the remaining
steps after 10 to install it.

CHECK MAIN FILTER (HB335_3-K-AED0-289-00-B)

k Immediately after the engine is stopped, the parts are still very hot. Accordingly, do not replace the
filter immediately. Wait for all of parts to cool down before starting the work.
k High pressure is generated inside the engine fuel piping system when the engine is running.
When replacing the filter, wait for at least 30 seconds after stopping the engine to let the internal
pressure go down before replacing the filter.
k Keep the open flame away.
k When you open the air bleeding plug of fuel filter head, be careful. Fuel may spout out due to the
remaining pressure.
NOTICE
• Komatsu genuine fuel filter cartridges adopt a special filter with high-efficiency filtering properties.
Komatsu recommends using Komatsu genuine parts when replacing.
• The common rail fuel injection system used on this machine consists of more precise parts than
those in the conventional injection pump and nozzles. If any cartridge other than a Komatsu genuine
fuel filter cartridge is used, foreign materials may enter and problem may occur in the injection sys-
tem. Never use a substitute.
• When performing inspection and maintenance of the fuel system, be careful not to let any foreign
material get in, more than ever before. If dust sticks to the fuel system, wash it off thoroughly with
fuel.
Items to be prepared
• Container to receive the drained oil.
• Filter wrench
1. Remove the cover (3) at the bottom of the fuel tank. (only
for the machine equipped with this)

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TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

2. Turn the valve (1) at the bottom of the fuel tank to CLOSE
position (S).

3. Open the door on the right side of machine.

4. Place a container under the filter cartridge (2) to receive
the fuel.
5. Turn the filter cartridge (2) counterclockwise by using the
filter wrench, and remove it.
• After removing the filter cartridge, fuel falls in drops
from the filter head.
• In order to prevent an outflow of the fuel, be sure not
to leave the machine while the filter cartridge is re-
moved.
6. Clean the filter holder, spread the oil thinly over the packing surface of the new filter cartridge, and install it
to the filter holder.
NOTICE
• Do not fill the new filter cartridge with fuel.
• Remove the cap (B) in center part, and install the
filter cartridge.
7. When installing the cartridge, tighten it until the packing
surface contacts the sealing surface of the filter head, then
tighten it 3/4 of a turn.
If the filter cartridge is fastened too much, the packing will
be damaged and this leads to leakage of fuel. If the filter
cartridge is too loose, fuel will also leak from the packing.
Be sure to observe the tightening angle.
When using a filter wrench for tightening, take care not to leave flaws or dents on the filter.
8. Set the valve (1) at the bottom of fuel tank to OPEN position (O).

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40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

9. Install the fuel tank cover (3). (only for the machine equip-
ped with this)
10. After completing the replacement of filter cartridge (2),
bleed the air from the fuel line.
REMARK
For the bleeding air from the fuel system, see TESTING
AND ADJUSTING, “BLEED AIR FROM FUEL SYSTEM”.

CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) (HB335_3-K-AB01-289-00-B)

k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
Items to be prepared
• Container to receive the drained oil.
REMARK
• When checking the oil level after the engine is stopped, wait at least 15 minutes after stopping the engine.
If the machine is inclined, make it level before checking.
• When the ambient temperature is low, water or emulsified matter may stick to the dipstick, oil filler cap, etc.
or the drained oil may be milky white because of water vapor in the blowby gas. However, if the coolant level
is normal, it is not a problem.
1. Open the engine hood.
2. Pull out the dipstick (G) and wipe the oil off with a cloth.
3. Fully insert the dipstick (G) into the dipstick pipe again,
then pull it out.

4. Check if the oil is sticking up to between marks H and L on

the dipstick (G).
REMARK
• If the oil level is between marks H and L, it is normal.
• If the oil level is below mark L, add oil through oil filler
port (F).

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TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

5. If the oil level is above mark H, make it normal by following

method.
1) Remove cover (1).
2) Install the hose (2) in the tool box.
3) Drain the extra engine oil through drain valve (P) at
the bottom of the engine oil pan.
When draining the engine oil, place a container to re-
ceive the oil under the drain plug.
6. Check the oil level again.
7. When the oil is at the correct level, tighten the oil filler cap
securely and close the engine hood.

CHECK OIL LEVEL IN MOTOR-GENERATOR CASE (HB335_3-K-PQH8-289-00-B)

k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
1. Pull out the dipstick (G) at oil filler port (F), and wipe off the
oil on the dipstick with a cloth.
2. Insert the dipstick (G) fully into oil filler port (F).

3. Pull out the dipstick (G) and check the oil level. If the oil
level is between (H) mark and (L) mark on the dipstick, it is
appropriate.
4. If the oil level is below mark (L) on dipstick (G), add oil
through oil filler port (F).

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40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

5. If the oil level is above (H) mark on dipstick (G), remove

the cover (A) under the motor-generator, and loosen the
drain valve (P) to drain the excess oil.
6. After checking oil level or adding oil, insert the dipstick (G)
into oil filler port (F).
REMARK
If the machine is inclined, make it level before checking.

CHECK COOLANT LEVEL (RESERVOIR TANK) (HB335_3-K-AC20-289-00-B)

k Do not open the radiator cap under normal conditions. Check the coolant level at the reservoir tank
when the engine has cooled down.
k Immediately after the engine is stopped, the coolant is still very hot and the pressure is accumulated
in the radiator. If the cap is removed in this condition, it is dangerous that you may get burn injury.
Wait until it has cooled down, and turn the cap slowly to release the pressure, and remove it careful-
ly.
1. Open the door at rear right of the machine.
2. Check the reservoir tank (1).
When the coolant level is between the FULL and LOW
marks, it is normal.
If it is below LOW mark, add the coolant to FULL mark
from water filler port of reservoir tank (1).
NOTICE
If the reservoir tank is empty, leakage of coolant
should be suspected. If any abnormality is found after
check, repair it immediately.
3. After adding, tighten the cap securely.
4. Check the coolant level in the radiator. If it is low, add Non-
Amine Engine Coolant (AF-NAC) of the same density to
the radiator, then add it to reservoir tank.

HB365LC-3 40-63
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

5. Check that the coolant sight gauge (3) for hybrid radiator is
filled with coolant. If it is not filled, remove the radiator cap
(4) for hybrid component, and add the coolant to position
(a) of sight gauge (5).
NOTICE
• Check the coolant level of radiator for hybrid com-
ponent. If it is low, add coolant to the radiator.

Radiator for engine

(6) Radiator for engine
(7) Radiator cap for engine

Radiator for hybrid component

(8) Radiator for hybrid component
(4) Radiator cap for hybrid component

CHECK CLOGGING OF AIR CLEANER (HB335_3-K-A910-289-00-B)

k When using compressed air for cleaning, put on personal protective items such as protective eye-
glasses, gloves, dust mask to protect yourself from dirt that will fly out.
k When removing the outer element from the air cleaner body, do not forcibly pull it out, otherwise it
can be dangerous.
k When working in high places or on poor footing, be careful not to fall because of the reaction when
pulling out the outer element.

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40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

Check that the air cleaner clogging caution lamp (1) lights up
on monitor panel.
REMARK
• Until the air cleaner clogging caution lamp on monitor panel
lights up, do not clean the air cleaner element. If you clean
the element frequently before the air cleaner clogging cau-
tion lamp on monitor panel lights up, the air cleaner will not
deliver optimum performance and the cleaning efficiency
will be reduced.
• Inspection, cleaning or servicing while the engine is running
allows entry of dusts into the engine since dusts attached to
the element drop into the inner cylinder element more fre-
quently, and it can damage the engine. Be sure to stop the
engine before cleaning.

OUTER ELEMENT - CLEAN (HB335_3-K-A92G-289-00-B)

NOTICE
• Never remove the inner element. Dust may enter and it may lead to failures of the engine.
• Do not use a screwdriver or other tool.
• When cleaning the element, do not hit it or beat it against something.
• Before and after cleaning, be careful not to leave or store the element being exposed to the direct
sunlight.
Clean the outer element according to the following procedure.
1. Open the door on the rear right of the machine, remove
the hooks (2) (3 places), and remove the cover (3).

2. Hold the outer element (5), rock it lightly up and down and
to the right and left, and pull it out while turning it to the
right and left.
3. When outer element (5) is removed, check that inner ele-
ment (6) does not come off or incline.
NOTICE
• If it is tilted, push it straight to the bottom with your
hand.
4. After removing the outer element (5), cover the inner ele-
ment (6) with a clean cloth or tape to protect from dusts.
5. Clean dusts inside of air cleaner body (7) and on cover (3) by using a clean cloth or brush.

HB365LC-3 40-65
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

6. Remove any dirt or dust that is accumulated on vacuator

valve (4) installed to cover (3).
7. When the outer element has been cleaned 6 times or used
for 1 year, replace it.
• When the replacement is necessary,
Replace the inner and outer elements with new ones
referring to the paragraph of "REPLACE ELEMENT".
• When the replacement is not necessary,
Clean the outer element. Continue the cleaning proce-
dure.
8. Blow the dry compressed air (0.2 MPa {2.1 kg/cm2} or
less) from the inside of outer element along the pleats.
9. Blow the air along the pleats from the outside, then blow
again from the inside.

10. After cleaning the element, illuminate the inside of the ele-
ment with an electric bulb to check.
REMARK
If any holes or thin places are found, replace the inner and
outer elements.
11. Remove the cover of cloth or tape attached to inner ele-
ment (6).

NOTICE
• Do not use the element if its pleats or gasket or seal are damaged.
• Do not reuse by cleaning an element or O-ring that has been in service for one year since it may
cause troubles.
12. Check the seal of the cleaned or new element for adhesion of dusts and oil, and wipe them off, if any.
NOTICE
• Air cleaner element has directional properties for the
installation. When installing the air cleaner element, set
it in such that its cylinder bottom (side without a hole)
(B) and (C) comes to cover (3) side. If they are installed
in the wrong direction, serious troubles including dam-
age on the air cleaner elements and engine may occur.
• When inserting the element, if cover (3) is forcibly in-
stalled with hook (2) in the condition that rubber at the
end is swelling or the outer element has not been in-
serted straight, the hook or air cleaner body may be
damaged. Take care.
13. Push the outer element straight into the air cleaner body with your hand.
Hold the outer element, and rock it lightly up and down and to the right and left while pushing it in, and you
can insert it easily.
14. Install the cover (3) according to the following procedure.

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40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

1) Check that O-ring (8) is fitted to cover (3).

2) Align the cover (3) with the element.

3) Lock the tip of hook (2) on the protrusion of the air

cleaner body.

4) Install the cover (3) so that vacuator (4) faces down

(A).
5) When cover (3) is installed, check that the clearance
between the air cleaner body and cover (3) is not too
large.
If the clearance is too large, remove the cover (3), and
then install it again.
15. Check the air cleaner clogging caution lamp on monitor
panel.

ELEMENTS - REPLACE (HB335_3-K-A92H-289-00-B)

Replace the element according to the following procedure.
1. Open the door on the rear right of the machine, remove
the hooks (2) (3 places), and remove the cover (3).

2. Hold the outer element (5), rock it lightly up and down and to the right and left, and pull it out while turning it
to the right and left.

HB365LC-3 40-67
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

Do not remove the inner element (6) at this time.

3. When outer element (5) is removed, check that inner ele-
ment (6) does not come off or incline.
REMARK
If it is tilted, push it straight to the bottom with your hand.

4. Clean dusts inside of air cleaner body (7) and on cover (3)
by using a clean cloth or brush.
5. Remove any dirt or dust that is accumulated on vacuator
valve (4) installed to cover (3).

NOTICE
• Do not clean and reuse the inner element. When replacing the outer element, replace the inner ele-
ment with new one at the same time.
• If the outer element and cover are installed while the inner element is not installed properly, the outer
element may be damaged.
• The sealing area of the imitation part lacks precision, and allows the entry of dust, which leads to
damage of the engine. Do not use such imitation part.
6. Remove the inner element (6), and then install the new inner element immediately.
Install the inner element securely so that it does not move.
7. Push the outer element (5) straight into the air cleaner body with your hand.
Hold the outer element, and rock it lightly up and down and to the right and left while pushing it in, and you
can insert it easily.
8. Install the cover (3) according to the following procedure.
1) Check that O-ring (8) is fitted to cover (3).
2) Align the cover (3) with the element.

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40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

3) Lock the tip of hook (2) on the protrusion of the air

cleaner body.

4) Install the cover (3) so that vacuator valve (4) faces

down (A).
5) When cover (3) is installed, check that the clearance
between the air cleaner body and cover (3) is not too
large.
REMARK
If the clearance is too large, remove the cover (3), and
then install it again.

CHECK HYDRAULIC OIL LEVEL (HB335_3-K-L2U0-289-00-B)

k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
k When removing the oil filler cap, the oil may spout out. Turn it slowly to release the internal pres-
sure, then remove it.
1. Set the work equipment to the posture shown in the figure
according to the following procedure.
1) Start the engine, and run it at low idle.
2) Retract the cylinder rod of arm and bucket fully.
3) Lower the boom so that the bucket tooth contacts the
ground.
4) Stop the engine.
2. Turn the starting switch to ON position within 15 seconds
from the engine stop. Operate all control levers (work
equipment and travel) to the travel end in each direction to
release internal pressure.
3. Stop the engine.
4. Open the door on the left side of machine, and then check
the sight gauge (G).
When the oil level is between the lines H and L, it is appro-
priate.

5. If the oil level is below L line, add oil through the oil filler port (F) until the oil level comes between H line
and L line of sight gauge (G).

HB365LC-3 40-69
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

NOTICE
• Do not add oil above H line. It may damage the oil
circuit and cause the oil to spurt out.
• If oil is added above H line, swing the upper struc-
ture so that drain plug (P) under the tank comes in
the middle between the right and left tracks. Stop
the engine, wait for the hydraulic oil to cool down,
and then remove the cover (1) and discharge ex-
cess oil from drain plug (P) to a container to re-
ceive the drained oil.
REMARK
Since the oil level varies in accordance with the oil temper-
ature, use the following as a guide for check.
• Before operation, the oil level should be at the middle
between lines H and L.
(oil temperature: 10 to 30 °C)
• At the normal operation, the oil level should be around
H line.
(oil temperature: 50 to 80 °C)

CHECK HYDRAULIC OIL STRAINER (HB335_3-K-PM3E-289-00-B)

k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
k When removing the oil filler cap, the oil may spout out. Turn it slowly to release the internal pres-
sure, then remove it.
1. Remove the cap of the hydraulic tank oil filler port (F) to re-
lease the internal pressure.
NOTICE
When removing the cover, it may jump out under the
reaction force of spring. Loosen bolts evenly while
holding cover down, and remove it.

2. Remove the bolts (6 pieces), and remove the cover (1).

3. Hold the top of the rod (3) and pull it up to remove the
spring (2) and strainer (4).
4. Remove any dirt stuck to strainer (4), then wash it in flush-
ing oil. If strainer (4) is damaged, replace it with a new
one.
5. Insert the strainer (4) in protruding portion (5) of the tank
side to install.
6. Install the bolts while pressing down spring (2) with the
projection at the bottom of cover (1).
7. Install the cap of the oil filler port.

CHECK HYDRAULIC FILTER (HB335_3-K-PM35-289-00-B)

k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
k When removing the oil filler cap, the oil may spout out. Turn it slowly to release the internal pres-
sure, then remove it.

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40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

Items to be prepared
• Container to receive the drained oil.
• Refill capacity188 ℓ
1. Place the machine on a level and firm ground, put the work
equipment on the ground with the posture as shown in the
figure, and stop the engine.

2. Remove the cap of the hydraulic tank oil filler port (F) to re-
lease the internal pressure.

3. Loosen the bolts (6 pieces) and remove the cover (1).

The cover may jump out by spring (2). Keep pressing down the cover and remove the bolts.
REMARK
Loosen the mounting bolts of cover (1) and leave as is for
approximately 5 minutes, and internal pressure of case is
released, so the oil in the element disappears and oil drip
decreases during replacement of element.
4. Remove the spring (2), valve (3) and strainer (4), and then
remove the element (5).
5. Check the bottom of the filter case, and remove the dirt,
etc. if any.
Take extreme care that the dirt, etc. does not fall into the
hydraulic tank.
6. Clean the removed parts by using cleaning oil.
7. Install the element (5).
8. Set the strainer (4), valve (3) and spring (2) onto the element.
9. Set the cover (1) and install it with the cover mounting bolts while pressing it by hand.
10. Install the oil filler cap.
11. To bleed the air, run the engine at low idle for 10 minutes.
12. Stop the engine.
REMARK
Rest for 5 minutes or more, and then start the operation. By this action, the bubbles in the oil inside the tank
is discharged.
13. Check the oil leakage, and wipe off the spilled oil thoroughly.

HB365LC-3 40-71
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

CHECK CAPACITOR (HB335_3-K-PQGB-289-00-B)

1. Turn the starting switch key to ON position (B).

NOTICE
Do not start the engine at this point.

2. Open the cover at the front right of machine, look into the
inspection window (1) of the capacitor, and check that LED
lamp (1 piece) is lit.
• After the engine is stopped for a long time, all LED
lamps may go out.
If all LED lamps are not lit, start the engine and wait
for approximately 2 minutes, stop the engine and
check again.

3. Turn the starting switch key to START position (C) to start

the engine.
4. Look into the inspection window (1) of the capacitor again,
and check that both right and left LED lamps are lit.

CHECK OIL LEVEL IN ELECTRIC SWING MOTOR CASE (HB335_3-K-RA23-289-00-B)

k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
Items to be prepared
• Container to receive the drained oil.
• Refill capacity3.0 ℓ

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40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

1. Remove the undercover (A).

2. Place a container under drain plug (P) for swing machinery
on the bottom side of the machine and drain plug (Q) for
electric swing motor to receive the oil.
3. Loosen the drain plug (P) for swing machinery on the bot-
tom side of the machine and drain plug (Q) for electric
swing motor, and drain the oil. After completing to drain the
oil, tighten them.
REMARK
• When the draining oil becomes thread-like, you can
stop the draining work.
• Before draining the oil, swing the upper structure to
raise the oil temperature, so that the draining work time
can be shortened. However, never swing the upper
structure during the draining work, because it may
cause the damage of swing machinery.

4. Remove the dipstick (G) from oil filler port (F) of the swing
machinery, and add the refill capacity of oil.
5. Remove the dipstick (G) from oil filler port (F) of the swing
machinery, and add the refill capacity of oil.
6. Check the oil level with dipstick (G) of the swing machinery
and dipstick (K) of the swing motor.
7. Start the engine, and leave it as is for 5 minutes or more.
8. Stop the engine and wait until each part has cooled down
to the normal temperature. Check the oil level again with
dipstick (G) of the swing machinery and dipstick (K) of the
swing motor.

CHECK OIL LEVEL IN SWING MACHINERY CASE (HB335_3-K-J130-289-00-B)

k Immediately after the engine is stopped, its parts and oil are still very hot and may cause burn injury.
Wait for the temperature to go down, and then start the work.
1. Pull out the dipstick (G) at oil filler port (F), and wipe off the
oil on the dipstick with a cloth.
2. Insert the dipstick (G) fully into guide (F).

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TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

3. Pull out the dipstick (G) and check the oil level. If the oil
level is between (H) mark and (L) mark on the dipstick, it is
appropriate.
4. If the oil level is below mark (L) on dipstick (G), add oil
through oil filler port (F).

5. If the oil level is above mark (H) of dipstick (G), loosen the
drain valve (P) and drain the excess oil.
When draining the oil, place an oil container under drain
valve (P).
6. After checking oil level or adding oil, insert the dipstick (G)
into oil filler port (F).

CHECK OIL LEVEL IN FINAL DRIVE CASE (PC400_11-K-DF10-289-00-B)

k Since the oil may spurt out due to internal pressure, rotate the plug gradually from its side to release
the internal pressure and then remove it carefully.
k Immediately after the engine is stopped, its parts and oil are still very hot, and may cause burn in-
jury. Accordingly, wait until all parts have cooled down before starting the work.
• Refill capacity (each of right and left): 5.0 ℓ
• Prepare a hex wrench for the work.
1. Set the TOP mark at the top, and the line running on TOP
mark and plug (P) perpendicular to the ground.
2. Place the oil container to receive oil under plug (P).
3. Remove plugs (P) and (F) by using the hex wrench, and
drain oil.
Check for damages on O-ring attached to the plugs. Re-
place it if necessary.
4. Tighten plug (P).
5. Refill oil through plug (F) hole.
6. If oil flows out of the plug (F) hole, install the plug (F).
3 Tightening torque of plugs (P) and (F): :
68.6 ± 9.8 Nm 7 ± 1 kgm
NOTICE
There are 2 plugs (F). For refilling, use the one which
is easier for refilling and inner gear is not seen
through.

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BLEED AIR FROM FUEL SYSTEM (PC400_11-K-AD00-289-02-B)

For the bleeding air from the fuel system, see “TESTING AND ADJUSTING”, “BLEED AIR FROM FUEL SYS-
TEM”.

BLEED AIR FROM HYDRAULIC SYSTEM (PC400_11-K-C000-289-00-B)

For bleeding air from the hydraulic system, see “TESTING AND ADJUSTING”, “BLEED AIR FROM HYDRAUL-
IC CIRCUIT”.

METHOD FOR CHECKING ELECTRIC EQUIPMENTmethod (HB335_3-P-E000-289-00-B)

Check of battery terminal for looseness and corrosion
1. Check the battery cable terminals for looseness and corrosion.
2. Check for any accumulated dirt and combustibles (dead leaves, twigs, etc.) around the batteries. If any, re-
move them.
Check of alternator terminal for looseness and corrosion
3. Check the alternator terminals B, R and E for open circuit, looseness and corrosion.
Check of starting motor terminal for looseness and corrosion
4. Check the starting motor terminals B and C for open circuit, looseness and corrosion.
Check of battery voltage (with engine stopped)
5. Check the battery voltage by using the battery tester while the engine is stopped.
Check of battery electrolyte level
6. Check the battery electrolyte level according to the following procedure.
k Battery electrolyte level must be checked before operating the machine.
k Do not use the battery if the battery electrolyte level is below LOWER LEVEL line. If you do so, it
will reduce the service life of the battery. In addition, it may cause an explosion.
k Since the battery produces combustible gas that can explode, do not bring any open flame near
it.
k Battery electrolyte is dangerous. Take care that it does not come in contact with your eyes or
skin. If it does, wash it off with a large amount of water and consult a doctor.
NOTICE
• Do not add the electrolyte to the battery exceeding UPPER LEVEL line. If the electrolyte level is
too high, it may leak and cause damage to the paint surface or corrode other parts.
• To avoid freezing, add the purified water (such as a commercial battery fluid) before starting the
work in the next day.
• When checking the electrolyte level through the side face of the battery
1) Clean around the electrolyte level lines with a wet
cloth, and check that the electrolyte level is be-
tween the UPPER LEVEL (U.L.) and LOWER
LEVEL (L.L.) lines.
k Do not clean the battery with a dry cloth
since static electricity may cause an explo-
sion.
2) If the electrolyte level is below the center between
the UPPER LEVEL (U.L.) and LOWER LEVEL
(L.L.) lines, remove cap and add purified water
(example: commercially available battery fluid) to
the UPPER LEVEL (U.L.) line immediately.
3) After adding, tighten the cap securely.

HB365LC-3 40-75
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

NOTICE
If the purified water is added to above UPPER LEVEL (U.L.) line, remove the fluid by using a
syringe to lower the level to UPPER LEVEL (U.L.) line. Neutralize the removed fluid with
baking soda (sodium bicarbonate), and then flush it away with a large amount of water.
• When electrolyte level cannot be checked through the side face of the battery
1) Remove the caps from the top of battery. (descri-
bed before)
2) Look into the fluid filler port (3) and check the
electrolyte level. If the electrolyte does not reach
the sleeve (4), always add the purified water (e.g.
commercially available replenishment water for a
battery) so that the level reaches the bottom of
the sleeve (UPPER LEVEL line).
• (A) Correct level: Since the electrolyte level
reaches to the sleeve bottom, the shape of
the electrode plates will appear distorted due
to the surface tension.
• (B) Low: Since the electrolyte level does not reach the sleeve bottom, the shape of the elec-
trode plates will appear straight.
3) After adding, tighten the cap.
NOTICE
If the purified water is added to above UPPER LEVEL (U.L.) line, remove the fluid by using a
syringe to lower the level to UPPER LEVEL (U.L.) line. Neutralize the removed fluid with
baking soda (sodium bicarbonate), and then flush it away with a large amount of water.
Check of wiring harness for discoloration, burn and cover peeling
7. Check the wiring harness and cables for discoloration and burn.
k If discolored or burnt, the circuit may be shorted or grounded.
• Check the wiring harnesses and cables for damage and peeling of the covers.
• If any abnormality is found, repair or replace the wiring harness or cables.
Check for coming off of wiring harness clamp and sagging of wiring harness
8. Check wiring harness for sagging and looseness due to
coming off of harness clamp.
REMARK
In particular, carefully check the wiring harness around the
hot and movable parts. If removed from the clamp, secure
it with the clamp.

40-76 HB365LC-3
40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

Check of grounding
9. Check the connecting state of each ground terminal.
• Check the mounting bolts and nuts for looseness.
• Check the contact face between ground terminal (1)
and mounting place of machine body for sticking of
the insulator such as foreign material, etc.
Battery ground cable is shown in the figure as an ex-
ample.
• For the position of each ground, see “CONNECTORS
LIST AND LAYOUT”.

Check of connector for looseness and lock for damage

10. Check the connection of male and female connectors by pulling them by hand.
11. If the connection is loose, secure it.
12. Check the connectors for unlocking, and check the lock
and connector housing for cracking.

13. Check the lock screw (2) of engine controller (1) for loose-
ness.
REMARK
Use a hexagonal wrench with 5 mm width across flats.

Check of connector pin for corrosion, bends and deformation

14. Disconnect the connectors, and check their pins for corrosion, bending, sinking than other pins, and exten-
sion of female pins.
• If pins are defective, repair or replace them.
• If the pins are not shiny, apply contact restorer to them and connect and disconnect the connectors
several times to shine them. (If the pins do not become shiny, connect and disconnect the connectors
10 times)

HB365LC-3 40-77
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 40 TROUBLESHOOTING

Check of connector for entering of water and foreign material

15. Disconnect the connectors, and check them for entering of
water or foreign material inside the connector.
REMARK
If there is entering of water or foreign material inside con-
nector, the seals may be damaged. Check the seals for
damage.

• If the seal is defective, repair or replace it.

• Dry the inside of the connector with a dryer.

• Wipe and remove any foreign material inside connec-

tor with a cloth or others, and blow the air to clean the
connector.

Check of wiring harness for open or short circuit

16. Check the connection (crimped part) between connector pins and wiring harness.
17. If it is open as shown as A, repair or replace the wiring har-
ness or cables.
18. Visually check wiring harnesses for peeling of harness
covers and the pins for contact with adjacent pins due to
defective crimping.

Check of fuse for blowing out and corrosion

19. When replacing a fuse, be sure to turn off the power (turn the starting switch to OFF position) and turn the
battery disconnect switch to OFF position.

40-78 HB365LC-3
40 TROUBLESHOOTING TESTING IN ACCORDANCE WITH TESTING PROCEDURE

• A fusible link is a large-capacity fuse.

• If a fuse is corroded and coated with white powder, or there is any play between the fuse and fuse
holder, replace the fuse.
• Replace each fuse with the one of the same capacity.
20. The fuse holder is provided behind the operator's seat.

21. Open the rear left cover, and fusible links F04, F05 and
(F11, F12) are seen.

Check of alternator voltage (when engine speed is medium or higher)

22. Open the engine hood.
23. Connect the positive (+) lead of the multimeter to alternator terminal (B) and connect the negative (-) lead to
the chassis ground.
24. Start the engine and warm it up, and measure the voltage while running the engine at a medium or a higher
speed.
REMARK
If the voltage is abnormal, repair or replace the alternator.
Check of battery relay operation sound
25. Open the side cover on the left side of the machine.
26. Turn the starting switch to ON and OFF positions, and check if the battery relay operation sound is heard.
• If the operation sound is not heard, check the related circuit. For details, see “ENGINE DOES NOT
START (ENGINE DOES NOT CRANK)” in E mode.
• If the relating circuit is normal, replace the battery relay.

HB365LC-3 40-79
AUTOMATIC GREASE SYSTEM
AUTOMATIC GREASE SYSTEM
FINDING MALFUNCTIONS
General
The greasing system is equipped as standard with an electronic control unit with a database. All relevant data
concerning the functioning of the greasing system are stored in that database. This data can be read with a lap-
top and software.
Recognising malfunctions
Malfunctions are recognisable or discovered as follows:
• Display shows a malfunction report.
• Reading the malfunction reports saved in the database of the control unit.
• The grease level in the pump no longer decreases.
• When visually checking the bearings, it appears that no fresh grease is present.
Malfunction reports of the display
Malfunction Cause
1. Signal lamp lights continuously for The grease pressure switch did not
2minutes at the end of every pumping switch. Probable causes:
phase.
a. The primary grease line leaks. Be-
cause of this, no pressure can be
built up.
b. Air in the system. Within the maxi-
mum pumping time insufficient pres-
sure is built up.
c. Broken grease pressure switch.
d. O-ring damaged or left out when
replacing a metering unit, grease
pressure switch or blind plug. Be-
cause of this it is possible that grease
flows from one line to the other.
e. 5/2 valve broken. Because of this,
no pressure can be built up.
f. Internal leak of metering unit or
grease pressure switch.
g. Surrounding temperature too low
or grease too viscous.
h. Wiring defect or bad contacts.
i. Other probable cause.
2. Display still gives no signal after 1 a. No supply voltage on the display
minute.
b. Earth (ground) lead disconnected.
c. Display broken
40-80
40 TROUBLESHOOTING
(PC490_11-K-Q810-001-00-B)
(PC490_11-K-Q810-383-00-B)
Solution
a. Replace or repair the line and vent
the relevant line.
b. Vent both primary lines and carry
out the single-test cycle twice.
c. See malfunction finding procedure
for the grease pressure switch.
d. Check and mount a new O-ring if
necessary. Also see malfunction find-
ing procedure of internal system leak.
e. See malfunction finding procedure
pump and 5/2 magnetic valve.
f. Replace the metering unit or grease
pressure switch.
g. Replace the grease.
h. Check the wiring and contacts. Re-
place if necessary.
i. Consult the dealer.
a. Check the fuses and/or feeder con-
nection (grey wire no. 1). Replace or
repair it if necessary.
b. Check the earth (ground) wire
(grey wire no. 2). Repair it if necessa-
ry.
c. Replace the display.
HB365LC-3
40 TROUBLESHOOTING
3. Red alarm lamp flashes continu-
ously, for 1 minute after turning on
the contact switch.
No operating mode is indicated.
4. Yellow lamp is lit continuously.
5. Yellow lamp is lit and red lamp
flashes continuously.
No operating mode is indicated.
6. All grease points contain no grease a. The adjusted greasing interval is
and no malfunction reports have
been given and the signal lamp is not
defect.
7. All greasing points contain an ex-
cessive amount of grease.
8. One or more greasing points con-
tain no grease while the other points
receive sufficient grease.
9. One or more greasing points re-
ceive excessive amount of grease
while the other points do receive the
right amount of grease.
HB365LC-3
AUTOMATIC GREASE SYSTEM
a. No communication between dis- a. Check the communication wire
play and control unit. (grey wire no. 6, connected to wire
no. 6 of the pump cable).
Red lamp is automatically reset after
communication is restored.
b. Pump is switched off because the b. See Cause and Solution of point 1
pressure switch did not switch during of the signal lamp table.
a sequence of successive cycles. Press the test push-button on the
pump for 1 second to reset this mal-
function.
NOTICE
Pump remains switched OFF if
this malfunction is not reset.
Minimum grease level in the reservoir Refill the reservoir. The malfunction
is reached. report is automatically reset after re-
filling the reservoir.
Pump is switched off because the Refill the reservoir, after which the
pressure switch did not switch during malfunction is automatically reset and
a sequence of successive cycles, the operating mode is indicated
while the grease level was at the min- again.
imum level.
a. Adjust a shorter greasing time in-
too long for the relevant application. terval with the push-button (if
present) or with the laptop and soft-
ware.
b. No supply voltage on pin 3, invert b. Check why no supply voltage is
option CSI not switched on (=0) at present as soon as the machine is
parameters, causing the time clock of switched on. Check the fuse (if
the control unit to stand still and no present) and wiring.
pause time is counted down.
c. Supply voltage on pin 3, invert op- c. Check why the supply voltage does
tion CSI switched on (=1) at parame- not drop as soon as the machine is
ters, causing the time clock of the switched on.
control unit to stand still and no
pause time is counted down.
The adjusted greasing interval for the Adjust a longer greasing time interval
concerning application is too short. with push-button (if present) or with
laptop and software.
a. Squashed or broken secondary a. Check and replace the relevant
grease lines. secondary line if necessary.
b. Metering unit with too little grease b. Mount metering unit with larger
output chosen. grease output.
c. Metering unit defect. c. Remove and clean the metering
unit or mount a new one.
a. Metering unit with too much output. a. Mount a metering unit with less
grease output.
b. Metering unit with internal leak. b. Remove the metering unit and
mount a new one.
40-81
AUTOMATIC GREASE SYSTEM 40 TROUBLESHOOTING

10. The green lamp flashes (2 sec- A single-test cycle is carried out. The green lamp goes out after the
onds on - 2 seconds off) during one test cycle has ended or after turning
complete greasing cycle. off the key switch.
11. The green lamp flashes (0, 2 sec- A continuously-test cycle is carried The green lamp goes off after the
onds on - 0, 2 seconds off) continu- out. test. This is after turning off the key
ously. switch.
12. The laptop and software shows a a. Bad connection (breaking in a wire, a. Check wire and connector.
'communication error'. connector).
b. After switching on the laptop and b. Repeat start-up procedure and
software pushed a button too quickly. wait 8 seconds before switching on
laptop and software.
c. Supply voltage too low; e.g., be- c. Start the engine.
cause of bad battery.
13. The laptop and software shows The laptop and software does not A different laptop and software is
'device not supported'. recognise the control unit. needed.

MALFUNCTION FINDING PROCEDURES (PC490_11-K-Q810-383-01-B)

A number of procedures to determine the correct cause of a certain malfunction are described below.
Procedure to check the correct working of the grease pressure switch cable
1. Disconnect the 2-pole connector from the pressure switch.
2. Measure the resistance between the two contacts using a multimeter.
When the system is pressureless, the contact of the switch should be open. If required, remove the switch
to make sure that no pressure below the pressure switch is present. Remove only the upper part, the divert-
er valve can be left in place.
When the adjusted pressure (see side of relevant switch) is reached the contact should close.
3. Start a test cycle by pressing the push-button on the pump.
4. If possible, mount a pressure gauge between the diverter valve and the pressure switch to check the
switching moment.
k Use a pressure gauge that is suitable for a grease pressure up to : 25 MPa.
k Because the connector of the grease pressure is disconnected, the control unit cannot
switch off the pump when adjusted pressure is reached.
5. Therefore turn off the contact switch, when the switching pressure has been reached. The test cycle is
ended.
If the grease pressure switch functions properly, the cable should be checked for breaks (internally) in the
cable.
6. Disconnect the pump connector.
7. Connect both contacts of the connector of the grease pressure switch with a separate wire.
8. Measure the resistance between pin 7 and 8 of the pump connector. The measured resistance should be
nearly zero.
9. Remove the wire between the contacts of the connector of the grease pressure switch.
The multimeter should read an open-load.
Procedure to check the working of the pump and the 5/2 magnetic valve
1. Disconnect both grease lines (channel A and B) from the pump unit.
k Some pressure can still be present in the channels.
2. Connect a pressure gauge to each channel of the pump unit. Use pressure gauges that are suitable for a
grease pressure of 25 MPa.

40-82 HB365LC-3
40 TROUBLESHOOTING AUTOMATIC GREASE SYSTEM

3. Press the test push-button for about 4 seconds to start a test cycle. The pump now pumps grease from one
of the channels. The pressure reading of the gauge connected to this channel should increase to the
maximum attainable pressure of 23 to 25 MPa.
k The pump is switched off by the pressure switch, because the system is disconnected.
If the pump does not reach the indicated pressure, it has following causes:
• Air lock in the grease (air bubbles). Disconnect the pressure gauge and let the grease flow until no
more air bubbles come from the line. If necessary, refill the reservoir with some oil to remove the air
around the pumping element.
• Grease is viscous. Therefore it is sucked in by the pumping piston. Replace the grease in the reservoir
and the main lines.
• Pump is faulty. Replace the pump.
4. End the test cycle by turning off the contact switch or by disconnecting the pump connector for a moment.
5. Start another test cycle with the test push-button on the pump. The pump should start in the second chan-
nel and the pressure gauge will quickly increase to the maximum adjusted grease pressure of 23 to
25 MPa.
The first channel should become pressureless.
When the pressure in the first channel does not drop and no pressure is built up in the new channel, the 5/2
magnetic valve is faulty. Replace the valve or the entire pump.
6. End the test cycle by turning of the contact switch or by disconnecting the pump connector for a moment.
Procedure when an internal system leak is suspected
1. Disconnect channel B of the pump unit.
k Some grease pressure can still be present in the channel.
2. Press the test push-button for about 4 seconds to start a test cycle. The pump is started and pumps grease
through one of the grease channels. If this is not channel A, break off the test cycle by turning the contact
switch off or by momentarily disconnecting the pump connector. Start another test cycle with the test push-
button on the pump. The pump starts automatically in the other channel (A).
While the pressure in channel A builds up some returning grease can come from the other channel. When
grease keeps flowing from this channel, there is an open connection between the main line channels. The
cause is a missing or damaged O-ring under one (or more) metering units.
When a leak is established in the system, it has to be determined in which distribution block the leak is
present.
3. Disconnect the main line from channel B, directly after the first distribution block after the pump.
4. Restart the pump in channel A.
When the grease leaks from channel B of this first distribution block, the leak must be found in this block.
When the grease leaks from the disconnected line, the leak must be sought farther down the system.
Therefore repeat this procedure every time using the next distribution block until the leak is found
REMARK
To determine which main line is connected to channel A and which line to channel B at the distribution blocks,
follow the main lines from the pump to the distribution blocks. When there is only little leak, it may be impossible
to establish the leak with the operating pump. Therefore, switch off the pump when the maximum pressure is
reached. Turn off the contact switch or momentarily disconnect the pump connector. The pressure should be
steady (minimum : 20 MPa; this procedure only works for channel A). The pressure may only drop when the
control unit opens the valve, as soon as a new test cycle is started in channel B. When there is no pressure
drop, but there is also no grease coming back, it indicates a leaking metering unit. Because of this one of the
greasing points will be greased excessively. Therefore check all connected greasing points.

HB365LC-3 40-83
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 40 TROUBLESHOOTING

PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM

(ALL-P-E000-42C-00-B)

• When performing troubleshooting of connectors connected to each controller, expose the applicable con-
nector part according to the following procedure.
• For connectors whose lock method is special, perform disconnection and connection.

PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR

(HB335_3-K-Q180-42C-00-B)
1. Remove the mounting screws (3 pieces) of cover (1).
REMARK
One of the screws (3 pieces) is covered with cap (2).
2. Disconnect the connector P31 of sunlight sensor (3), and
remove the cover (1).

3. Remove the bolt (4) (1 piece), and remove the duct (5).

4. Insert or connect the T-adapter for troubleshooting to con-

nectors CM01 (7), CM02 (8), CM03 (9) and CM04 (10) on
machine monitor (6).

PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER

(HB335_3-K-AP70-42C-00-B)
1. Remove the undercover.

40-84 HB365LC-3
40 TROUBLESHOOTING PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM

2. Insert or connect the T-adapters for troubleshooting to con-

nectors ECM J1 (2) and ECM J2 (3) of engine controller
(1).
REMARK
• Since the connectors are fixed with the screws, loosen
these screws before disconnecting the connector.
• When restoring them, fix them by tightening the screws
to the specified torque.
3 Screw:
9 ± 1 Nm {0.9 ± 0.1 kgm}

PREPARATION FOR TROUBLESHOOTING OF PUMP CONTROLLER

(HB335_3-K-C3V1-42C-00-B)
See DISSSEMBLY AND ASSEMBLY, “METHOD FOR REMOV-
ING PUMP CONTROLLER ASSEMBLY”, and connect the
adapter for troubleshooting to connectors CP01 (2) and CP02
(3) of pump controller.

PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL

(HB335_3-K-Q220-42C-00-B)
Insert or connect the adapter for troubleshooting to connectors
CK01 (2) and CK02 (3) of KOMTRAX terminal (1). For details,
see DISSSEMBLY AND ASSEMBLY, “METHOD FOR REMOV-
ING KomVision CONTROLLER ASSEMBLY”.

PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER

(HB335_3-K-K910-42C-00-B)
See DISSSEMBLY AND ASSEMBLY, “METHOD FOR REMOV-
ING KomVision CONTROLLER ASSEMBLY”, and connect the
adapter for troubleshooting to connectors CA01 (2) and CA02
(3) of KomVision controller (1).

HB365LC-3 40-85
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 40 TROUBLESHOOTING

PREPARATION FOR TROUBLESHOOTING OF INVERTER (HYBRID CONTROL-

LER) (HB335_3-K-PQGK-42C-00-B)
Insert or connect the T-adapter for troubleshooting to connec-
tors HC01 (1) and HC02 (2) of inverter (hybrid controller). For
details, see DISASSEMBLY AND ASSEMBLY, “METHOD FOR
REMOVING INVERTER AND CAPACITOR ASSEMBLY”.

METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH SPE-

CIAL LOCK (ALL-P-E550-42C-00-B)

REMARK
For details of each connector type, see “CONNECTORS LIST AND LAYOUT”.
• Precautions for disconnection of connectors
The direction of the lock for connector may be changed to-
ward the difficult direction for unlocking depending on the
position where the sensor is screwed in.
In such a case, use the needle nose pliers with curved tip
(commercially available) [1], then the lock can be canceled
easily.
Since the lock clicks when it is released, listen to the
sound and disconnect the connectors.
• Precautions for connecting connectors
When connecting connectors, pay attention not to connect
the connectors reverse.
FRAMATOME-3 and FRAMATOME-2 connectors
• Disconnecting and connecting of connectors
Disconnect them in the order of (a) to (c) and connect
them in the order of (d) to (f) as shown in the figure.
Disconnection: (a) Slide the lever, (b) unlock, and (c) dis-
connect the connectors.
Connection: (d) Connect the connectors, (e) engage the
lock, and (f) slide the lever.

40-86 HB365LC-3
40 TROUBLESHOOTING PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM

SUMITOMO-3 connector
• Disconnecting and connecting of connectors
Disconnect them in the order of (a) to (b) and connect
them in the order of (c) to (d) as shown in the figure.
Disconnection: (a) Unlock and (b) disconnect the connec-
tors.
Connection: (c) Connect the connectors, and (d) engage
the lock.

BOSCH connector and BDK connector

• Disconnecting and connecting of connectors
Disconnect them in the order of (a) to (b) and connect
them in the order of (c) to (d) as shown in the drawing.
Disconnection: (a) Unlock and (b) disconnect the connec-
tors.
Connection: (c) Connect the connectors, and (d) engage
the lock.

AMP-3 connector
• Disconnecting and connecting of connectors
Disconnect them in the order of (a) to (b) and connect
them in the order of (c) to (d) as shown in the drawing.
Disconnection: (a) Unlock and (b) disconnect the connec-
tors.
Connection: (c) Connect the connectors, and (d) engage
the lock.

PACKARD-2 connector
• Disconnecting and connecting of connectors
Disconnect them in the order of (a) to (b) and connect
them in the order of (c) to (d) as shown in the drawing.
Disconnection: (a) Unlock and (b) disconnect the connec-
tors.
Connection: (c) Connect the connectors, and (d) engage
the lock.

HB365LC-3 40-87
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM 40 TROUBLESHOOTING

TYCO connector
• Procedure for disconnecting connectors
1. Insert the small flat-head screwdriver [1] to the yellow
lock part (2) of TYCO connector (1).
2. Turn the small minus screwdriver [1] clockwise and
counterclockwise to slowly release the lock part (2).

3. After the yellow lock portion (2) is somewhat released,

lightly hold lock portion (2), and release the lock com-
pletely.
REMARK
Take care not to apply excessive force when releasing
the lock so that yellow lock portion (2) does not comes
off.

4. Remove connector (1) after the lock part (2) is com-

pletely released.

• Procedure of connecting connectors

1. Connect connector (1) straight as matching the faces
to be engaged when the yellow lock part (2) is com-
pletely unlocked.

2. Connect connector (1) gradually as pushing yellow

lock part (2).

40-88 HB365LC-3
40 TROUBLESHOOTING PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM

FRAMATOME-24 connector
• Procedure for disconnecting connectors
1. Slide down lock (red) (L1).

2. While pressing lock (L2), pull out connector (1).

REMARK
Lock (L2) is located behind connector (1) in the figure.

3. Hold the connector body (black portions on the male

and female sides) and disconnect the connector.
• Procedure of connecting connectors
Insert it straight until it clicks.

AMP-81 and DELPHE-96 connectors

• Disconnecting and connecting of connectors
Disconnect them in the order of (a) to (c) and connect
them in the order of (d) to (f) as shown in the drawing.
Disconnection: (a) Unlock, (b) slide the lever, and (c) dis-
connect the connectors.
Connection: (d) Position the connectors, (e) slide the lever,
and (f) engage the lock.

HB365LC-3 40-89
PROCEDURE FOR TESTING AND TROUBLESHOOTING 40 TROUBLESHOOTING

PROCEDURE FOR TESTING AND TROUBLESHOOTING (HB335_3_E-A-5160-422-00-B)

Classification of troubleshooting
Mode Content
Display of code Troubleshooting by failure code
E mode Troubleshooting of electrical system
H mode Troubleshooting of hydraulic and mechanical systems
S mode Troubleshooting of engine
Y mode Troubleshooting of hybrid component

1. Check if action level and failure code are displayed on machine monitor.
REMARK
If multiple failure codes are displayed simultaneously, all codes are displayed repeatedly in order. Write
down those codes.
If action level and failure code are displayed on the standard screen of the machine monitor, perform the
troubleshooting for the “Display of code” corresponding to the displayed failure code.
2. Check a mechanical system failure code and an electrical system failure code with the abnormality record
function of the machine monitor.
1) Press numeric key 1, 2, and 3 in this order on the
standard screen while pressing numeric key 4 on the
panel switch.

2) On the service menu screen, press switch F3 twice on

the panel switch, and select “03 Abnormality Record”.

40-90 HB365LC-3
40 TROUBLESHOOTING PROCEDURE FOR TESTING AND TROUBLESHOOTING

3) Press switch F6 on the panel switch to confirm, and

go to “Abnormality Record” screen.

4) Press switch F6 on the panel switch to confirm, and

go to “Mechanical System Abnormality Record”
screen.
5) Press switch F3 on the panel switch to see if the next
failure code is displayed and write down all of the fail-
ure codes.
REMARK
A failure code of the mechanical system cannot be de-
leted.
6) Press switch F5 on the panel switch to return to “Ab-
normality Record” screen.
7) On the service menu screen, press switch F3 twice on
the panel switch, and select “03 Abnormality Record”.

8) Press switch F6 on the panel switch to confirm, and

go to “Abnormality Record” screen.

HB365LC-3 40-91
PROCEDURE FOR TESTING AND TROUBLESHOOTING 40 TROUBLESHOOTING

9) Press switch F6 on the panel switch to confirm, and

go to “Electrical System Abnormality Record” screen.
10) Press switch F3 on the panel switch to see if the next
failure code is displayed and write down all of the fail-
ure codes.
REMARK
"E" on the left of a failure code indicates that the fail-
ure code is “active” (the failure remains or restoration
to normal has not been checked). A failure code hav-
ing no "E" is a “non-active” one. Since it disappears in
clear mode, be sure to write it down.
• When a failure code is recorded
Perform the troubleshooting for the “Display of code” corresponding to the displayed failure code.
REMARK
• If an electrical system failure code is recorded, clear all the codes once and reproduce them, and
then see if the failure is still detected.
• A failure code of the mechanical system cannot be deleted.
• If air conditioner abnormality is displayed on "Electrical Sys Abnormality Record", see “Air condi-
tioner”, “Inspection by self-diagnosis function” and perform troubleshooting.
• When no failure code is recorded on abnormality record
• A failure in electrical system that the machine cannot perform self-diagnosis or a failure in hydraul-
ic and mechanical system may have occurred, so check a phenomenon which seems to be a fail-
ure again.
• Select the corresponding phenomenon from the table of “Symptoms of failure and troubleshooting
numbers”, and then perform troubleshooting corresponding to that phenomenon in “E mode”, “H
mode”, “S mode” and “Y mode”.
3. Clear all the failure codes in the electrical system abnormality record after the failure is repaired.
1) While pressing numeric key 4 on the panel switch, press numeric key 1, 2, and 3 in this order to go to
“Delete mode”.
2) Press switch F2 (CLEAR) on the panel switch.
3) Press switch F6 on the panel switch to clear all failure codes once.
4) Press switch F5 on the panel switch to return to “Elec-
trical System Abnormality Record” screen. See if any
failure code is still displayed and write down the dis-
played one.
5) Press switch F5 on the panel switch to return to “Ab-
normality Record” screen.
6) Write down the information of all the column.
REMARK
"E" on the left of a failure code as with "Electrical Sys-
tem Abnormality Record" screen indicates that the fail-
ure code is “active” (the failure remains or restoration
to normal has not been checked).
7) Press switch F2 on the panel switch to clear all codes once. Check if “Abnormality” is still displayed,
and write down the displayed one.
8) Press switch F5 on the panel switch to return to “Abnormality Record” screen.

40-92 HB365LC-3
40 TROUBLESHOOTING SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS

SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS

(HB335_3-A-5540-441-00-B)

Troubleshooting
No. Symptom of failure
Index
User code, failure code
Action level is displayed on the machine monitor. Press the function switch [F5] to
1
display "Current Abnormality".
Perform troubleshoot-
2 Failure code is displayed on mechanical system abnormality record. ing for failure code
3 Failure code is displayed on electrical system abnormality record.
Symptom related to engine
4 Engine does not start. E-1, S-1
5 Engine does not crank when starting switch is turned to “START” position. E-1, S-1
6 Engine cranks but no exhaust smoke comes out. S-2
7 Fuel is being injected but engine does not start. S-3
8 Engine startability is poor. S-4
9 Engine does not pick up smoothly. S-5
10 Engine stops during operation. S-6, H-5
11 Engine runs rough or is unstable. S-7
12 Engine lacks power. S-8
13 KDPF gets clogged in a short time. S-9
14 Engine oil consumption is excessive. S-10
15 Engine oil becomes contaminated quickly. S-11
16 Fuel consumption is excessive. S-12
17 Oil mixes into coolant (or coolant spurts back or coolant level goes down). S-13
18 Engine oil pressure drops. S-14
19 Fuel mixes into engine oil. S-15
20 Water mixes into engine oil (milky). S-16
21 Coolant temperature rises too high (overheating). S-17
22 Unusual noise is heard. S-18
23 Vibration is excessive. S-19
24 Air cannot be bled from fuel circuit. S-20
25 Active regeneration is executed frequently. S-21
26 Active regeneration takes time. S-22
27 White smoke is exhausted during active regeneration. S-23
28 AdBlue/DEF consumption is excessive. S-24
29 There is an unusual smell (irritating odor). S-25
30 Foreign material mixes into AdBlue/DEF (AdBlue/DEF level increases). S-26
31 Manual preheating system does not work. E-2
32 Automatic preheating function does not work. E-3
33 While preheating is working, preheating monitor does not light up. E-4

HB365LC-3 40-93
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 40 TROUBLESHOOTING

Troubleshooting
No. Symptom of failure
Index
34 Automatic warm-up system does not operate (in cold weather). E-26
Auto-deceleration monitor does not light up or does not go out, when auto-decel-
35 E-27
eration switch is operated.
Auto-deceleration function does not operate or is not canceled while lever is oper-
36 E-28
ated.
Symptom related to hybrid system
37 Motor-generator temperature increases abnormally. Y-13
38 Inverter temperature increases abnormally. Y-14
39 Capacitor temperature increases abnormally. Y-15
Symptom related to work equipment, swing and travel system.
40 All work equipment, swing and travel do not work. E-36, H-1
41 All work equipment, swing and travel cannot be locked. E-37
42 All work equipment and travel speed or power is low. H-2
43 Engine speed drops significantly or engine stalls. H-5, S-6
Working mode selection screen is not displayed when working mode selector
44 E-29
switch is operated.
Setting of engine and hydraulic pump is not changed when working mode is
45 E-30
changed.
46 Unusual noise is heard from around hydraulic pump. H-4
47 Fine control performance or response is poor. H-3
Symptom related to work equipment
48 Boom speed or power is low. H-6
49 Arm speed or power is low. H-7
50 Bucket speed or power is low. H-8
51 Work equipment does not move in single operation. H-9
52 Hydraulic drift of boom is large. H-10
53 Hydraulic drift of arm is large. H-11
54 Hydraulic drift of bucket is large. H-12
When single work equipment is relieved hydraulically, another work equipment
55 H-13
moves.
56 Time lag of work equipment is large. H-14
57 One-touch power maximizing function does not operate. H-15, E-39
58 One-touch power maximizing function cannot be canceled. E-40
59 Attachment hydraulic circuit cannot be changed while attachment is installed. H-17, E-58
60 Oil flow in attachment circuit cannot be changed. H-18
61 Machine push-up function is not canceled. E-60
62 Machine push-up function does not operate. H-16, E-61
Symptom related to combined operation
In combined operation of work equipment, equipment having heavier load moves
63 H-19
slower.

40-94 HB365LC-3
40 TROUBLESHOOTING SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS

Troubleshooting
No. Symptom of failure
Index
Symptom related to travel
64 Machine does not travel straight. H-20
65 Machine is not steered well or steering power is low. H-21
66 Travel speed is slow. H-22
67 One of tracks does not run. H-23
68 Travel speed does not change, or travel speed is too slow or fast. H-24, E-31, E-32
69 Alarm does not sound during travel. E-42
70 Travel alarm does not stop sounding while machine is stopped. E-43
Symptom related to swing
Upper structure does not swing while swing parking brake cancel switch is set to
71 E-38
CANCEL position.
Swing brake does not operate while swing parking brake cancel switch is set to
72 E-39
NORMAL position.
73 Upper structure does not swing both to the right and left. Y-2
74 Upper structure swings only in one direction. Y-3
75 Swing acceleration or swing speed is low in both directions of right and left. Y-4
Swing acceleration performance is poor or swing speed is slow in only one direc-
76 Y-5
tion.
Upper structure overruns excessively when it stops swinging in both directions of
77 Y-6
right and left.
78 Upper structure overruns excessively when it stops swinging in only one direction. Y-7
79 Shock is large when upper structure stops swinging. Y-8
80 Large unusual noise is heard when upper structure stops swinging. Y-9
81 Swing drift on a slope is large (while swing parking brake is applied). Y-10
82 Swing drift on a slope is large (while swing parking brake is released). Y-11
83 Electric swing motor temperature increases abnormally. Y-12
Symptom related to machine monitor
84 When starting switch is turned to ON position, machine monitor displays nothing. E-5
When starting switch is turned to ON position (with engine stopped), engine oil
85 E-6
level caution lamp lights up in yellow.
When starting switch is turned to ON position (with engine stopped), radiator cool-
86 E-7
ant level caution lamp lights up in yellow.
Engine coolant temperature caution lamp lights up in white while engine is run-
87 E-8
ning.
88 Hydraulic oil temperature caution lamp lights up in white while engine is running. E-9
89 Air cleaner clogging caution lamp lights up in yellow while engine is running. E-10
90 Charge level caution lamp lights up in red while engine is running. E-11
91 Fuel level caution lamp lights up in red while engine is running. E-12
92 Water separator caution lamp lights up in red while engine is running. E-13
93 Engine coolant temperature caution lamp lights up in red while engine is running. E-14

HB365LC-3 40-95
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 40 TROUBLESHOOTING

Troubleshooting
No. Symptom of failure
Index
94 Engine oil pressure caution lamp lights up in red while engine is running. E-15
95 Hydraulic oil temperature caution lamp lights up in red while engine is running. E-16
96 Fuel gauge indication does not move from minimum or maximum. E-17
97 Fuel gauge indicates incorrect amount. E-18
Engine coolant temperature gauge indication does not move from minimum or
98 E-19
maximum.
99 Engine coolant temperature gauge indicates incorrect temperature. E-20
100 Hydraulic oil temperature gauge does not move from minimum or maximum. E-21
101 Hydraulic oil temperature gauge indicates incorrect temperature. E-22
102 Hybrid temperature gauge does not indicate correct temperature. E-23
103 Some areas of machine monitor screen are not displayed. E-24
104 Function switch does not work. E-25
105 Alarm buzzer does not stop sounding. E-33
106 Service meter is not displayed while starting switch is in OFF position. E-34
107 Service mode cannot be selected. E-35
108 Horn does not sound. E-44
109 Horn does not stop sounding. E-45
Wiper pilot lamp does not light up or does not go out, when wiper switch is operat-
110 E-46
ed.
111 Wiper does not operate when wiper switch is operated. E-47
112 Window washer does not operate when window washer switch is operated. E-48
“PROCEDURE FOR
Air conditioner does not operate normally (including failure codes related to air TESTING AND TROU-
113
conditioner). BLESHOOTING” in
Chapter 80
114 Lever operation signal is not displayed correctly with monitoring function. E-49 through E-57
115 Hybrid system stop caution lamp does not go out. Y-1
Others
116 KOMTRAX system does not operate normally. E-59

40-96 HB365LC-3
40 TROUBLESHOOTING INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE

INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE (PC400_11-A-5171-421-00-B)

The following types of information are described in the troubleshooting list and related circuit diagram. Fully un-
derstand the description and perform troubleshooting.
Action level Failure code
Display on Display on Failure name displayed on "Abnormality Record" screen of the machine
Failure
machine machine monitor
monitor monitor
Details of
Description of the failure detected by the machine monitor or controller
failure
Action of An action that is performed to protect the system and devices when a failure is detected by the ma-
controller chine monitor or controller
Problem on A problem that is displayed as a failure on the lift truck as a result of an action (shown above) that is
machine performed by the machine monitor or controller.
Related in-
Information related to the occurred failure and its troubleshooting
formation

No. Cause Procedure, measuring location, criteria, and remarks

1 Defective --- Contents of description
Open or short circuit • Procedure
2
in wiring harness • Measuring point
Open circuit in wiring "Between A and B" denotes measuring values such as voltage and resistance
harness between A and B.
3 "Between A and ground" means the measurement of voltage, resistance or
(wire breakage or de-
others between place A and the place which has a continuity with chassis
fective contact of con-
nector) frame such as unpainted hexagonal head bolt or bolt hole which has no rust,
etc.
Ground fault in wiring
• Criteria to judge probable causes (standard value), remarks
harness
4 How to use troubleshooting sheet
(contact with ground
circuit) • Perform troubleshooting procedures in following order.
5 Hot short circuit • If the check result does not meet the criteria, the probable cause described on
the left column is the actual cause of the failure.
• If the check result meet the criteria and there is no specific instruction, pro-
ceed to the next step (cause).
• If a defect is found and repaired, check that the defect has been corrected.
Failures in wiring harness
• Open circuit
When the wiring and the internal circuit of the connector are not connected
with each other, and there is no continuity
Short circuit in wiring
6 • Ground fault
harness
A wiring harness not to be connected to the GND (ground) circuit comes into
contact with the GND (ground) circuit or chassis accidentally.
• Hot short circuit
A wiring harness not to be connected to the power circuit comes into contact
with the power circuit accidentally.
• Short circuit
An independent wire in the harness abnormally comes into contact with one of
another wire. (Defective insulation in connector or others)

HB365LC-3 40-97
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria, and remarks

Precautions for troubleshooting
(1) Connector number indication method and handling of T-adapter
For troubleshooting, insert or connect T-adapters as follows unless otherwise speci-
fied.
• When (male) or (female) is not indicated with a connector number, disconnect
the connector, and insert T-adapters to both sides of male and female.
• When (male) or (female) is indicated with a connector number, disconnect the
connector, and connect T-adapter to the indicated side of connector.
7 Defective controller • "Male and female" means male and female of connector pins, not connector
housings.
• Male and female of connector pins and housing in DT series, etc, are opposite
to those described in this manual. Take care.
(2) Pin number description sequence and tester lead handling
For troubleshooting, connect the positive (+) and negative (-) leads of a multimeter as
shown below unless otherwise specified.
• Connect the positive (+) lead to pin or wiring harness indicated first.
• Connect the negative (-) lead to a pin or wiring harness indicated second.

Related circuit diagram

This is the excerpted circuit diagram related to troubleshooting
• The circuit diagram contains the connector No., pin No., and connector color related to the failure.
• “/” is used in the connector No. in the following 2 cases.
• Abbreviation (3 letters in many cases)
Example) T/C: Abbreviation for Torque Converter
• Male side and female side have different connector Nos.
Example) BREAK OUT / E24
• The circuit diagram contains the destination or source of the branch line in a wiring harness.
• Arrow (↔): Approximate installation position on the machine
NO: Normally Open
NC: Normally Closed
• Signal names such as GND and 24 V are included in addition to connector numbers at junctions, etc. in
circuit diagrams.
• Except for GND and 24 V, a signal name indicated at a junction, etc. shows that the wire is connected to
another junction or controller at where the same signal name is indicated.

40-98 HB365LC-3
 TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HAR-
40 TROUBLESHOOTING NESS OF PRESSURE SENSOR SYSTEM

TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS

OF PRESSURE SENSOR SYSTEM (PC220_11-P-E720-42A-00-B)

The pressure sensor consists of not only resistance but also electrical circuit such as amplifier. Accordingly, it
has dispersion and polarity, and care must be taken for measurement.
Object failure code
• CA123: Charge Air Pressure Sensor Low Error
• CA451: Common Rail Pressure Sensor High Error
Procedure
1. Measure the resistance of pressure sensor unit and write down the value.
1) Disconnect connector (1) of the pressure sensor, and connect socket (2) to sensor side.
2) Measure the resistance R1 and R2 between each pins.
• If the polarity of multimeter is reversed, the measurement value may vary. Set the polarity of multi-
meter probe to match with the one of pressure sensor, and measure the resistance.
• If the measured value is infinite, reverse the polarity and measure again. If a value is measured,
take it as a measured value.
• The measured value may vary, so measure several times.
The reason of this may be that the electric charge is stored in the sensor. Measure several times in
step 1 and 2 as well. In step 3, judge if the wiring harness is broken taking this dispersion into con-
sideration.

2. Connect the wiring harness between pressure sensor and engine controller, and measure the resistance of
pressure sensor, and then write down the value.
1) 5V power supply for pressure sensor provides power to other sensors as well. Accordingly, disconnect
connector of other sensors. (*)
2) With target pressure sensor connected, disconnect connector (3) at the engine controller side, and
connect T-adapter (4) to the wiring harness side.
3) Connect T-box (5) to T-adapter (4), and measure the resistance R1' and R2' between each pins.
3. Judgment for open circuit
If there is a difference of 10 times or more between resistance R1 and R2 measured in step 1 and resist-
ance R1' and R2' measured in step 2, you may judge that "the wiring harness has an open circuit".

HB365LC-3 40-99
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HAR-
NESS OF PRESSURE SENSOR SYSTEM 40 TROUBLESHOOTING

List of pressure sensor measuring locations and reference values

Measured value of resist-
Measuring location at sen-
Sensor ance inside sensor (refer- Remarks
sor pin
ence value)

Charge pressure sen- R2: Between (2) and (4) Approximately 100 Ω Common sensor is used for 107
sor R1: Between (1) and (4) Approximately 200 Ω and 114 engine.

R2: Between (3) and (1) Approximately 23 kΩ

Common rail pres- By reversing polarity, the resistance
sure sensor R1: Between (1) (+) and becomes infinite.
Approximately 10 MΩ
(2) (-)

*: Other sensor connectors to be disconnected when measuring R2' are as follows. (Refer related circuit dia-
gram for each code.)
• When measuring R2' of charge pressure sensor (CA123):
Connectors for ambient pressure sensor, CAM sensor, and crankcase pressure sensor
• When measuring R2' of common rail pressure sensor (CA451)
Since 5V power supply is only for this sensor, there is no connector to be disconnected.
Measurement record (For measuring locations, see related circuit diagram of each code.)
Sensor and wiring harness
Sensor unit
Sensor Measured value (Measuring location at en- Measured value
(Measuring location at
gine controller wiring har-
sensor pin)
ness)
R2': Between (78) and
R2: Between (2) and (4)
Charge pressure sen- (54) (*)
sor R1': Between (45) and
R1: Between (1) and (4)
(54)

40-100 HB365LC-3
 TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HAR-
40 TROUBLESHOOTING NESS OF PRESSURE SENSOR SYSTEM

R2': Between (82) and

R2: Between (3) and (1)
Common rail pres- (58) (*)
sure sensor R1: Between (1) (+) and R1': Between (58) (+) and
(2) (-) (42) (-)

HB365LC-3 40-101
CONNECTOR LIST AND LAYOUT 40 TROUBLESHOOTING

CONNECTOR LIST AND LAYOUT (HB365_3-P-E000-056-00-B)

Three-dimension-
Number
Connector No. Connector type Location al drawing ad-
of pins
dress
A13 DT 2 Intermediate connector D-6
A15 DT 2 Intermediate connector B-9
A40 DT 4 Intermediate connector J-4
A41 DT 4 Intermediate connector F-1
A42 DT 4 Intermediate connector B-1
A45 - 4 Camera J-9
A46 DT 4 Camera 2 (if equipped) -
A71 DT-A 8 Intermediate connector F-1
A72 DT-B 8 Intermediate connector F-1
A76 DT 4 Camera 2 E-9
A77 DT 4 Camera 3 D-9
A78 DT 4 Camera 4 H-1
A79 DT 12 Intermediate connector G-1
A80 DT-A 8 Intermediate connector I-2
A81 DT-A 8 Intermediate connector D-8
AC01 - 10 Air conditioner unit N-6
AC02 - 4 Air conditioner unit O-6
Air conditioner compressor solenoid
AC03 X 1 G-9
clutch
C3 DELPHI 2 Engine coolant temperature sensor AF-3
C4 DT 3 CAN terminating resistor AH-1
Engine oil pressure switch (low pres-
C6 FRAMATOME 2 AI-1
sure)
C7 DT 2 Fuel feed pump AE-7
Boost pressure and temperature sen-
C14 SUMITOMO 4 AI-5
sor
C15 FRAMATOME 3 Bkup sensor AF-1
C16 DT 4 Intermediate connector AF-3
C17 DT 4 Intermediate connector AI-5
C18 DT 4 Intermediate connector AJ-6
C19 FRAMATOME 3 NE sensor AH-5
C21 - 3 Common rail pressure sensor AE-8
C23 DT 3 CAN terminating resistor AE-7
C26 BOSCH 2 Supply pump flow control valve AE-9
C30 DT 12 Intermediate connector AH-9
C31 FRAMATOME 3 Ambient pressure sensor AF-9
CA01 AMP 81 KomVision controller O-6

40-102 HB365LC-3
40 TROUBLESHOOTING CONNECTOR LIST AND LAYOUT

CA02 AMP 40 KomVision controller O-6

CC01 070 14 ID key controller P-8
CE01 DRC 96 Engine controller AF-5
CE02 DRC 96 Engine controller AE-6
CE03 DRC 70 Engine controller AE-5
CK01 070 18 KOMTRAX controller X-6
CK02 070 12 KOMTRAX controller X-6
CM01 070 18 Machine monitor M-4
CM02 070 12 Machine monitor M-4
CM04 070 8 Machine monitor M-5
CP01 AMP 81 Pump controller O-9
CP02 AMP 40 Pump controller P-9
D01 SWP 8 Diode array M-8
D02 SWP 8 Diode array M-8
D03 SWP 8 Diode array M-9
D04 SWP 8 Diode array M-9
D12 YAZAKI 2 Diode (if equipped) W-2
E01 Terminal 1 Ribbon heater H-9
E25 FRAMATOME 4 KDPF pressure sensor K-7
E26 TYCO 4 KDPF temperature sensor K-7
E31 TYCO 4 Turbocharger outlet NOx sensor K-9
E32 TYCO 4 Ammonia sensor J-9
E34 TYCO 4 SCR temperature sensor K-9
E36 TYCO 4 SCR outlet NOx sensor J-9
EGR-SOL DT 2 EGR valve solenoid AG-9
F01 Terminal 20 Fuse box V-9
F02 Terminal 20 Fuse box V-9
F04 L 2 Fusible link A-7
F05 L 2 Fusible link B-6
F11 Terminal 1 Fuse B-6
F12 Terminal 1 Fuse A-6
GM01 DT 8 Engine built-in generator K-6
GM02 - 3 Engine built-in generator K-6
GM03 - 3 Engine built-in generator K-6
H08 M 4 Intermediate connector AD-4
H09 M 8 Intermediate connector AD-4
Intermediate connector (R.H. console
H14 090 22 S-9
wiring harness)
H15A DT 6 Intermediate connector S-9
H15B 090 22 Intermediate connector T-9

HB365LC-3 40-103
CONNECTOR LIST AND LAYOUT 40 TROUBLESHOOTING

H16 S 22 Intermediate connector X-4

H20 M 6 Intermediate connector (if equipped) AD-5
H21 D 4 Intermediate connector (if equipped) AD-9
H22 D 4 Intermediate connector (if equipped) AA-9
HB01 - 1 Inverter A-5
HC01 DRC 24 Inverter C-6
HC02 DRC 40 Inverter C-6
HC03 - 3 Inverter A-3
HC04 - 3 Inverter A-5
HC05 - 3 Inverter B-5
HC06 - 1 Inverter B-5
HH05 DT 2 Service connector W-8
HK01 DT 2 Coolant pump D-7
HK04 DT 2 Coolant pump D-7
HK05 DT 3 CAN terminating resistor A-4
HP01 DT 12 Capacitor B-5
HP04 AMP 3 Swing (LEFT) pressure sensor L-2
HP06 AMP 3 Swing (RIGHT) pressure sensor L-4
INJECTOR #1 - 2 Injector #1 AF-4
INJECTOR #2 - 2 Injector #2 AG-5
INJECTOR #3 - 2 Injector #3 AH-5
INJECTOR #4 - 2 Injector #4 AH-5
INJECTOR #5 - 2 Injector #5 AJ-7
INJECTOR #6 - 2 Injector #6 AJ-7
J01 - 20 Junction connector W-2
J02 - 20 Junction connector V-2
J03 - 20 Junction connector V-1
J04 - 20 Junction connector X-2
J05 - 20 Junction connector X-3
J06 - 20 Junction connector X-6
K01 M 2 Pump (PC) resistor M-7
K02 DT 3 Terminating resistor H-1
K04 DT 2 Horn relay dummy resistance X-8
K10 DT 3 Terminating resistor C-6
K11 DT 3 Terminating resistor H-1
K12 DT 2 Fan clutch resistor A-7
Intermediate connector (work equip-
L01 DT 2 D-7
ment wiring harness)
L01A DT 2 Working lamp (boom) A-3
L02 DT 2 Working lamp (right) A-4

40-104 HB365LC-3
40 TROUBLESHOOTING CONNECTOR LIST AND LAYOUT

L03 M 2 Room lamp T-9

L05 SWP 2 Intermediate connector AC-9
L09 DT 2 Working lamp (rear) (if equipped) G-9
L19 DT 2 System operating lamp D-9
M1A M 2 Optional power supply connector M-5
M01 070 10 Radio S-1
M01A PA 3 Radio U-1
M01B M 3 Radio AD-4
M01C - 3 Radio AD-6
M02 M 2 Speaker (L.H.) AD-9
M03 M 2 Speaker (R.H.) AB-9
M04 - 2 Cigarette lighter S-9
M05 M 6 Wiper motor M-3
Window washer tank (with washer
M06 YAZAKI 2 I-2
motor)
Washer motor for front window wiper
M06 090 2 -
(if equipped)
Washer motor for ceiling window wip-
M06B 090 2 C-6
er (if equipped)
M07 090 2 Horn (treble tone) A-2
M08 090 2 Horn (bass tone) A-3
M09 M 2 Optional power supply connector (1) M-5
M10 M 2 Optional power supply connector (2) X-4
M10A M 2 Optional power supply N-5
M11 DT 6 DC/DC converter X-5
Optional power supply connector (12
M12 M 2 X-5
V)
M12 Terminal 1 Alternator (B terminal) I-9
M13A M 2 12 V socket X-7
M13B M 2 12 V socket X-7
M14 DT 2 Travel alarm F-9
M17 DT 2 Intermediate connector K-6
M18 Terminal 1 Alternator (R terminal) I-9
M22 DTM-A 12 R.H. knob switch (if equipped) P-6
M22 Terminal 1 Alternator (E terminal) I-9
M23 DTM-B 12 L.H. knob switch (if equipped) S-1
M24 DT 2 Intermediate connector D-9
M35 DT 2 Heated seat (if equipped) U-1
M36 DT 2 Air suspension (if equipped) T-1
M40 - 2 Headlamp Z-8
M41 - 2 Headlamp Y-8

HB365LC-3 40-105
CONNECTOR LIST AND LAYOUT 40 TROUBLESHOOTING

M60 M 4 Wiper motor (if equipped) AA-9

Bucket quick coupler control box (if
M80 X 3 M-4
equipped)
M81 X 2 Bucket quick coupler solenoid D-3
MB02 TYCO 12 AdBlue/DEF pump E-9
MB03 BDK 2 AdBlue/DEF injector K-9
MB04 DT 2 AdBlue/DEF line heater (suction side) F-9
MB05 DT 2 AdBlue/DEF line heater (return side) F-9
AdBlue/DEF line heater (high temper-
MB06 DT 2 K-7
ature pressure side)
AdBlue/DEF line heater (low temper-
MB07 DT 2 F-9
ature pressure side)
N08 DT 12 Service connector W-8
P01 AMP 3 Bucket CURL pressure sensor L-4
P02 AMP 3 Boom LOWER pressure sensor L-4
P03 AMP 3 Swing (LEFT) pressure sensor L-1
P04 AMP 3 Arm IN pressure sensor L-2
P05 AMP 3 Bucket DUMP pressure sensor L-2
P06 AMP 3 Boom RAISE pressure sensor L-1
P07 AMP 3 Swing (RIGHT) pressure sensor L-3
P08 AMP 3 Arm OUT pressure sensor L-1
P09 AMP 3 Left front travel pressure sensor D-1
P10 AMP 3 Left rear travel pressure sensor E-1
P11 AMP 3 Right front travel pressure sensor C-1
P12 AMP 3 Right rear travel pressure sensor D-1
P13 X 2 Intermediate connector A-1
Oil pressure switch for service, front
P14 X 2 A-2
(if equipped)
Oil pressure switch for service, rear
P15 X 2 A-1
(if equipped)
Air conditioner high-low pressure
P17 S090 2 G-1
switch
Air conditioner outside air tempera-
P18 090 2 E-9
ture sensor
P20 M 3 Fuel dial P-8
P21 DT 2 Fuel level sensor D-6
P22 D 2 Hydraulic oil temperature sensor I-2
P23 DT 2 Air cleaner clogging sensor D-9
Radiator coolant tank (with radiator
P24 X 2 D-9
coolant level sensor)
P25 AMP 3 Front pump pressure sensor L-3
P26 AMP 3 Rear pump pressure sensor L-3

40-106 HB365LC-3
40 TROUBLESHOOTING CONNECTOR LIST AND LAYOUT

P27 DT 3 Front pump swash plate sensor K-5

P28 DT 3 Rear pump swash plate sensor K-5
P31 - 2 Sunlight sensor M-5
P44 DT 2 Engine oil level sensor H-1
P47 DT 2 Water in fuel sensor D-7
P49 AMP 3 Service pressure sensor (if equipped) J-4
P55 FRAMANOME 4 MAF sensor E-9
P57 FRAMATOME 3 Crankcase pressure sensor J-9
P63 DT 4 AdBlue/DEF level sensor C-6
P65 PACKARD 2 Ambient temperature sensor E-9
P66 - 2 Engine room temperature sensor I-9
PM01 DT 12 Swing motor D-8
PM02 - 3 Swing motor D-8
R01 Terminal 1 Battery relay (E terminal) C-7
R02 Terminal 1 Battery relay (BR terminal) C-8
R03 Terminal 1 Battery relay (M terminal) C-9
R04 Terminal 1 Battery relay (B terminal) C-8
R05 RELAY 5 Light relay U-9
Starting motor cut-off relay (PPC
R06 RELAY 5 X-8
lock)
Starting motor cut-off relay (personal
R07 RELAY 5 X-8
code)
R08 RELAY 5 Horn relay V-9
R10 RELAY 5 Rear light relay (if equipped) U-9
R12 RELAY 5 Cab light relay (if equipped) U-9
R15 Terminal 1 Ribbon heater relay A-8
R16 Terminal 1 Ribbon heater relay A-8
R17 Terminal 1 Ribbon heater relay A-8
R18 RELAY 5 Auto preheater relay T-9
R21 RELAY 5 Compressor clutch relay P-6
Ceiling window wiper relay (if equip-
R26 RELAY 5 N-5
ped)
R43 RELAY 5 BR cut-off relay W-8
R48 RELAY 5 PPC lock relay W-8
R52 DT-D 12 Smart sensor relay A-9
R53A DT-C 12 AdBlue/DEF heater relay C-9
R53B DT 6 AdBlue/DEF heater relay B-9
S01 Terminal 6 Starting motor switch O-7
S02 SWP 6 Light switch Q-8
S04 SWP 6 Swing lock switch Q-8
S05 SWP 6 Machine push-up switch Q-9

HB365LC-3 40-107
CONNECTOR LIST AND LAYOUT 40 TROUBLESHOOTING

Revolving warning lamp switch (if

S07 SWP 6 R-9
equipped)
S10 Y090 2 R.H. knob switch (horn) P-8
L.H. knob switch (one-touch power
S11 Y090 2 S-1
maximizing)
S14 M 3 PPC oil pressure lock switch T-1
S18 SWP 6 Engine shutdown secondary switch S-1
S19 DT 2 Seat belt switch R-9
S21 - 12 Emergency pump drive switch N-9
S22 - 6 Swing parking brake cancel switch N-9
S23 - 3 PPC lock lever bypass switch N-9
S24 - 6 Hybrid system stop switch M-9
S25 090 22 Intermediate connector O-9
S30 S 8 Model selection connector V-9
Ceiling window wiper switch (if equip-
S40 SWP 6 R-9
ped)
SB Terminal 1 Starting motor (B terminal) K-8
SEGR DT 3 EGR valve position sensor AJ-8
SVGT DT 3 VGT position sensor AI-9
T01 Terminal 1 Floor frame ground W-2
T02 Terminal 1 Cab ground X-6
T04 Terminal 1 Revolving frame ground F-1
T05 Terminal 1 Revolving frame ground F-1
T06 Terminal 1 Revolving frame ground F-1
T07 Terminal 1 Revolving frame ground E-1
T08 Terminal 1 Revolving frame ground C-6
T09 Terminal 1 Revolving frame ground E-1
T10 Terminal 1 Revolving frame ground E-1
T11 Terminal 1 Engine body ground K-8
T12 Terminal 1 Engine cylinder block ground I-2
T13 Terminal 1 Revolving frame ground B-6
T14 Terminal 1 Revolving frame ground D-8
T15 Terminal 1 Ribbon heater relay C-8
T16 Terminal 1 Revolving frame ground C-7
T17A Terminal 1 Revolving frame ground A-2
T17B Terminal 1 Revolving frame ground A-3
T18 Terminal 1 Floor frame ground U-1
T19 Terminal 1 Right console frame ground V-1
T20 Terminal 1 Cab ground O-1
T21 Terminal 1 Floor frame ground Q-1

40-108 HB365LC-3
40 TROUBLESHOOTING CONNECTOR LIST AND LAYOUT

PPC source pressure lock solenoid

V01 DT 2 J-4
valve
V03 DT 2 Travel junction valve solenoid valve J-4
V04 DT 2 Travel Hi/Lo selector solenoid valve J-4
V05 DT 2 Swing parking brake solenoid valve J-3
V06 DT 2 Machine push-up solenoid valve J-3
ATT return selector solenoid valve (if
V07 DT 2 J-3
equipped)
V08 DT 2 2-stage relief solenoid valve J-3
V11 D 2 F-PC-EPC valve K-5
V12 D 2 R-PC-EPC valve J-3
V13 DT 6 Fan clutch H-9
V19 D 2 LS-EPC valve J-2
V23 D 2 Merge-divider EPC valve (main) K-4
V24 D 2 Merge-divider EPC valve (LS) K-4
Variable back pressure solenoid
V25 D 2 K-1
valve
ATT flow adjustment EPC (if equip-
V30 DT 2 A-1
ped)
V41 DT 2 AdBlue/DEF tank heater valve J-4
VGT-REV AMP 3 VGT speed sensor AH-9
VGT-SOL DT 2 VGT solenoid AG-9
W03 X 2 Rear limit switch AB-9

HB365LC-3 40-109
CONNECTOR LIST AND LAYOUT 40 TROUBLESHOOTING

1/6

KSP00603

40-110 HB365LC-3
40 TROUBLESHOOTING CONNECTOR LIST AND LAYOUT

2/6

HB365LC-3 40-111
CONNECTOR LIST AND LAYOUT 40 TROUBLESHOOTING

3/6

KSP00601

40-112 HB365LC-3
40 TROUBLESHOOTING CONNECTOR LIST AND LAYOUT

4/6

KSP00602

HB365LC-3 40-113
CONNECTOR LIST AND LAYOUT 40 TROUBLESHOOTING

5/6

40-114 HB365LC-3
40 TROUBLESHOOTING CONNECTOR LIST AND LAYOUT

6/6

HB365LC-3 40-115
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING

CONNECTOR CONTACT IDENTIFICATION (PC400_11-P-E000-030-00-B)

(Rev.2014.11)

The male or female is for pin, and the convex or concave is for fitting (housing).

40-116 HB365LC-3
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION

HB365LC-3 40-117
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING

40-118 HB365LC-3
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION

HB365LC-3 40-119
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING

40-120 HB365LC-3
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION

HB365LC-3 40-121
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING

40-122 HB365LC-3
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION

HB365LC-3 40-123
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING

40-124 HB365LC-3
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION

HB365LC-3 40-125
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING

40-126 HB365LC-3
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION

HB365LC-3 40-127
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING

40-128 HB365LC-3
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION

HB365LC-3 40-129
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING

40-130 HB365LC-3
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION

HB365LC-3 40-131
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING

40-132 HB365LC-3
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION

HB365LC-3 40-133
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING

40-134 HB365LC-3
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION

HB365LC-3 40-135
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING

40-136 HB365LC-3
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION

HB365LC-3 40-137
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING

40-138 HB365LC-3
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION

HB365LC-3 40-139
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING

40-140 HB365LC-3
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION

HB365LC-3 40-141
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING

40-142 HB365LC-3
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION

HB365LC-3 40-143
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING

40-144 HB365LC-3
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION

HB365LC-3 40-145
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING

40-146 HB365LC-3
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION

HB365LC-3 40-147
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING

40-148 HB365LC-3
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION

HB365LC-3 40-149
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING

40-150 HB365LC-3
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION

HB365LC-3 40-151
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING

40-152 HB365LC-3
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION

HB365LC-3 40-153
CONNECTOR CONTACT IDENTIFICATION 40 TROUBLESHOOTING

*:No.1 and 7 pin in male pin side do not exist.

40-154 HB365LC-3
40 TROUBLESHOOTING CONNECTOR CONTACT IDENTIFICATION

HB365LC-3 40-155
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 40 TROUBLESHOOTING

T-BRANCH BOX AND T-BRANCH ADAPTER TABLE (PC400_11-P-T000-056-00-B)

(Rev.2014.11)

The part numbers of the T-boxes and T-adapters are listed in the vertical column, and the part numbers of har-
ness checker assemblies are listed in the horizontal line.
T-adapter kit

Number of pins

Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Part No. Part name ID marking

799-601-2600 T-box (for ECONO) 21 ● ● ● ● ●

799-601-3100 T-box (for MS) 37 ●
799-601-3200 T-box (for MS) 37 ●
799-601-3380 Plate for MS (14 pins) ●
799-601-3410 Adapter for BENDIX (MS) 24 MS-24P ●
799-601-3420 Adapter for BENDIX (MS) 24 MS-24P ●
799-601-3430 Adapter for BENDIX (MS) 17 MS-17P ●
799-601-3440 Adapter for BENDIX (MS) 17 MS-17P ●
799-601-3450 Adapter for BENDIX (MS) 5 MS-5P ●
799-601-3460 Adapter for BENDIX (MS) 10 MS-10P ●
799-601-3510 Adapter for BENDIX (MS) 5 MS-5P ●
799-601-3520 Adapter for BENDIX (MS) 17 MS-17P ●
799-601-3530 Adapter for BENDIX (MS) 19 MS-19P ●
799-601-2910 Adapter for BENDIX (MS) 14 MS-14P ●
799-601-3470 Case ●
799-601-2710 Adapter for MIC 5 MIC-5P ● ● ●
799-601-2720 Adapter for MIC 13 MIC-13P ● ● ●
799-601-2730 Adapter for MIC 17 MIC-17P ● ● ● ● ● ●
799-601-2740 Adapter for MIC 21 MIC-21P ● ● ● ● ● ●
799-601-2950 Adapter for MIC 9 MIC-9P ● ● ● ●
ECONO
799-601-2750 Adapter for ECONO 2 ● ●
2P
ECONO
799-601-2760 Adapter for ECONO 3 ● ●
3P
ECONO
799-601-2770 Adapter for ECONO 4 ● ●
4P
ECONO
799-601-2780 Adapter for ECONO 8 ● ●
8P
ECONO
799-601-2790 Adapter for ECONO 12 ● ●
12P
799-601-2810 Adapter for DLI 8 DLI-8P ● ●
799-601-2820 Adapter for DLI 12 DLI-12P ● ●
799-601-2830 Adapter for DLI 16 DLI-16P ● ●

40-156 HB365LC-3
40 TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH ADAPTER TABLE

T-adapter kit

Number of pins

Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Part No. Part name ID marking

Extension cable (ECONO ECONO

799-601-2840 12 ● ● ●
type) 12P
799-601-2850 Case ●
799-601-4350 T-box (for DRC60, ECONO) 60 ●
799-601-4360 Case ●
799-601-7010 Adapter for X (T-adapter) 1 ● ●
799-601-7020 Adapter for X 2 X2P ● ● ● ●
799-601-7030 Adapter for X 3 X3P ● ● ● ●
799-601-7040 Adapter for X 4 X4P ● ● ● ●
799-601-7050 Adapter for SWP 6 SW6P ● ● ●
799-601-7060 Adapter for SWP 8 SW8P ● ● ●
799-601-7310 Adapter for SWP 12 SW12P ●
799-601-7070 Adapter for SWP 14 SW14P ● ●
799-601-7320 Adapter for SWP 16 SW16P ●
799-601-7080 Adapter for M (T-adapter) 1 ● ●
799-601-7090 Adapter for M 2 M2P ● ● ● ●
799-601-7110 Adapter for M 3 M3P ● ● ● ●
799-601-7120 Adapter for M 4 M4P ● ● ● ●
799-601-7130 Adapter for M 6 M6P ● ● ● ●
799-601-7340 Adapter for M 8 M8P ●
799-601-7140 Adapter for S 8 S8P ● ● ● ●
799-601-7150 Adapter for S (white) 10 S10P ● ● ● ●
799-601-7160 Adapter for S (blue) 12 S12P ● ● ●
799-601-7170 Adapter for S (blue) 16 S16P ● ● ● ●
799-601-7330 Adapter for S (white) 16 S16PW ●
799-601-7350 Adapter for S (white) 12 S12PW ●
799-601-7180 Adapter for AMP040 8 A8P ●
799-601-7190 Adapter for AMP040 12 A12P ● ●
799-601-7210 Adapter for AMP040 16 A16P ● ● ● ●
799-601-7220 Adapter for AMP040 20 A20P ● ● ● ●
799-601-7230 Short socket adapter for X 2 ● ● ● ●
799-601-7240 Case ● ●
799-601-7270 Case ●
799-601-7510 Adapter for 070 10 07-10 ●
799-601-7520 Adapter for 070 12 07-12 ●

HB365LC-3 40-157
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 40 TROUBLESHOOTING

T-adapter kit

Number of pins

Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Part No. Part name ID marking

799-601-7530 Adapter for 070 14 07-14 ●

799-601-7540 Adapter for 070 18 07-18 ●
799-601-7550 Adapter for 070 20 07-20 ●
799-601-7360 Adapter for relay 5 REL-5P ●
799-601-7370 Adapter for relay 6 REL-6P ●
799-601-7380 Adapter for JFC 2 ●
799-601-9010 Adapter for DTM 2 DTM2 ● ●
799-601-9020 Adapter for DT 2 DT2 ● ● ● ●
799-601-9030 Adapter for DT 3 DT3 ● ●
799-601-9040 Adapter for DT 4 DT4 ● ● ● ●
799-601-9050 Adapter for DT 6 DT6 ● ●
799-601-9060 Adapter for DT (gray) 8 DT8GR ● ●
799-601-9070 Adapter for DT (black) 8 DT8B ● ●
799-601-9080 Adapter for DT (green) 8 DT8G ● ●
799-601-9090 Adapter for DT (brown) 8 DT8BR ● ●
799-601-9110 Adapter for DT (gray) 12 DT12GR ● ●
799-601-9120 Adapter for DT (black) 12 DT12B ● ●
799-601-9130 Adapter for DT (green) 12 DT12G ● ●
799-601-9140 Adapter for DT (brown) 12 DT12BR ● ●
799-601-9210 Adapter for HD30-18 8 D18-8 ● ●
799-601-9220 Adapter for HD30-18 14 D18-14 ● ●
799-601-9230 Adapter for HD30-18 20 D18-20 ● ●
799-601-9240 Adapter for HD30-18 21 D18-21 ● ●
799-601-9250 Adapter for HD30-24 9 D24-9 ● ●
799-601-9260 Adapter for HD30-24 16 D24-16 ● ●
799-601-9270 Adapter for HD30-24 21 D24-21 ● ●
799-601-9280 Adapter for HD30-24 23 D24-23 ● ●
799-601-9290 Adapter for HD30-24 31 D24-31 ● ●
799-601-9310 Plate for HD30 (24 pins) ● ● ●
799-601-9320 T-box (for ECONO) 24 ● ● ●
799-601-9330 Case ●
799-601-9340 Case ●
799-601-9350 Adapter for DRC 40 DRC-40 ●
799-601-9360 Adapter for DRC 24 DRC-24 ●
799-601-9410* Socket for engine (CRI-T2) 2 G ●

40-158 HB365LC-3
40 TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH ADAPTER TABLE

T-adapter kit

Number of pins

Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Part No. Part name ID marking

Adapter for engine (CRI-T2)

Adapter PFUEL for engine
799-601-9420 3 A3 ● ●
(CRI-T3)
Oil pressure sensor
Socket for engine (CRI-T2)
799-601-9430* Socket PCV for engine (CRI- 2 P ● ●
T3)
799-601-9440* Socket for engine (CRI-T2) 3 1, 2, 3 ●
795-799-5520* Socket for engine (HPI-T2) 2 S ●
Socket for engine (HPI-T2)
795-799-5530* Socket for engine (CRI-T3) 2 C ● ●
Temperature sensor
Socket for engine (HPI-T2)
795-799-5540* Socket TIM for engine (CRI- 2 A ● ●
T3)
795-799-5460 Cable for engine (HPI-T2) 3 ●
795-799-5470 Cable for engine (HPI-T2) 3 ●
795-799-5480 Cable for engine (HPI-T2) 3 ●
Adapter PIM for engine (140-
799-601-4110 4 ITT3N ● ●
T3)
Adapter NE, CAM for engine
799-601-4130 3 FCIN ● ●
(CRI-T3)
Adapter for engine (CRI-T3)
799-601-4140 3 FCIG ● ●
Ambient pressure
Adapter POIL for engine
799-601-4150 3 FCIB ● ●
(CRI-T3)
Adapter for engine (CRI-T3)
799-601-4160 2 4160 ● ●
Oil pressure switch
Adapter PEVA for engine
799-601-4180 3 4180 ● ●
(CRI-T3)
Socket for engine (CRI-T3)
799-601-4190* 3 1, 2, 3L ● ●
Common rail pressure
Socket for engine (CRI-T3)
799-601-4230* 4 1, 2, 3, 4C ● ●
Intake pressure/temperature
Socket PAMB for engine
799-601-4240* 3 1, 2, 3A ● ●
(CRI-T3)
Socket PIM for engine (CRI-
799-601-4250* 3 1, 2, 3B ● ●
T3)
Socket G for engine (CRI-
799-601-4330* 3 1, 2, 3G ● ●
T3)

HB365LC-3 40-159
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 40 TROUBLESHOOTING

T-adapter kit

Number of pins

Non-kit part
799-601-2500
799-601-2700
799-601-2800
799-601-7000
799-601-7100
799-601-7400
799-601-7500
799-601-8000
799-601-9000
799-601-9100
799-601-9200
799-601-9300
799-601-4101
799-601-4201
Part No. Part name ID marking

Socket for engine (CRI-T3)

799-601-4340* 2 2, PA ● ●
Pump actuator
Socket for engine (CRI-T3)
799-601-4380* (95) 4 1, 2, 3, 4T ●
Intake pressure/temperature
799-601-4260 Adapter for controller (ENG) 4 DTP4 ● ●
799-601-4211 Adapter for controller (ENG) 50 DRC50 ●
799-601-4220 Adapter for controller (ENG) 60 DRC60 ●
Socket for controller
799-601-4390* 60 ●
(95ENG)
799-601-4280* Box for controller (PUMP) 121 ●
799-601-9720 Adapter for controller (HST) 16 HST16A ●
799-601-9710 Adapter for controller (HST) 16 HST16B ●
799-601-9730 Adapter for controller (HST) 26 HST26A ●
Multi-adapter for DT 2 to 4, 2, 3,
799-601-9890 ●
DTM 2 pins 4
799-902-9600 T-adapter for ICT control box 26 ●
799-902-9700 T-box 26 ●
Adapter for radio control re-
799-970-1010 7 ●
ceiver

*: These are not T-adapters but sockets.

40-160 HB365LC-3
40 TROUBLESHOOTING T-BRANCH BOX AND T-BRANCH ADAPTER TABLE

T-adapter kit

Number of pins

Non-kit part
799-A65-4600

799-902-9300
Part No. Part name ID marking

799-601-4620 Adapter for controller (ENG-T4) 4 799-601-4620 ●

799-601-4630 Adapter for controller (ENG-T4) 2 799-601-4630 ●
799-601-4640 Adapter for controller (ENG-T4) 2 799-601-4640 ●
799-601-4651 Adapter for controller (ENG-T4) 24 799-601-4651 ●
799-601-4660 Adapter for controller (ENG-T4) 3 799-601-4660 ●
799-902-9310 Adapter for control box 19 799-902-9310 ●
799-902-9320 Adapter for IMU 10 799-902-9320 ●
799-902-9330 Adapter for MS cylinder 6 799-902-9330 ●
KDPF differential pressure sensor
799T-601-4611 4 799T-601-4611 ●
short socket adapter
KDPF outlet pressure sensor short
799T-601-4670 4 799T-601-4670 ●
socket adapter
799T-601-4680 KDPF dummy temperature sensor 4 799T-601-4680 ●

HB365LC-3 40-161
FUSE LOCATION TABLE 40 TROUBLESHOOTING

FUSE LOCATION TABLE (HB335_3-P-E400-056-00-B)

• This connection table shows the devices which receive the power from the fuse box. (A switched power
supply is the power which is supplied while the starting switch is in ON position and a continuous power
supply is the power which is supplied while the starting switch is in ON and OFF positions.)
• When performing troubleshooting related to the electrical system, at first, check the fuses and fusible links
to see if the power is supplied properly.

Connection table of fuse box

Type of pow- Power supply Fuse Fuse ca-
Destination of power
er supply to fuse No. pacity
1 5A Light relay, pump secondary drive switch
2 30 A Solenoid valve
3 5A PPC hydraulic lock solenoid
4 10 A Window washer, cigarette lighter
5 10 A Horn
6 5A Auto preheater
Fusible link
F04 (65 A) 7 10 A Revolving lamp
Switched
power supply 8 10 A Radio, speaker, left knob switch
9 20 A Headlamp, rear lamp
10 20 A Air conditioner unit
11 10 A Optional power supply (1)
Optional power supply (2), 12 A power supply, and air suspen-
12 30 A
sion seat with heater

Starting switch 13 5A Air conditioner ECU power supply

ACC 14 5A Key ACC signal
15 10 A Work equipment lamp
16 10 A Radio backup, room lamp, system operating lamp
17 20 A Monitor and pump controller
18 30 A Engine controller
19 5A Air conditioner ECU backup
Continuous Fusible link
20 25 A Optional power supply (continuous power supply)
power supply F05 (65 A)
21 20 A Sensor power supply relay (1)
22 10 A Sensor power supply relay (2)
23 10 A AdBlue/DEF line heater relay (1)
24 20 A AdBlue/DEF line heater relay (2)
25 10 A KomVision controller
Switched Fusible link
30 30 A Hybrid controller, capacitor
power supply F04 (65 A)
Fusible link Electric intake air heater (ribbon heater)
Switched
F11, F12 - 80 A
power supply Electric intake air heater relay (ribbon heater relay)
(80 A)

40-162 HB365LC-3
40 TROUBLESHOOTING FUSE LOCATION TABLE

Locations of fusible links

Open the battery cover, and 3 fusible links (F04), (F05) and
(F11, F12) are seen.
NOTICE
• When replacing a fusible link, be sure to turn the start-
ing switch to OFF position and turn the battery discon-
nect switch to OFF position.
• When the starting switch is turned to START position, if
the starting motor does not operate, open circuit of fu-
sible link (F04) or (F05) is suspected. Remove the in-
side cover on the rear right of machine, and then check
or replace the fusible link.
REMARK
A fusible link is a large-capacity fuse wiring which is installed in the circuit where large current flows. It protects
the electric parts and wiring from blowing out due to abnormal current, same as normal fuse does.
Locations of fuse boxes and fuse No.

• Fuse box (F01)

• Fuse box (F02)

HB365LC-3 40-163
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and
KDOC) 40 TROUBLESHOOTING

PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and

KDOC) (PC400_11-K-A9H0-2A4-00-B)

k Since KDPF and KDOC are heated to 500 °C or above, take care not to get burn injury.
Related information
Soot accumulation amount of KCSF in KDPF is classified in 8 levels. From “Service menu” of machine monitor,
display “Diagnostic Tests” screen, and current level of accumulated soot can be checked on “Active Regenera-
tion for Service” screen.
Following failure codes are displayed corresponding to the soot accumulation level.
• If the soot accumulation level is 4 or 5, the failure code [CA2639] is displayed.
• If the soot accumulation level is 6 or 7, the failure code [CA1921] is displayed.
• If the soot accumulation level is 8, the failure code [CA1922] is displayed.
• If the soot accumulation level is 8, you need to check, clean or replace because KDPF is completely
clogged with soot.
• Manual stationary regeneration can be performed up to soot accumulation level 7, and soot in KCSF
can be burnt and removed.
• If the soot accumulation level is 4 to 7, perform the manual stationary regeneration.
Manual stationary regeneration can be performed from Active Regeneration for Service (see below) or from
operator mode.
Method of manual stationary regeneration from “Active Regeneration for Service”.
• When the soot accumulation level is 3 or below, manual stationary regeneration can be performed only
from “Active Regeneration for Service” according to the following procedure.
1. Start the engine.
2. Secure the safety of the machine.
3. From “Service menu” of machine monitor, display “Diagnostic Tests” screen, open “Active Regenera-
tion for Service”, and then perform “Manual Stationary Regeneration”.
• Time required for manual stationary regeneration varies depending on soot accumulation amount in KCSF.
Rough guide is described below.
Soot accumulation level 4: Approximately 40 minutes to 1 hour
Soot accumulation level 5: Approximately 1 hour to 2 hours
• How to reset KDPF (KCSF) cleaning.
From “Service menu” of machine monitor, display “Diagnostic Tests” screen, open “KDPF Memory Re-
set”, and perform “KDPF Cleaning” (Reset KDPF cleaning).
• How to reset KDPF (KCSF) replacing.
From “Service menu” of machine monitor, display “Diagnostic Tests” screen, open “KDPF Memory Re-
set”, and perform “KDPF Change” (Reset KDPF change).
• If KCSF in KDPF is replaced, perform reset of “KDPF Cleaning” and reset of “KDPF Change”, and perform
Manual Stationary Regeneration from always “Active Regeneration for Service” to remove moisture from
KCSF.
• How to reset after KDOC change
From “Service menu” of the machine monitor, display “Diagnostic Tests” screen, open “KDPF Memory
Reset”, and perform “KDOC Change” (Reset after KDOC change).
• If KDOC in KDPF is replaced, perform reset of “KDOC Change” but it is not necessary to perform manual
stationary regeneration.
In case of KCSF cleaning or change
• At 4500 h period periodical cleaning
1. Check the soot accumulation level, if it is displayed, perform “Active Regeneration for Service” until it
becomes zero.

40-164 HB365LC-3
 PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and
40 TROUBLESHOOTING KDOC)

2. Stop the engine, wait for the piping around the engine to be cooled down, and then remove KDPF. Fur-
thermore, remove KCSF.
3. Perform cleaning of KCSF at the specified repair shop, etc. (In case of reusing removed KCSF after
cleaning)
4. Install cleaned up KCSF to the machine. (In case of reusing removed KCSF after cleaning)
5. Install alternative KCSF to the machine. (In case of changing to a new KCSF)
6. Turn the starting switch to ON position. From “Service menu” of machine monitor, display “Diagnostic
Tests” screen, open “KDPF Memory Reset”, and perform reset of “KDPF Cleaning”.
7. On “KDPF Memory Reset” screen, perform reset of “KDPF Change”.
After resetting “KDPF Change”, the changes in the parentheses are reflected. (“Soot Correction by Ash
Influence” is changed to 0 g/ℓ.)
8. Start the engine, and run it at low idle to warm up.
9. Perform “Active Regeneration for Service”.
• When breakage or damage is found in check.
1. Stop the engine, wait for the piping around the engine to be cooled down, and then remove KDPF. Fur-
thermore, remove KCSF.
2. Install alternative KCSF (new or used).
3. Turn the starting switch to ON position. From “Service menu” of machine monitor, display “Diagnostic
Tests” screen, open “KDPF Memory Reset”, and perform reset of “KDPF Cleaning”.
4. On “KDPF Memory Reset” screen, perform reset of “KDPF Change”.
5. Start the engine, and run it at low idle to warm up.
6. Perform “Active Regeneration for Service”.
• When KDPF Soot Accumulation High Error 2 [CA1922] is displayed
1. Stop the machine, and check that failure code [CA1922] is displayed on the machine monitor.
2. Check the display record of “[CA2639]: Manual Stationary Regeneration Request”, “[CA1921]: KDPF
Soot Accumulation High Error 1”, and “[CA1922]: KDPF Soot Accumulation High Error 2” on the ma-
chine monitor
3. Calculate the time between displays [CA2639] and [CA1921], and time between displays [CA1921] and
[CA1922].
• In the case that time between displays [CA2639] and [CA1921] ≧ 0.1 h, and time between dis-
plays [CA1921] and [CA1922] ≧ 0.1 h, perform item 4, replacing KCSF.
REMARK
Since the soot accumulation exceeds the limit which the regeneration can be performed, KCSF
must be replaced by removing KDPF.
• In the case that either time between displays [CA2639] and [CA1921] < 0.1 h, or time between dis-
plays [CA1921] and [CA1922] < 0.1 h, proceed to item 5, performing “Active Regeneration for
Service”.
REMARK
Actually, soot is not sedimented (equivalent to 9 g/ℓ), but accumulation condition of soot is uneven
and it makes clogging and causes increase of differential pressure. With this level of soot accumu-
lation, even if active regeneration is performed, abnormal combustion does not occur. Accordingly,
do not replace KCSF, perform “Active Regeneration for Service” to reduce soot, and continue to
use KCSF.
4. In case of KCSF change
1) Stop the engine, wait for the piping around the engine to be cooled down, and then remove KCSF.
2) Install alternative KCSF (new or used).
3) Turn the starting switch to ON position. From “Service menu” of machine monitor, display “Diag-
nostic Tests” screen, and perform reset of “KDPF Cleaning” from “KDPF Memory Reset”screen.

HB365LC-3 40-165
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and
KDOC) 40 TROUBLESHOOTING

After resetting “KDPF Cleaning”, the changes in the parentheses is reflected. (Soot accumulation:
9 g/ℓ → 8.1 g/ℓ, action level: L04 → L03, failure code: [CA1922] → [CA1921])
4) From “Service menu” of machine monitor, display “Diagnostic Tests” screen, and perform reset of
“KDPF Change” from “KDPF Memory Reset” screen.
After resetting “KDPF Change”, the changes in the parentheses are reflected. (“Soot Correction by
Ash Influence” is changed to 0 g/ℓ.)
5) Start the engine, and run it at low idle to warm up.
6) Perform “Active Regeneration for Service”. (Active regeneration for service may continue for ap-
proximately 2 hours.)
7) Check that failure codes [CA1922], [CA1921], and [CA2639] are not displayed after finishing “Ac-
tive Regeneration for Service”.
5. In case of performing “Active Regeneration for Service”
NOTICE
When performing “Active Regeneration for Service” (KDPF does not need to be removed), do
not reset “KDPF Change”.
If “KDPF Change” is reset, “Soot Correction by Ash Influence” calculated in engine controller
becomes 0 g/ℓ, and it differs from actual ash accumulation value in KDPF.
When resetting “KDPF Change” by any chance, and “Soot Correction by Ash Influence” be-
comes 0 g/ℓ, perform TESTING AND ADJUSTING, “SET AND OPERATE MACHINE MONITOR”,
“SERVICE MODE”, “METHOD FOR OPERATING TESTING MENU (ASH IN SOOT ACCUMULA-
TION CORRECTION)”.
Check that there is no abnormality of sensor system by troubleshooting, and then perform it.
1) Start the engine and run it at low idle to warm up the engine. From “Service menu” of machine
monitor, display “Diagnostic Tests” screen, and perform reset of “KDPF Cleaning” from “KDPF
Memory Reset”screen.
After resetting “KDPF Cleaning”, the changes in the parentheses is reflected. (Soot accumulation:
9 g/ℓ → 8.1 g/ℓ, action level: L04 → L03, failure code: [CA1922] → [CA1921])
2) Perform “Active Regeneration for Service”. (Active regeneration for service may continue for ap-
proximately 2 hours.)
3) Check that failure codes [CA1922], [CA1921], and [CA2639] are not displayed after finishing “Ac-
tive Regeneration for Service”.
6. When Ash Accumulation High Error [CA5383] is displayed
If the expected cause as the results of investigation referring to failure code [CA5383] is “Ash Accumu-
lation High”, perform same contents of “At the 4500 H period periodical cleaning” in “In case of KCSF
cleaning or change” described in precautions of this chapter.
In case of KDOC cleaning or change
• When breakage or damage is found in check.
1. When damage or crack is found in KDOC, change KDOC.
2. From “Service menu” of machine monitor, display “Diagnostic Tests” screen, and perform reset of
“KDOC Change” from “KDPF Memory Reset” screen.
• When Defective Regeneration [CA1691] is displayed
1. Stop the machine and check that failure code [CA1691] is displayed on the machine monitor.
([CA2637] may be displayed at the same time.)
2. Check exhaust gas color of the engine.
3. Stop the engine, wait for the piping around the engine to be cooled down, and remove KDOC, and then
check it for damage or crack.
4. When crack or damage is found in KDOC
1) Replace KDOC.
2) From “Service menu” of machine monitor, display “Diagnostic Tests” screen, and perform reset of
“KDOC Change” from “KDPF Memory Reset” screen.

40-166 HB365LC-3
 PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and
40 TROUBLESHOOTING KDOC)

5. When crack or damage is not found in KDOC

1) Clean KDOC and install it again.
2) From “Service menu” of machine monitor, display “Diagnostic Tests” screen, and perform reset of
“KDOC Change” from “KDPF Memory Reset” screen.
3) Perform “Active Regeneration for Service” twice. (The fuel is injected during regeneration.)
REMARK
When “Active Regeneration for Service” is performed continuously, stop the engine once.
Engine controller stops after starting switch is turned to OFF position and AdBlue/DEF is retracted
(for up to 6 minutes). So when you restart engine, wait for the system operating lamp to go out
after starting switch is turned OFF, and then turn the starting switch to ON position.
4) If “[CA2637]: KDOC Face Plugging” is displayed after performing “Active Regeneration for Serv-
ice”, KDOC efficiency is decreased, so replace KDOC.

HB365LC-3 40-167
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR
(FOR FAILURE CODES [CA1883] AND [CA3135]) 40 TROUBLESHOOTING

PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR

FAILURE CODES [CA1883] AND [CA3135]) (PC400_11-P-T000-2A4-01-B)

NOTICE
The KDPF differential pressure sensor and the KDPF outlet pressure sensor use the same connector.
Contained in kit part No. 799-A65-4600.
Short socket adapter for KDPF differential pressure used in failure code [CA1883]

40-168 HB365LC-3
 PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR
40 TROUBLESHOOTING (FOR FAILURE CODES [CA1883] AND [CA3135])

Short socket adapter for KDPF outlet pressure used in failure code [CA3135]

HB365LC-3 40-169
FAILURE CODES TABLE 40 TROUBLESHOOTING

FAILURE CODES TABLE (HB365_3-A-5520-441-00-B)

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [879AKA] A/C Recirculation Air Electrical
879AKA MON ―
Temperature Sensor Open Circuit system
FAILURE CODE [879AKB] A/C Recirculation Air Electrical
879AKB MON ―
Temperature Sensor Short Circuit system
FAILURE CODE [879BKA] A/C Fresh Air Tempera- Electrical
879BKA MON ―
ture Sensor Open Circuit system
FAILURE CODE [879BKB] A/C Fresh Air Tempera- Electrical
879BKB MON ―
ture Sensor Short Circuit system
FAILURE CODE [879CKA] Ventilating Sensor Open Electrical
879CKA MON ―
Circuit system
FAILURE CODE [879CKB] Ventilating Sensor Short Electrical
879CKB MON ―
Circuit system
FAILURE CODE [879DKZ] Sunlight Sensor Open Electrical
879DKZ MON ―
Circuit or Short Circuit system
FAILURE CODE [879EMC] Ventilation Damper Mal- Electrical
879EMC MON L01
function system
FAILURE CODE [879FMC] Air Mix Damper Mal- Electrical
879FMC MON L01
function system
FAILURE CODE [879GKX] Refrigerant Pressure In- Electrical
879GKX MON L01
put Signal Out of Range system
FAILURE CODE [989L00] Engine Controller Lock Electrical
989L00 MON ―
Caution 1 system
FAILURE CODE [989M00] Engine Controller Lock Electrical
989M00 MON ―
Caution 2 system
FAILURE CODE [989N00] Engine Controller Lock Electrical
989N00 MON ―
Caution 3 system
Electrical
A1U0N3 FAILURE CODE [A1U0N3] HC Desorb Request 1 ENG L01
system
Electrical
A1U0N4 FAILURE CODE [A1U0N4] HC Desorb Request 2 ENG L03
system
FAILURE CODE [A900FR] Abrupt Engine Stop by Mechanical
A900FR MON L03
Auto Idling Stop 3 system
FAILURE CODE [A900N6] Abrupt Engine Stop by Mechanical
A900N6 MON ―
Auto Idling Stop 1 system
FAILURE CODE [A900NY] Abrupt Engine Stop by Mechanical
A900NY MON L01
Auto Idling Stop 2 system
Mechanical
AA10NX FAILURE CODE [AA10NX] Air Cleaner Clogging MON L01
system
Mechanical
AB00KE FAILURE CODE [AB00KE] Charge Voltage Low MON L03
system
FAILURE CODE [AQ10N3] Manual Stationary Re- Electrical
AQ10N3 ENG L01
generation Request (KDOC Face Plugging) system
FAILURE CODE [AS00N3] Manual Stationary Re- Electrical
AS00N3 ENG L01
generation Request (SCR) system

40-170 HB365LC-3
40 TROUBLESHOOTING FAILURE CODES TABLE

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [AS00R2] Warning 2 (SCR Device Electrical
AS00R2 ENG L01
Abnormality) system
FAILURE CODE [AS00R3] Inducement 1 (SCR De- Electrical
AS00R3 ENG L03
vice Abnormality) system
FAILURE CODE [AS00R4] Inducement 2 (SCR De- Electrical
AS00R4 ENG L04
vice Abnormality) system
FAILURE CODE [AS00R5] Inducement 3 (SCR De- Electrical
AS00R5 ENG L04
vice Abnormality) system
FAILURE CODE [AS00R6] Temporary Recovery of Electrical
AS00R6 ENG ―
Inducement system
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Electrical
AS00ZK ENG L04
Error 5 system
FAILURE CODE [AS10KM] AdBlue/DEF Injector Mechanical
AS10KM MON L01
Overheat Warning system
FAILURE CODE [AS10NR] AdBlue/DEF Injector Mechanical
AS10NR ENG ―
High Temperature Warning system
FAILURE CODE [AS10NT] AdBlue/DEF Injector Mechanical
AS10NT MON ―
Overheat Caution system
Mechanical
B@BAZG FAILURE CODE [B@BAZG] Eng Oil Press Low ENG L03
system
Mechanical
B@BAZK FAILURE CODE [B@BAZK] Eng Oil Level Low MON L01
system
FAILURE CODE [B@BCNS] Engine Coolant Over- Mechanical
B@BCNS ENG L02
heat system
Mechanical
B@BCZK FAILURE CODE [B@BCZK] Eng Water Level Low MON L01
system
Mechanical
B@HANS FAILURE CODE [B@HANS] Hyd Oil Overheat ENG L02
system
FAILURE CODE [CA115] Engine NE and Backup Electrical
CA115 ENG L04
Speed Sensor Error system
FAILURE CODE [CA122] Charge Air Pressure Sen- Electrical
CA122 ENG L03
sor High Error system
FAILURE CODE [CA123] Charge Air Pressure Sen- Electrical
CA123 ENG L03
sor Low Error system
FAILURE CODE [CA131] Throttle Sensor High Er- Electrical
CA131 ENG L03
ror system
Electrical
CA132 FAILURE CODE [CA132] Throttle Sensor Low Error ENG L03
system
FAILURE CODE [CA144] Coolant Temperature Electrical
CA144 ENG L01
Sensor High Error system
FAILURE CODE [CA145] Coolant Temperature Electrical
CA145 ENG L01
Sensor Low Error system
FAILURE CODE [CA153] Charge Air Temperature Electrical
CA153 ENG L03
Sensor High Error system
FAILURE CODE [CA154] Charge Air Temperature Electrical
CA154 ENG L03
Sensor Low Error system

HB365LC-3 40-171
FAILURE CODES TABLE 40 TROUBLESHOOTING

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [CA187] Sensor 2 Supply Voltage Electrical
CA187 ENG L03
Low Error system
FAILURE CODE [CA221] Ambient Pressure Sensor Electrical
CA221 ENG L03
High Error system
FAILURE CODE [CA222] Ambient Pressure Sensor Electrical
CA222 ENG L03
Low Error system
FAILURE CODE [CA227] Sensor 2 Supply Voltage Electrical
CA227 ENG L03
High Error system
Mechanical
CA234 FAILURE CODE [CA234] Engine Overspeed ENG L02
system
FAILURE CODE [CA238] NE Speed Sensor Supply Electrical
CA238 ENG L01
Voltage Error system
FAILURE CODE [CA239] NE Speed Sensor Supply Electrical
CA239 ENG L01
Voltage High Error system
FAILURE CODE [CA249] Ambient Air Temp Sensor Electrical
CA249 ENG L01
High Error system
FAILURE CODE [CA256] Ambient Air Temp Sensor Electrical
CA256 ENG L01
Low Error system
FAILURE CODE [CA271] IMV or PCV 1 Short Cir- Electrical
CA271 ENG L03
cuit Error system
FAILURE CODE [CA272] IMV or PCV 1 Open Cir- Electrical
CA272 ENG L03
cuit Error system
FAILURE CODE [CA281] Supply Pump Pressure Electrical
CA281 ENG L03
Balance Error system
FAILURE CODE [CA322] Injector #1 (L#1) Open Electrical
CA322 ENG L03
Circuit Error or Short Circuit Error system
FAILURE CODE [CA323] Injector #5 (L#5) Open Electrical
CA323 ENG L03
Circuit Error or Short Circuit Error system
FAILURE CODE [CA324] Injector #3 (L#3) Open Electrical
CA324 ENG L03
Circuit Error or Short Circuit Error system
FAILURE CODE [CA325] Injector #6 (L#6) Open Electrical
CA325 ENG L03
Circuit Error or Short Circuit Error system
FAILURE CODE [CA331] Injector #2 (L#2) Open Electrical
CA331 ENG L03
Circuit Error or Short Circuit Error system
FAILURE CODE [CA332] Injector #4 (L#4) Open Electrical
CA332 ENG L03
Circuit Error or Short Circuit Error system
FAILURE CODE [CA343] Engine Controller Internal Electrical
CA343 ENG L04
Failure system
FAILURE CODE [CA351] Injectors Drive Circuit Er- Electrical
CA351 ENG L03
ror system
FAILURE CODE [CA352] Sensor 1 Supply Voltage Electrical
CA352 ENG L03
Low Error system
Electrical
CA356 FAILURE CODE [CA356] MAF Sensor High Error ENG L03
system
Electrical
CA357 FAILURE CODE [CA357] MAF Sensor Low Error ENG L03
system

40-172 HB365LC-3
40 TROUBLESHOOTING FAILURE CODES TABLE

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [CA386] Sensor 1 Supply Voltage Electrical
CA386 ENG L03
High Error system
FAILURE CODE [CA428] Water in Fuel Sensor Electrical
CA428 ENG L01
High Error system
FAILURE CODE [CA429] Water in Fuel Sensor Low Electrical
CA429 ENG L01
Error system
FAILURE CODE [CA435] Engine Oil Pressure SW Electrical
CA435 ENG L01
Error system
Electrical
CA441 FAILURE CODE [CA441] Battery Voltage Low Error ENG L04
system
FAILURE CODE [CA442] Battery Voltage High Er- Electrical
CA442 ENG L04
ror system
FAILURE CODE [CA449] Common Rail Pressure Electrical
CA449 ENG L03
High Error 2 system
FAILURE CODE [CA451] Common Rail Pressure Electrical
CA451 ENG L03
Sensor High Error system
FAILURE CODE [CA452] Common Rail Pressure Electrical
CA452 ENG L03
Sensor Low Error system
FAILURE CODE [CA488] Charge Air Temperature Electrical
CA488 ENG L03
High Torque Derate system
FAILURE CODE [CA515] Common Rail Pressure Electrical
CA515 ENG L03
Sensor Supply Voltage High Error system
FAILURE CODE [CA516] Common Rail Pressure Electrical
CA516 ENG L03
Sensor Supply Voltage Low Error system
FAILURE CODE [CA553] Common Rail Pressure Electrical
CA553 ENG L01
High Error 1 system
FAILURE CODE [CA555] Crankcase Pressure High Electrical
CA555 ENG L01
Error 1 system
FAILURE CODE [CA556] Crankcase Pressure High Electrical
CA556 ENG L03
Error 2 system
FAILURE CODE [CA559] Common Rail Pressure Electrical
CA559 ENG L01
Low Error 1 system
FAILURE CODE [CA595] Turbocharger Speed High Electrical
CA595 ENG L01
Error 2 system
FAILURE CODE [CA687] Turbocharger Speed Low Electrical
CA687 ENG L01
Error system
FAILURE CODE [CA689] Engine NE Speed Sensor Electrical
CA689 ENG L01
Error system
FAILURE CODE [CA691] Intake Air Temperature Electrical
CA691 ENG L01
Sensor High Error system
FAILURE CODE [CA692] Intake Air Temperature Electrical
CA692 ENG L01
Sensor Low Error system
FAILURE CODE [CA697] Engine Controller Internal Electrical
CA697 ENG L01
Temperature Sensor High Error system
FAILURE CODE [CA698] Engine Controller Internal Electrical
CA698 ENG L01
Temperature Sensor Low Error system

HB365LC-3 40-173
FAILURE CODES TABLE 40 TROUBLESHOOTING

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [CA731] Engine Backup Speed Electrical
CA731 ENG L01
Sensor Phase Error system
FAILURE CODE [CA778] Engine Backup Speed Electrical
CA778 ENG L01
Sensor Error system
FAILURE CODE [CA1117] Engine Controller Partial Electrical
CA1117 ENG L04
Data Lost Error system
Electrical
CA1664 FAILURE CODE [CA1664] KDOC Abnormality ENG L03
system
FAILURE CODE [CA1669] AdBlue/DEF Level Sen- Electrical
CA1669 ENG L01
sor Voltage High Error system
FAILURE CODE [CA1673] AdBlue/DEF Level Low Electrical
CA1673 ENG L03
Error 3 system
FAILURE CODE [CA1677] AdBlue/DEF Tempera- Electrical
CA1677 ENG L01
ture Sensor Low Error system
FAILURE CODE [CA1678] AdBlue/DEF Tempera- Electrical
CA1678 ENG L01
ture Sensor High Error system
FAILURE CODE [CA1682] AdBlue/DEF Pump Pri- Electrical
CA1682 ENG L01
ming Error system
FAILURE CODE [CA1683] AdBlue/DEF Tank Heat- Electrical
CA1683 ENG L01
ing Valve Voltage High Error system
FAILURE CODE [CA1684] AdBlue/DEF Tank Heat- Electrical
CA1684 ENG L01
ing Valve Voltage Low Error system
FAILURE CODE [CA1686] AdBlue/DEF Quality Electrical
CA1686 ENG L01
Sensor Voltage High Error system
Electrical
CA1691 FAILURE CODE [CA1691] Defective Regeneration ENG L03
system
FAILURE CODE [CA1694] SCR Outlet NOx Sensor Electrical
CA1694 ENG L01
In Range Error system
FAILURE CODE [CA1695] Sensor 5 Supply Voltage Electrical
CA1695 ENG L03
High Error system
FAILURE CODE [CA1696] Sensor 5 Supply Voltage Electrical
CA1696 ENG L03
Low Error system
FAILURE CODE [CA1712] AdBlue/DEF Tank Thaw- Electrical
CA1712 ENG L01
ing Error system
FAILURE CODE [CA1713] AdBlue/DEF Tank Heat- Electrical
CA1713 ENG L01
ing Valve Open Stuck Error system
FAILURE CODE [CA1714] AdBlue/DEF Quality Electrical
CA1714 ENG L01
Sensor Out of Calibration Error system
FAILURE CODE [CA1715] AdBlue/DEF Quality Electrical
CA1715 ENG L01
Sensor Internal Circuit Error system
FAILURE CODE [CA1776] Sensor Supply Relay Electrical
CA1776 ENG L01
Voltage High Error system
FAILURE CODE [CA1777] Sensor Supply Relay Electrical
CA1777 ENG L01
Voltage Low Error system
FAILURE CODE [CA1843] Crankcase Pressure Electrical
CA1843 ENG L01
Sensor High Error system

40-174 HB365LC-3
40 TROUBLESHOOTING FAILURE CODES TABLE

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [CA1844] Crankcase Pressure Electrical
CA1844 ENG L01
Sensor Low Error system
FAILURE CODE [CA1879] KDPF Differential Pres- Electrical
CA1879 ENG L03
sure Sensor High Error system
FAILURE CODE [CA1881] KDPF Differential Pres- Electrical
CA1881 ENG L03
sure Sensor Low Error system
FAILURE CODE [CA1883] KDPF Differential Pres- Electrical
CA1883 ENG L03
sure Sensor In Range Error system
FAILURE CODE [CA1885] Turbo Outlet NOx Sen- Electrical
CA1885 ENG L01
sor Circuit Error system
FAILURE CODE [CA1887] SCR Outlet NOx Sensor Electrical
CA1887 ENG L01
Circuit Error system
FAILURE CODE [CA1921] KDPF Soot Accumula- Electrical
CA1921 ENG L03
tion High Error 1 system
FAILURE CODE [CA1922] KDPF Soot Accumula- Electrical
CA1922 ENG L04
tion High Error 2 system
FAILURE CODE [CA1942] Crankcase Pressure Electrical
CA1942 ENG L01
Sensor In Range Error system
FAILURE CODE [CA1993] KDPF Differential Pres- Electrical
CA1993 ENG L03
sure Low Error system
FAILURE CODE [CA2185] Throttle Sensor Supply Electrical
CA2185 ENG L03
Voltage High Error system
FAILURE CODE [CA2186] Throttle Sensor Supply Electrical
CA2186 ENG L03
Voltage Low Error system
FAILURE CODE [CA2249] Common Rail Pressure Electrical
CA2249 ENG L03
Low Error 2 system
FAILURE CODE [CA2265] Fuel Feed Pump Open Electrical
CA2265 ENG L01
Circuit Error system
FAILURE CODE [CA2266] Fuel Feed Pump Short Electrical
CA2266 ENG L01
Circuit Error system
FAILURE CODE [CA2271] EGR Valve Position Electrical
CA2271 ENG L03
Sensor High Error system
FAILURE CODE [CA2272] EGR Valve Position Electrical
CA2272 ENG L03
Sensor Low Error system
FAILURE CODE [CA2288] Turbocharger Speed Electrical
CA2288 ENG L01
High Error 1 system
Electrical
CA2311 FAILURE CODE [CA2311] IMV Solenoid Error ENG L03
system
FAILURE CODE [CA2349] EGR Valve Solenoid Electrical
CA2349 ENG L03
Open Circuit Error system
FAILURE CODE [CA2353] EGR Valve Solenoid Electrical
CA2353 ENG L03
Short Circuit Error system
Electrical
CA2357 FAILURE CODE [CA2357] EGR Valve Servo Error ENG L03
system
FAILURE CODE [CA2381] KVGT Position Sensor Electrical
CA2381 ENG L03
High Error system

HB365LC-3 40-175
FAILURE CODES TABLE 40 TROUBLESHOOTING

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [CA2382] KVGT Position Sensor Electrical
CA2382 ENG L03
Low Error system
FAILURE CODE [CA2383] KVGT Solenoid Open Electrical
CA2383 ENG L03
Circuit Error system
FAILURE CODE [CA2386] KVGT Solenoid Short Electrical
CA2386 ENG L03
Circuit Error system
Electrical
CA2387 FAILURE CODE [CA2387] KVGT Servo Error ENG L03
system
FAILURE CODE [CA2555] Intake Air Heater Relay Electrical
CA2555 ENG L01
Open Circuit Error system
FAILURE CODE [CA2556] Intake Air Heater Relay Electrical
CA2556 ENG L01
Short Circuit Error system
Electrical
CA2637 FAILURE CODE [CA2637] KDOC Face Plugging ENG L01
system
FAILURE CODE [CA2639] Manual Stationary Re- Electrical
CA2639 ENG L01
generation Request system
FAILURE CODE [CA2771] SCR Outlet NOx Sensor Electrical
CA2771 ENG L01
Datalink Timeout Error system
FAILURE CODE [CA2777] Manual Stationary Re-
Electrical
CA2777 generation Request but KDPF Regeneration Disa- ENG ―
system
ble
FAILURE CODE [CA2976] AdBlue/DEF Pump Tem- Electrical
CA2976 ENG L01
perature Sensor Signal Error system
FAILURE CODE [CA3133] KDPF Outlet Pressure Electrical
CA3133 ENG L03
Sensor High Error system
FAILURE CODE [CA3134] KDPF Outlet Pressure Electrical
CA3134 ENG L03
Sensor Low Error system
FAILURE CODE [CA3135] KDPF Outlet Pressure Electrical
CA3135 ENG L03
Sensor In Range Error system
FAILURE CODE [CA3142] SCR Temperature Sen- Electrical
CA3142 ENG L01
sor High Error system
FAILURE CODE [CA3143] SCR Temperature Sen- Electrical
CA3143 ENG L01
sor Low Error system
FAILURE CODE [CA3144] SCR Temperature Sen- Electrical
CA3144 ENG L01
sor In Range Error system
FAILURE CODE [CA3146] SCR Outlet Temperature Electrical
CA3146 ENG L01
Sensor High Error system
FAILURE CODE [CA3147] SCR Outlet Temperature Electrical
CA3147 ENG L01
Sensor Low Error system
FAILURE CODE [CA3148] SCR Outlet Temperature Electrical
CA3148 ENG L01
Sensor In Range Error system
FAILURE CODE [CA3151] SCR Catalyst Efficiency Electrical
CA3151 ENG L01
Low Error 2 system
FAILURE CODE [CA3165] SCR Outlet Temperature Electrical
CA3165 ENG L03
High Error system

40-176 HB365LC-3
40 TROUBLESHOOTING FAILURE CODES TABLE

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [CA3229] SCR Temperature High Electrical
CA3229 ENG L03
Error system
FAILURE CODE [CA3231] SCR Temperature High Electrical
CA3231 ENG L03
Error - Non Regeneration system
FAILURE CODE [CA3232] Turbo Outlet NOx Sen- Electrical
CA3232 ENG L01
sor Datalink Timeout Error system
FAILURE CODE [CA3235] SCR Outlet Temperature Electrical
CA3235 ENG L03
High Error - Non Regeneration system
FAILURE CODE [CA3239] AdBlue/DEF Line Heater Electrical
CA3239 ENG L01
2 Voltage High Error system
FAILURE CODE [CA3241] AdBlue/DEF Line Heater Electrical
CA3241 ENG L01
2 Voltage Low Error system
FAILURE CODE [CA3242] AdBlue/DEF Tank Heat- Electrical
CA3242 ENG L01
ing Error system
FAILURE CODE [CA3251] KDOC Inlet Temperature Electrical
CA3251 ENG L03
High Error system
FAILURE CODE [CA3253] KDOC Temperature Er- Electrical
CA3253 ENG L03
ror - Non Regeneration system
FAILURE CODE [CA3254] KDOC Outlet Tempera- Electrical
CA3254 ENG L01
ture High Error 1 system
FAILURE CODE [CA3255] KDPF Temperature Er- Electrical
CA3255 ENG L03
ror - Non Regeneration system
FAILURE CODE [CA3256] KDPF Outlet Tempera- Electrical
CA3256 ENG L01
ture High Error 1 system
FAILURE CODE [CA3311] KDOC Outlet Tempera- Electrical
CA3311 ENG L03
ture High Error 2 system
FAILURE CODE [CA3312] KDPF Outlet Tempera- Electrical
CA3312 ENG L03
ture High Error 2 system
FAILURE CODE [CA3313] KDOC Inlet Temperature Electrical
CA3313 ENG L03
Sensor Low Error system
FAILURE CODE [CA3314] KDOC Inlet Temperature Electrical
CA3314 ENG L03
Sensor High Error system
FAILURE CODE [CA3315] KDOC Inlet Temperature Electrical
CA3315 ENG L03
Sensor In Range Error system
FAILURE CODE [CA3316] KDOC Outlet Tempera- Electrical
CA3316 ENG L03
ture Sensor Low Error system
FAILURE CODE [CA3317] KDOC Outlet Tempera- Electrical
CA3317 ENG L03
ture Sensor High Error system
FAILURE CODE [CA3318] KDOC Outlet Tempera- Electrical
CA3318 ENG L03
ture Sensor In Range Error system
FAILURE CODE [CA3319] KDOC Outlet Tempera- Electrical
CA3319 ENG L03
ture Sensor High Error system
FAILURE CODE [CA3321] KDPF Outlet Tempera- Electrical
CA3321 ENG L03
ture Sensor Low Error system
FAILURE CODE [CA3322] KDPF Outlet Tempera- Electrical
CA3322 ENG L03
ture Sensor In Range Error system

HB365LC-3 40-177
FAILURE CODES TABLE 40 TROUBLESHOOTING

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [CA3419] MAF Sensor Supply Electrical
CA3419 ENG L03
Voltage High Error system
FAILURE CODE [CA3421] MAF Sensor Supply Electrical
CA3421 ENG L03
Voltage Low Error system
FAILURE CODE [CA3497] AdBlue/DEF Level Low Electrical
CA3497 ENG ―
Error 1 system
FAILURE CODE [CA3498] AdBlue/DEF Level Low Electrical
CA3498 ENG ―
Error 2 system
FAILURE CODE [CA3543] AdBlue/DEF Quality Er- Electrical
CA3543 ENG L01
ror (SCR Catalyst Efficiency Low) system
FAILURE CODE [CA3545] SCR Outlet NOx Sensor Electrical
CA3545 ENG L01
Unstable Error system
FAILURE CODE [CA3547] AdBlue/DEF Level Low Electrical
CA3547 ENG L04
Error 4 system
FAILURE CODE [CA3558] AdBlue/DEF Pump Volt- Electrical
CA3558 ENG L01
age High Error system
FAILURE CODE [CA3559] AdBlue/DEF Pump Volt- Electrical
CA3559 ENG L01
age Low Error system
FAILURE CODE [CA3562] AdBlue/DEF LineHeater Electrical
CA3562 ENG L01
Relay 1 Voltage High Error system
FAILURE CODE [CA3563] AdBlue/DEF LineHeater Electrical
CA3563 ENG L01
Relay 1 Voltage Low Error system
FAILURE CODE [CA3567] AdBlue/DEF Injector Electrical
CA3567 ENG L01
Open Circuit Error or Short Circuit Error system
FAILURE CODE [CA3568] AdBlue/DEF Injector Electrical
CA3568 ENG L01
Malfunction system
FAILURE CODE [CA3571] AdBlue/DEF Pump Electrical
CA3571 ENG L01
Pressure Sensor High Error system
FAILURE CODE [CA3572] AdBlue/DEF Pump Electrical
CA3572 ENG L01
Pressure Sensor Low Error system
FAILURE CODE [CA3574] AdBlue/DEF Pump Electrical
CA3574 ENG L01
Pressure Too Low Error system
FAILURE CODE [CA3575] AdBlue/DEF Pump Electrical
CA3575 ENG L01
Pressure Too High Error system
FAILURE CODE [CA3577] AdBlue/DEF FCV Volt- Electrical
CA3577 ENG L01
age High Error system
FAILURE CODE [CA3578] AdBlue/DEF FCV Volt- Electrical
CA3578 ENG L01
age Low Error system
FAILURE CODE [CA3582] SCR Catalyst Efficiency Electrical
CA3582 ENG ―
Low Error 1 system
FAILURE CODE [CA3583] SCR Outlet NOx Sensor Electrical
CA3583 ENG L01
Heater Warming up Error system
FAILURE CODE [CA3596] AdBlue/DEF Pump Electrical
CA3596 ENG L01
Pressure Unstable Error system
FAILURE CODE [CA3649] Turbo Outlet NOx Sen- Electrical
CA3649 ENG L01
sor Heater Warming up Error system

40-178 HB365LC-3
40 TROUBLESHOOTING FAILURE CODES TABLE

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [CA3681] SCR Outlet NOx Sensor Electrical
CA3681 ENG L01
Power Voltage Error system
FAILURE CODE [CA3682] Turbo Outlet NOx Sen- Electrical
CA3682 ENG L01
sor Power Voltage Error system
FAILURE CODE [CA3713] AdBlue/DEF Line Heater Electrical
CA3713 ENG L01
1 Voltage High Error system
FAILURE CODE [CA3717] SCR Outlet NOx Sensor Electrical
CA3717 ENG L01
Voltage Mismatch Error system
FAILURE CODE [CA3718] Turbo Outlet NOx Sen- Electrical
CA3718 ENG L01
sor Voltage Mismatch Error system
FAILURE CODE [CA3725] Turbo Outlet NOx Sen- Electrical
CA3725 ENG L01
sor Unstable Error system
FAILURE CODE [CA3741] Common Rail Pressure Electrical
CA3741 ENG L03
Valve Trip Error system
FAILURE CODE [CA3748] Turbo Outlet NOx Sen- Electrical
CA3748 ENG L01
sor Stuck In Range Error system
FAILURE CODE [CA3751] SCR Catalyst Degrada- Electrical
CA3751 ENG L03
tion Error system
FAILURE CODE [CA3755] AdBlue/DEF Dosing Electrical
CA3755 ENG L03
Performance Degradation Error system
FAILURE CODE [CA3866] AdBlue/DEF Low Con- Electrical
CA3866 ENG L01
centration Error 2 system
FAILURE CODE [CA3867] AdBlue/DEF Low Con- Electrical
CA3867 ENG ―
centration Error 1 system
FAILURE CODE [CA3868] AdBlue/DEF Tank Sen- Electrical
CA3868 ENG L01
sor Datalink Timeout Error system
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Electrical
CA3899 ENG L01
Error system
FAILURE CODE [CA3911] SCR NH3 Sensor Data- Electrical
CA3911 ENG L01
link Timeout Error system
FAILURE CODE [CA3912] SCR NH3 Sensor Heat- Electrical
CA3912 ENG L01
er Warming up Error system
FAILURE CODE [CA3932] SCR NH3 Sensor Heat- Electrical
CA3932 ENG L01
er Voltage High Error system
FAILURE CODE [CA3933] SCR NH3 Sensor Heat- Electrical
CA3933 ENG L01
er Voltage Low Error system
FAILURE CODE [CA3934] SCR NH3 Sensor Power Electrical
CA3934 ENG L01
Interrupt Error system
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Electrical
CA3935 ENG L01
Resistance Error system
FAILURE CODE [CA3936] SCR NH3 Sensor Inter- Electrical
CA3936 ENG L01
nal Circuit Error system
FAILURE CODE [CA4151] KDOC and KDPF Tem- Electrical
CA4151 ENG L03
perature Sensor Datalink Timeout Error system
FAILURE CODE [CA4152] SCR Temperature Sen- Electrical
CA4152 ENG L01
sor Datalink Timeout Error system

HB365LC-3 40-179
FAILURE CODES TABLE 40 TROUBLESHOOTING

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [CA4155] AdBlue/DEF Pump Electrical
CA4155 ENG L01
Heater Relay Voltage High Error system
FAILURE CODE [CA4156] AdBlue/DEF Pump Electrical
CA4156 ENG L01
Heater Relay Voltage Low Error system
FAILURE CODE [CA4157] AdBlue/DEF FCV Mal- Electrical
CA4157 ENG L01
function system
FAILURE CODE [CA4158] KDOC and KDPF Tem- Electrical
CA4158 ENG L03
perature Sensor Internal Circuit Error system
FAILURE CODE [CA4159] SCR Temperature Sen- Electrical
CA4159 ENG L01
sor Internal Circuit Error system
FAILURE CODE [CA4161] KDOC and KDPF Tem- Electrical
CA4161 ENG L03
perature Sensor ECU Voltage High Error system
FAILURE CODE [CA4162] KDOC and KDPF Tem- Electrical
CA4162 ENG L03
perature Sensor ECU Voltage Low Error system
FAILURE CODE [CA4163] KDOC and KDPF Tem- Electrical
CA4163 ENG L01
perature Sensor ECU Over Temperature Error system
FAILURE CODE [CA4164] SCR Temperature Sen- Electrical
CA4164 ENG L01
sor ECU Voltage High Error system
FAILURE CODE [CA4165] SCR Temperature Sen- Electrical
CA4165 ENG L01
sor ECU Voltage Low Error system
FAILURE CODE [CA4166] SCR Temperature Sen- Electrical
CA4166 ENG L01
sor ECU High Temperature Error system
FAILURE CODE [CA4168] AdBlue/DEF Pump Electrical
CA4168 ENG L01
Heater ON Stuck Error system
FAILURE CODE [CA4169] AdBlue/DEF Pump Electrical
CA4169 ENG L01
Heater OFF Stuck Error system
FAILURE CODE [CA4171] AdBlue/DEF Pump Electrical
CA4171 ENG L01
Thawing Error system
FAILURE CODE [CA4249] AdBlue/DEF Pump Tem- Electrical
CA4249 ENG L01
perature Sensor 1 In Range Error system
FAILURE CODE [CA4251] AdBlue/DEF Pump Tem- Electrical
CA4251 ENG L01
perature Sensor 2 In Range Error system
FAILURE CODE [CA4259] KDOC and KDPF Tem- Electrical
CA4259 ENG L03
perature Sensor Power Interrupt Error system
FAILURE CODE [CA4261] SCR Temperature Sen- Electrical
CA4261 ENG L01
sor Power Interrupt Error system
FAILURE CODE [CA4277] AdBlue/DEF Quality Electrical
CA4277 ENG L01
Sensor Liquid Distinction Impossible Error system
FAILURE CODE [CA4281] SCR NH3 Sensor Stuck Electrical
CA4281 ENG L01
Response Error system
FAILURE CODE [CA4459] AdBlue/DEF LineHeater Electrical
CA4459 ENG L01
Relay 2 Voltage High Error system
FAILURE CODE [CA4461] AdBlue/DEF LineHeater Electrical
CA4461 ENG L01
Relay 2 Voltage Low Error system
FAILURE CODE [CA4658] AdBlue/DEF Flow Low Electrical
CA4658 ENG ―
Error system

40-180 HB365LC-3
40 TROUBLESHOOTING FAILURE CODES TABLE

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [CA4731] AdBlue/DEF Tempera- Electrical
CA4731 ENG L01
ture Sensor Transmission Data Error system
FAILURE CODE [CA4732] AdBlue/DEF Level Sen- Electrical
CA4732 ENG L01
sor Transmission Data Error system
FAILURE CODE [CA4739] AdBlue/DEF Level Sen- Electrical
CA4739 ENG L01
sor Internal Circuit Error system
FAILURE CODE [CA4768] Fuel in AdBlue/DEF Electrical
CA4768 ENG L03
Tank Error system
FAILURE CODE [CA4768] AdBlue/DEF Level Electrical
CA4769 ENG L01
Measurement Impossible system
FAILURE CODE [CA4842] AdBlue/DEF High Con- Electrical
CA4842 ENG L01
centration Error system
FAILURE CODE [CA4952] System Operating Lamp Electrical
CA4952 ENG ―
Short Circuit (Engine Controller) system
FAILURE CODE [CA5115] AdBlue/DEF Line Heater Electrical
CA5115 ENG L01
1 Voltage Low Error system
FAILURE CODE [CA5179] Engine Room Tempera- Electrical
CA5179 ENG L01
ture Sensor High Error system
FAILURE CODE [CA5181] Engine Room Tempera- Electrical
CA5181 ENG L01
ture Sensor Low Error system
FAILURE CODE [CA5383] Ash Accumulation High Electrical
CA5383 ENG ―
Error system
FAILURE CODE [D110KB] Battery Relay Output Electrical
D110KB PUMP L01
Short Circuit system
FAILURE CODE [D19JKZ] Personal Code Relay Electrical
D19JKZ MON L03
Open Circuit or Short Circuit system
Electrical
D811MC FAILURE CODE [D811MC] KOMTRAX Malfunction KOMTRAX ―
system
FAILURE CODE [D862KA] GPS Antenna Open Cir- Electrical
D862KA KOMTRAX ―
cuit system
FAILURE CODE [D8ALKA] System Operating Lamp Electrical
D8ALKA KOMTRAX ―
Open Circuit (KOMTRAX) system
FAILURE CODE [D8ALKB] System Operating Lamp Electrical
D8ALKB KOMTRAX ―
Short Circuit (KOMTRAX) system
FAILURE CODE [D8AQKR] CAN 2 Defective Com- Electrical
D8AQKR MON ―
munication (KOMTRAX) system
FAILURE CODE [DA20MC] Pump Controller Mal- Electrical
DA20MC PUMP ―
function system
FAILURE CODE [DA22KK] Pump Controller Sole- Electrical
DA22KK PUMP L03
noid Power Voltage Low Error system
FAILURE CODE [DA25KP] 5V Sensor 1 Power Electrical
DA25KP PUMP ―
Voltage Low Error system
FAILURE CODE [DA26KP] 5V Sensor 2 Power Electrical
DA26KP PUMP ―
Voltage Low Error system
FAILURE CODE [DA29KQ] Model Selection Signal Electrical
DA29KQ PUMP L01
Mismatch (Pump Controller) system

HB365LC-3 40-181
FAILURE CODES TABLE 40 TROUBLESHOOTING

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [DA2LKA] System Operating Lamp Electrical
DA2LKA PUMP ―
Open Circuit (Pump Controller) system
FAILURE CODE [DA2LKB] System Operating Lamp Electrical
DA2LKB PUMP ―
Short Circuit (Pump Controller) system
FAILURE CODE [DA2QKR] Controller Area Net- Electrical
DA2QKR MON L03
work 2 Defective Communication (Pump Controller) system
FAILURE CODE [DA2RKR] Controller Area Net- Electrical
DA2RKR MON L04
work 1 Defective Communication (Pump Controller) system
FAILURE CODE [DAF0KM] Inconsistency of Kom- Electrical
DAF0KM MON L01
Vision Setting system
FAILURE CODE [DAF0MB] Monitor ROM Abnor- Electrical
DAF0MB MON ―
mality system
Electrical
DAF0MC FAILURE CODE [DAF0MC] Monitor Malfunction MON ―
system
FAILURE CODE [DAF8KB] Camera Power Supply Electrical
DAF8KB MON L03
Short Circuit system
FAILURE CODE [DAF9KQ] Model Selection Signal Electrical
DAF9KQ MON L03
Mismatch (Monitor) system
FAILURE CODE [DAF9KQ] GPS Module Malfunc- Electrical
DAFGMC KOMTRAX ―
tion system
FAILURE CODE [DAFLKA] System Operating Electrical
DAFLKA MON ―
Lamp Open Circuit (Monitor) system
FAILURE CODE [DAFLKB] System Operating Electrical
DAFLKB MON ―
Lamp Short Circuit (Monitor) system
FAILURE CODE [DAFQKR] CAN 2 Defective Com- Electrical
DAFQKR KOMTRAX ―
munication (Monitor) system
FAILURE CODE [DAZ9KQ] Model Selection Signal Electrical
DAZ9KQ MON ―
Mismatch (A/C) system
FAILURE CODE [DAZQKR] CAN 2 Defective Com- Electrical
DAZQKR MON L01
munication (A/C ECU) system
FAILURE CODE [DB2QKR] CAN 2 Defective Com- Electrical
DB2QKR MON L03
munication (Engine Controller) system
FAILURE CODE [DB2RKR] CAN 1 Defective Com- Electrical
DB2RKR MON L03
munication (Engine Controller) system
FAILURE CODE [DBP0KM] KomVision Setting Er- Electrical
DBP0KM KomVision L01
ror system
FAILURE CODE [DBP0KT] KomVision Controller Electrical
DBP0KT KomVision L01
Abnormality system
FAILURE CODE [DBPQKR] CAN 2 Defective Com- Electrical
DBPQKR MON L01
munication (KomVision) system
FAILURE CODE [DDNRKA] W/E Lever Lock SW Electrical
DDNRKA PUMP L03
Open Circuit system
FAILURE CODE [DDNRKY] W/E Lever Lock SW Electrical
DDNRKY PUMP L03
Short Circuit system
FAILURE CODE [DDNS00] Lock Lever Auto Lock Electrical
DDNS00 PUMP ―
Release SW On system

40-182 HB365LC-3
40 TROUBLESHOOTING FAILURE CODES TABLE

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [DGH2KA] Hydraulic Oil Tempera- Electrical
DGH2KA PUMP L01
ture Sensor Open Circuit system
FAILURE CODE [DGH2KB] Hydraulic Oil Tempera- Electrical
DGH2KB PUMP L01
ture Sensor Ground Fault system
FAILURE CODE [DHA4KA] Air Cleaner Clog Sen- Electrical
DHA4KA MON L01
sor Open Circuit system
FAILURE CODE [DHAAMA] KDPF Differential Electrical
DHAAMA ENG ―
Pressure Sensor Frozen system
FAILURE CODE [DHACMA] KDPF Outlet Pressure Electrical
DHACMA ENG ―
Sensor Frozen system
FAILURE CODE [DHPAMA] Front Pump Pressure Electrical
DHPAMA PUMP L01
Sensor Defective Function system
FAILURE CODE [DHPBMA] Rear Pump Pressure Electrical
DHPBMA PUMP L01
Sensor Defective Function system
FAILURE CODE [DHS3MA] Arm IN PPC Pressure Electrical
DHS3MA PUMP L01
Sensor Defective Function system
FAILURE CODE [DHS4MA] Bucket CURL PPC Electrical
DHS4MA PUMP L01
Pressure Sensor Defective Function system
FAILURE CODE [DHS8MA] Boom RAISE PPC Electrical
DHS8MA PUMP L01
Pressure Sensor Defective Function system
FAILURE CODE [DHS9MA] Boom LOWER PPC Electrical
DHS9MA PUMP L01
Pressure Sensor Defective Function system
FAILURE CODE [DHSAKZ] Swing RIGHT PPC Electrical
DHSAKZ PUMP L03
Pressure Sensor Defective Function system
FAILURE CODE [DHSBKZ] Swing LEFT PPC Pres- Electrical
DHSBKZ PUMP L03
sure Sensor Defective Function system
FAILURE CODE [DHSCMA] Arm OUT PPC Pres- Electrical
DHSCMA PUMP L01
sure Sensor Defective Function system
FAILURE CODE [DHSDMA] Bucket DUMP PPC Electrical
DHSDMA PUMP L01
Pressure Sensor Defective Function system
FAILURE CODE [DHSFMA] Travel Forward Left Electrical
DHSFMA PUMP L01
PPC Pressure Sensor Defective Function system
FAILURE CODE [DHSGMA] Travel Forward Right Electrical
DHSGMA PUMP L01
PPC Pressure Sensor Defective Function system
FAILURE CODE [DHSHMA] Travel Reverse Left Electrical
DHSHMA PUMP L01
PPC Pressure Sensor Defective Function system
FAILURE CODE [DHSJMA] Travel Reverse Right Electrical
DHSJMA PUMP L01
PPC Pressure Sensor Defective Function system
FAILURE CODE [DHVAKZ] HYB Swing RIGHT Electrical
DHVAKZ HYB L03
PPC Pressure Sensor Open and Short Circuit system
FAILURE CODE [DHVAL8] HYB Swing RIGHT PPC Electrical
DHVAL8 HYB L03
Pressure Sensor Signal Mismatch system
FAILURE CODE [DHVAMA] HYB Swing RIGHT Electrical
DHVAMA HYB L03
PPC Sensor Malfunction system
FAILURE CODE [DHVBKZ] HYB Swing LEFT PPC Electrical
DHVBKZ HYB L03
Pressure Sensor Open and Short Circuit system

HB365LC-3 40-183
FAILURE CODES TABLE 40 TROUBLESHOOTING

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [DHVBL8] HYB Swing LEFT PPC Electrical
DHVBL8 HYB L03
Pressure Sensor Signal Mismatch system
FAILURE CODE [DHVBMA] HYB Swing LEFT PPC Electrical
DHVBMA HYB L03
Sensor Malfunction system
FAILURE CODE [DKR0MA] Front Pump Swash Electrical
DKR0MA PUMP L01
Plate Sensor Defective Function system
FAILURE CODE [DKR1MA] Rear Pump Swash Electrical
DKR1MA PUMP L01
Plate Sensor Defective Function system
FAILURE CODE [DKULKA] PPC Lock Relay Open Electrical
DKULKA PUMP L03
Circuit system
FAILURE CODE [DKULKB] PPC Lock Relay Short Electrical
DKULKB PUMP L03
Circuit system
FAILURE CODE [DKULKY] PPC Lock Relay Hot Electrical
DKULKY PUMP L03
Short Circuit system
FAILURE CODE [DLM5KA] Fan Speed Sensor Electrical
DLM5KA PUMP L01
Open Circuit system
Electrical
DLM5MB FAILURE CODE [DLM5MB] Fan Control: Mismatch PUMP L01
system
FAILURE CODE [DR10KA] KomVision Camera Electrical
DR10KA KomVision L01
Open Circuit system
FAILURE CODE [DR21KX] Camera 2 Picture Re- Electrical
DR21KX MON L01
verse Drive Input Out of Range system
FAILURE CODE [DUMBKA] Operating Lamp Open Electrical
DUMBKA KomVision L01
Circuit (KomVision) system
FAILURE CODE [DUMBKB] Operating Lamp Short Electrical
DUMBKB KomVision L01
Circuit (KomVision) system
FAILURE CODE [DV20KB] Travel Alarm Short Cir- Electrical
DV20KB PUMP L01
cuit system
FAILURE CODE [DW43KA] Travel Speed Solenoid Electrical
DW43KA PUMP L01
Open Circuit system
FAILURE CODE [DW43KB] Travel Speed Solenoid Electrical
DW43KB PUMP L01
Short Circuit system
FAILURE CODE [DW43KY] Travel Speed Solenoid Electrical
DW43KY PUMP L01
Hot Short Circuit system
FAILURE CODE [DW45KA] Swing Parking Brake Electrical
DW45KA HYB L03
Solenoid Open Circuit system
FAILURE CODE [DW45KB] Swing Parking Brake Electrical
DW45KB HYB L03
Solenoid Short Circuit system
FAILURE CODE [DW45KK] Swing Parking Brake Electrical
DW45KK HYB L03
Solenoid Valve Power Voltage Low Error system
FAILURE CODE [DW45KY] Swing Parking Brake Electrical
DW45KY HYB L03
Solenoid Hot Short Circuit system
FAILURE CODE [DW4CKY] PPC Lock Solenoid Electrical
DW4CKY PUMP L03
Hot Short Circuit system
FAILURE CODE [DW91KA] Travel Junction Sole- Electrical
DW91KA PUMP L01
noid Open Circuit system

40-184 HB365LC-3
40 TROUBLESHOOTING FAILURE CODES TABLE

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [DW91KB] Travel Junction Sole- Electrical
DW91KB PUMP L01
noid Short Circuit system
FAILURE CODE [DW91KY] Travel Junction Sole- Electrical
DW91KY PUMP L01
noid Hot Short Circuit system
FAILURE CODE [DWA2KA] Attachment Single or 2- Electrical
DWA2KA PUMP L03
Way Change Solenoid Open Circuit system
FAILURE CODE [DWA2KB] Attachment Single or 2- Electrical
DWA2KB PUMP L03
Way Change Solenoid Short Circuit system
FAILURE CODE [DWA2KY] Attachment Single or 2- Electrical
DWA2KY PUMP L03
Way Change Solenoid Hot Short Circuit system
FAILURE CODE [DWK0KA] 2-Stage Relief Sole- Electrical
DWK0KA PUMP L01
noid Open Circuit system
FAILURE CODE [DWK0KB] 2-Stage Relief Sole- Electrical
DWK0KB PUMP L01
noid Open Circuit system
FAILURE CODE [DWK0KY] 2-Stage Relief Sole- Electrical
DWK0KY PUMP L01
noid Hot Short Circuit system
FAILURE CODE [DWK2KA] Variable Back Pressure Electrical
DWK2KA PUMP L01
Solenoid Open Circuit system
FAILURE CODE [DWK2KB] Variable Back Pressure Electrical
DWK2KB PUMP L01
Solenoid Short Circuit system
FAILURE CODE [DWK2KY] Variable Back Pressure Electrical
DWK2KY PUMP L01
Solenoid Hot Short Circuit system
FAILURE CODE [DWN5KA] Fan Clutch Solenoid Electrical
DWN5KA PUMP L03
Open Circuit system
FAILURE CODE [DWN5KB] Fan Clutch Solenoid Electrical
DWN5KB PUMP L03
Short Circuit system
FAILURE CODE [DWN5KY] Fan Clutch Solenoid Electrical
DWN5KY PUMP L03
Hot Short Circuit system
FAILURE CODE [DXA8KA] Front Pump PC-EPC Electrical
DXA8KA PUMP L03
Solenoid Open Circuit system
FAILURE CODE [DXA8KB] Front Pump PC-EPC Electrical
DXA8KB PUMP L03
Solenoid Short Circuit system
FAILURE CODE [DXA9KA] Rear Pump PC-EPC Electrical
DXA9KA PUMP L03
Solenoid Open Circuit system
FAILURE CODE [DXA9KB] Rear Pump PC-EPC Electrical
DXA9KB PUMP L03
Solenoid Short Circuit system
FAILURE CODE [DXE0KA] LS-EPC Solenoid Open Electrical
DXE0KA PUMP L01
Circuit system
FAILURE CODE [DXE0KB] LS-EPC Solenoid Short Electrical
DXE0KB PUMP L01
Circuit system
FAILURE CODE [DXE4KA] Attachment Flow Regu- Electrical
DXE4KA PUMP ―
lation EPC Solenoid Open Circuit system
FAILURE CODE [DXE4KB] Attachment Flow Regu- Electrical
DXE4KB PUMP ―
lation EPC Solenoid Short Circuit system
FAILURE CODE [DXE4KY] Attachment Flow Regu- Electrical
DXE4KY PUMP ―
lation EPC Solenoid Hot Short Circuit system

HB365LC-3 40-185
FAILURE CODES TABLE 40 TROUBLESHOOTING

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [DXE5KA] Merge-divider Main Sol- Electrical
DXE5KA PUMP L01
enoid Open Circuit system
FAILURE CODE [DXE5KB] Merge-divider Main Sol- Electrical
DXE5KB PUMP L01
enoid Short Circuit system
FAILURE CODE [DXE6KA] Merge-divider LS Sole- Electrical
DXE6KA PUMP L01
noid Open Circuit system
FAILURE CODE [DXE6KB] Merge-divider LS Sole- Electrical
DXE6KB PUMP L01
noid Short Circuit system
FAILURE CODE [DXE7KA] Attachment Flow Regu- Electrical
DXE7KA PUMP ―
lating EPC 2 Solenoid Open Circuit system
FAILURE CODE [DXE7KB] Attachment Flow Regu- Electrical
DXE7KB PUMP ―
lating EPC 2 Solenoid Short Circuit system
FAILURE CODE [DXE7KY] Attachment Flow Regu- Electrical
DXE7KY PUMP ―
lating EPC 2 Hot Short Circuit system
FAILURE CODE [DXE8KA] Attachment Flow Regu- Electrical
DXE8KA PUMP ―
lating EPC 3 Solenoid Open Circuit system
FAILURE CODE [DXE8KB] Attachment Flow Regu- Electrical
DXE8KB PUMP ―
lating EPC 3 Solenoid Short Circuit system
FAILURE CODE [DXE8KY] Attachment Flow Regu- Electrical
DXE8KY PUMP ―
lating EPC 3 Hot Short Circuit system
FAILURE CODE [DXE9KA] Attachment Flow Regu- Electrical
DXE9KA PUMP ―
lating EPC 4 Solenoid Open Circuit system
FAILURE CODE [DXE9KB] Attachment Flow Regu- Electrical
DXE9KB PUMP ―
lating EPC 4 Solenoid Short Circuit system
FAILURE CODE [DXE9KY] Attachment Flow Regu- Electrical
DXE9KY PUMP ―
lating EPC 4 Hot Short Circuit system
FAILURE CODE [DXEAKA] Attachment Flow Regu- Electrical
DXEAKA PUMP ―
lating EPC 5 Solenoid Open Circuit system
FAILURE CODE [DXEAKB] Attachment Flow Regu- Electrical
DXEAKB PUMP ―
lating EPC 5 Solenoid Short Circuit system
FAILURE CODE [DXEAKY] Attachment Flow Regu- Electrical
DXEAKY PUMP ―
lating EPC 5 Hot Short Circuit system
FAILURE CODE [DY20KA] Wiper Motor Open Cir- Electrical
DY20KA PUMP ―
cuit system
FAILURE CODE [DY20MA] Wiper Motor Defective Electrical
DY20MA PUMP ―
Function system
FAILURE CODE [DY2CKB] Washer Motor Short Electrical
DY2CKB PUMP ―
Circuit system
FAILURE CODE [DY2DKB] Wiper Motor (Normal Electrical
DY2DKB PUMP ―
Rotation) Short Circuit system
FAILURE CODE [DY2EKB] Wiper Motor (Reverse Electrical
DY2EKB PUMP ―
Rotation) Short Circuit system
FAILURE CODE [GA00NS] HYB Equipment Over- Electrical
GA00NS HYB L02
heat system
FAILURE CODE [GA01KA] Power Cable Interlock Electrical
GA01KA HYB L03
Open Circuit system

40-186 HB365LC-3
40 TROUBLESHOOTING FAILURE CODES TABLE

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [GA02KZ] DC Line Open and Electrical
GA02KZ HYB L04
Short Circuit system
FAILURE CODE [GA04KG] DC Line HW before Electrical
GA04KG HYB L03
Booster Power Voltage High Error system
FAILURE CODE [GA05KG] DC Line SW before Electrical
GA05KG HYB L03
Booster Power Voltage High Error system
FAILURE CODE [GA05KP] DC Line SW before Electrical
GA05KP HYB L03
Booster Output Voltage Low Error system
FAILURE CODE [GA06KZ] DC Line Voltage Sensor Electrical
GA06KZ HYB L03
before Booster Open and Short Circuit system
FAILURE CODE [GA08KG] DC Line HW before Electrical
GA08KG HYB L03
Booster Power Voltage High Error system
FAILURE CODE [GA09KG] Abnorm. DC SW Volt. Electrical
GA09KG HYB L03
After Booster system
FAILURE CODE [GA09KP] DC Line SW after Boos- Electrical
GA09KP HYB L03
ter Output Voltage Low Error system
FAILURE CODE [GA0AKZ] DC Line Voltage Sensor Electrical
GA0AKZ HYB L03
after Booster Open and Short Circuit system
FAILURE CODE [GA0BKZ] AC Line Open and Electrical
GA0BKZ HYB L04
Short Circuit system
FAILURE CODE [GA10MA] HYB Controller Mal- Electrical
GA10MA HYB L04
function system
FAILURE CODE [GA10MC] HYB Controller Mal- Electrical
GA10MC HYB ―
function system
FAILURE CODE [GA12NK] HYB Controller Power Electrical
GA12NK HYB L03
Supply Voltage Not Rise system
FAILURE CODE [GA13KP] HYB Controller Sensor Electrical
GA13KP HYB L03
Power Supply Output Voltage Low Error system
FAILURE CODE [GA13KY] HYB Controller Sensor Electrical
GA13KY HYB L03
Power Supply Short Circuit system
FAILURE CODE [GA15KZ] HYB Controller Insula- Electrical
GA15KZ HYB L03
tion Deterioration Sensor Open and Short Circuit system
FAILURE CODE [GA17KR] Motor-Generation Driv- Electrical
GA17KR HYB L03
er Defective Communication system
FAILURE CODE [GA17MB] Motor-Generation Driv- Electrical
GA17MB HYB ―
er Function Degraded system
FAILURE CODE [GA18MC] Motor-Generation Driv- Electrical
GA18MC HYB L03
er Energizing Power Supply Malfunction system
FAILURE CODE [GA19KR] Motor-Generation Driv- Electrical
GA19KR HYB L03
er Sub-CPU Defective Communication system
FAILURE CODE [GA19KT] Motor-Generation Driver Electrical
GA19KT HYB L03
Sub-CPU Controller Internal Failure system
FAILURE CODE [GA1BMA] Motor-Generation Driv- Electrical
GA1BMA HYB L01
er DC Voltage Sensor Defective Function system
FAILURE CODE [GA1FKR] Swing Motor Driver De- Electrical
GA1FKR HYB L03
fective Communication system

HB365LC-3 40-187
FAILURE CODES TABLE 40 TROUBLESHOOTING

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [GA1FMA] Swing Motor Driver Er- Electrical
GA1FMA HYB L03
ror system
FAILURE CODE [GA1GKR] Swing Motor Driver Electrical
GA1GKR HYB L03
Sub-CPU Defective Communication system
FAILURE CODE [GA1GKT] Swing Motor Driver Electrical
GA1GKT HYB L03
Sub-CPU Controller Internal Failure system
FAILURE CODE [GA1GKT] Swing Motor Driver Electrical
GA1GMB HYB ―
Sub-CPU Function Degraded system
FAILURE CODE [GA1HKZ] Swing Motor Driver
Electrical
GA1HKZ Phase-U Temperature Sensor Open and Short Cir- HYB L03
system
cuit
FAILURE CODE [GA1JKZ] Swing Motor Driver
Electrical
GA1JKZ Phase-V Temperature Sensor Open and Short Cir- HYB L03
system
cuit
FAILURE CODE [GA1KKZ] Swing Motor Driver
Electrical
GA1KKZ Phase-W Temperature Sensor Open and Short Cir- HYB L03
system
cuit
FAILURE CODE [GA1LKZ] Swing Motor Driver Cur- Electrical
GA1LKZ HYB L03
rent Sensor Open and Short Circuit system
FAILURE CODE [GA1MKZ] Swing Motor Driver DC Electrical
GA1MKZ HYB L03
Voltage Sensor Open and Short Circuit system
FAILURE CODE [GA1NNS] Swing Motor Driver Electrical
GA1NNS HYB ―
IGBT Overheat system
Electrical
GA1SFS FAILURE CODE [GA1SFS] Contactor Sticking HYB L03
system
Electrical
GA1SMC FAILURE CODE [GA1SMC] Contactor Malfunction HYB L03
system
FAILURE CODE [GA1TKP] Capacitor Output Volt- Electrical
GA1TKP HYB L03
age Low Error system
Electrical
GA1TNS FAILURE CODE [GA1TNS] Capacitor Overheat HYB ―
system
FAILURE CODE [GA1UKZ] Capacitor Temperature Electrical
GA1UKZ HYB L01
Sensor Open and Short Circuit system
FAILURE CODE [GA1VFS] Capacitor Contactor Electrical
GA1VFS HYB L03
Sticking system
FAILURE CODE [GA1VMC] Capacitor Contactor Electrical
GA1VMC HYB L03
Malfunction system
FAILURE CODE [GA1XKZ] Booster Inductor Tem- Electrical
GA1XKZ HYB L01
perature Sensor Open and Short Circuit system
FAILURE CODE [GA1YNS] Booster Inductor Over- Electrical
GA1YNS HYB ―
heat system
FAILURE CODE [GA1ZKZ] Booster IGBT Tempera- Electrical
GA1ZKZ HYB L03
ture Sensor Open and Short Circuit system
FAILURE CODE [GA1ZNS] Booster IGBT Tempera- Electrical
GA1ZNS HYB ―
ture Sensor Overheat system
FAILURE CODE [GA22NS] Booster IGBT Junction Electrical
GA22NS HYB ―
Overheat system

40-188 HB365LC-3
40 TROUBLESHOOTING FAILURE CODES TABLE

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [GA23KZ] Motor-Generator Driver Electrical
GA23KZ HYB L01
Temperature Sensor 0 Open and Short Circuit system
FAILURE CODE [GA24KZ] Motor-Generator Driver Electrical
GA24KZ HYB L01
Temperature Sensor 1 Open and Short Circuit system
FAILURE CODE [GA25MA] Motor-Generator Driver Electrical
GA25MA HYB L03
IGBT 0 Error system
FAILURE CODE [GA25NS] Motor-Generator Driver Electrical
GA25NS HYB ―
IGBT 0 Overheat system
FAILURE CODE [GA26MA] Motor-Generator Driver Electrical
GA26MA HYB L03
IGBT 1 Error system
FAILURE CODE [GA26NS] Motor-Generator Driver Electrical
GA26NS HYB ―
IGBT 1 Overheat system
FAILURE CODE [GA27KZ] DC Current Sensor be- Electrical
GA27KZ HYB L01
fore Booster Open and Short Circuit system
FAILURE CODE [GA2QKR] CAN 2 Defective Com- Electrical
GA2QKR MON L03
munication (HYB Controller) system
FAILURE CODE [GA2RKR] CAN 1 Defective Com- Electrical
GA2RKR MON L04
munication (HYB Controller) system
FAILURE CODE [GA60MC] Motor-Generator Mal- Electrical
GA60MC HYB L03
function system
FAILURE CODE [GA60N1] Motor-Generator Over- Electrical
GA60N1 HYB ―
run system
FAILURE CODE [GA61KZ] Motor-Generator Tem- Electrical
GA61KZ HYB L01
perature Sensor Open and Short Circuit system
FAILURE CODE [GA61NS] Motor-Generator Tem- Electrical
GA61NS HYB ―
perature Sensor Overheat system
FAILURE CODE [GA62KY] Motor-Generator
Electrical
GA62KY Phase-A Current Sensor Power Supply Line Short HYB ―
system
Circuit
FAILURE CODE [GA62KZ] Motor-Generator Electrical
GA62KZ HYB L01
Phase-A Current Sensor Open and Short Circuit system
FAILURE CODE [GA62MA] Motor-Generator Electrical
GA62MA HYB L03
Phase-A Current Sensor Defective Function system
FAILURE CODE [GA63KY] Motor-Generator
Electrical
GA63KY Phase-B Current Sensor Power Supply Line Short HYB L01
system
Circuit
FAILURE CODE [GA63KZ] Motor-Generator Electrical
GA63KZ HYB L01
Phase-B Current Sensor Open and Short Circuit system
FAILURE CODE [GA63MA] Motor-Generator Electrical
GA63MA HYB L03
Phase-B Current Sensor Defective Function system
FAILURE CODE [GA64KY] Motor-Generator
Electrical
GA64KY Phase-C Current Sensor Power Supply Line Short HYB L01
system
Circuit
FAILURE CODE [GA64KZ] Motor-Generator Electrical
GA64KZ HYB L01
Phase-C Current Sensor Open and Short Circuit system
FAILURE CODE [GA64MA] Motor-Generator Electrical
GA64MA HYB L03
Phase-C Current Sensor Defective Function system

HB365LC-3 40-189
FAILURE CODES TABLE 40 TROUBLESHOOTING

Failure Applicable Action History cate-

Failure (Displayed on screen) Remarks
code component level gory
FAILURE CODE [GA70KB] HYB Swing Motor Short Electrical
GA70KB HYB L03
Circuit system
FAILURE CODE [GA70MD] HYB Swing Motor Electrical
GA70MD HYB L03
Speed Detection Error system
FAILURE CODE [GA70NS] HYB Swing Motor Over- Electrical
GA70NS HYB ―
heat system
FAILURE CODE [GA71KZ] HYB Swing Motor Tem- Electrical
GA71KZ HYB L01
perature Sensor Open and Short Circuit system
FAILURE CODE [GA72MA] HYB Swing Motor Re- Electrical
GA72MA HYB L03
solver Defective Function system
FAILURE CODE [GA72MC] HYB Swing Motor Re- Electrical
GA72MC HYB L03
solver Malfunction system
FAILURE CODE [GA81KZ] Swing Motor Power Ca- Electrical
GA81KZ HYB L03
ble Open and Short Circuit system
FAILURE CODE [GAA0KB] HYB Controller Battery Electrical
GAA0KB HYB L01
Relay Output Short Circuit system
FAILURE CODE [GAA2KB] Swing Parking Brake Electrical
GAA2KB HYB L03
Solenoid Power Supply Line Short Circuit system
FAILURE CODE [GAA6KP] HYB Controller Sensor Electrical
GAA6KP HYB L03
Power Supply 2 Output Voltage Low Error system
FAILURE CODE [GAA6KY] HYB Controller Sensor Electrical
GAA6KY HYB L03
Power Supply 2 Short Circuit system
FAILURE CODE [GACA00] HYB Controller Power Electrical
GACA00 HYB ―
Mode Switch system

• In this table, failure codes are arranged in alphabetical order.

• Applicable component is the controller which checks the system.
MON: Machine monitor
ENG: Engine controller
PUMP: Pump controller
KOMTRAX: KOMTRAX terminal
HYB: Hybrid controller (inverter)
• The failure codes that do not have numbers in the action level columns are not displayed on the standard
screen even when a failure related to them occurs. They are simply recorded in the abnormality record
(electrical system or mechanical system) of the service menu.
• History category means the classification of either electrical system or mechanical system which is used for
storage in the Failure History of the service menu.

40-190 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [879AKA]

TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF

CODE) (ALL-K-1550-001-00-B)

FAILURE CODE [879AKA] (ALL-K-K55Y-410-00-B)

Action level Failure code Air Conditioner Recirculation Air Temperature Sensor Open Circuit
Failure
- 879AKA (Machine monitor system)
Details of
Air conditioner controller detects open circuit in recirculation air temperature sensor.
failure
Air conditioner controller transmits open circuit information of recirculation air temperature sensor to
Action of
machine monitor by CAN communication.
controller
Stops air conditioner when in automatic air conditioner mode.
Since air conditioner recirculation air temperature sensor has open circuit, automatic air conditioner
Phenomenon
does not operate.
on machine
(Air conditioner can be operated in manual mode.)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
Related • Check if this failure code is displayed on electrical system failure record screen in “SERV-
information ICE MODE” of machine monitor.
• Since connector of air conditioner recirculation air temperature sensor cannot be checked
when it is mounted on machine, troubleshooting cannot be performed.

No. Cause Procedure, measuring location, criteria and remarks

Air conditioner controller may be defective.
Defective air conditioner
1 (In case of an internal defect, troubleshooting is impossible as an assembly. Re-
controller
place whole assembly.)
Defective air conditioner Air conditioner unit may be defective. (In case of an internal defect, troubleshooting
2
unit is impossible as an assembly. Replace whole assembly.)

HB365LC-3 40-191
FAILURE CODE [879AKB] 40 TROUBLESHOOTING

FAILURE CODE [879AKB] (ALL-K-K55Y-410-01-B)

Action level Failure code Air Conditioner Recirculation Air Temperature Sensor Short Circuit
Failure
- 879AKB (Machine monitor system)

Details of
Air conditioner controller detects short circuit in recirculation air temperature sensor.
failure
• Air conditioner controller transmits short circuit information of recirculation air temperature
Action of
sensor to machine monitor by CAN communication.
controller
• Stops air conditioner when in automatic air conditioner mode.

Phenomenon Since air conditioner recirculation air temperature sensor has short circuit, automatic air conditioner
does not operate.
on machine (Air conditioner can be operated in manual mode)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
Related • Check if this failure code is displayed on electrical system failure record screen in SERV-
information ICE MODE of machine monitor.
• Since connector of air conditioner recirculation air temperature sensor cannot be checked
when it is mounted on machine, troubleshooting cannot be performed.

No. Cause Procedure, measuring location, criteria and remarks

Air conditioner controller may be defective.
Defective air conditioner
1 (In case of an internal defect, troubleshooting is impossible as an assembly. Re-
controller
place whole assembly.)
Defective air conditioner Air conditioner unit may be defective. (In case of an internal defect, troubleshooting
2
unit is impossible as an assembly. Replace whole assembly.)

40-192 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [879BKA]

FAILURE CODE [879BKA] (ALL-K-K565-410-00-B)

Action level Failure code Air Conditioner Fresh Air Temperature Sensor Open Circuit
Failure
- 879BKA (Machine monitor system)
Details of
Air conditioner controller detects open circuit in outside air temperature sensor.
failure
Air conditioner controller transmits open circuit information of outside air temperature sensor to ma-
Action of chine monitor by CAN communication.
controller Ignores data of outside air temperature sensor and continues control of air conditioner in automatic
air conditioner mode.
Since air conditioner outside air temperature sensor has open circuit, outside air temperature is not
Phenomenon
considered in automatic air conditioner mode.
on machine
(Air conditioner is not affected in manual mode.)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• Check if this failure code is displayed on electrical system failure record screen in service
mode of machine monitor.

Related • For each connector, see “Installation locations of air conditioner parts and arrangement of
connectors”.
information
• Since air conditioner controller connector ACECU has no T-adapter and has small pins,
perform troubleshooting by using intermediate connector (although intermediate connector
has no T-adapter either, it has large pins).
• When replacing air conditioner harness between air conditioner controller connector ACE-
CU and intermediate connector, replace air conditioner unit.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective fresh air tem- 2. Disconnect connector P18.
1
perature sensor
Between P18 (male) (1) Approx.
Resistance 25 °C
and (2) 1.7 kΩ
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connector AC01.
2
wiring harness
Between AC01 (female) Approx.
Resistance 25 °C
(7) and (8) 1.7 kΩ
If failure code is still displayed after above checks on cause 2, this check is not re-
quired.
Open circuit in wiring har- 1. Turn starting switch to OFF position.
ness (wire breakage or
3 2. Disconnect connectors P18 and AC01.
defective contact of con-
nector) Between AC01 (female) (7) and P18 (female) (1) Max. 1 Ω
Resistance
Between AC01 (female) (8) and P18 (female) (2) Max. 1 Ω
If failure code is still displayed after above checks, air conditioner controller is de-
Defective air conditioner
4 fective. (In case of an internal defect, troubleshooting is impossible as an assembly
controller
Replace whole assembly.)
If failure code is still displayed after above checks, air conditioner unit may be de-
Defective air conditioner
5 fective. (In case of an internal defect, troubleshooting is impossible as an assembly
unit
Replace whole assembly.)

HB365LC-3 40-193
FAILURE CODE [879BKA] 40 TROUBLESHOOTING

Circuit diagram related to air conditioner fresh air temperature sensor

40-194 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [879BKB]

FAILURE CODE [879BKB] (ALL-K-K565-410-01-B)

Action level Failure code Air Conditioner Fresh Air Temperature Sensor Short Circuit
Failure
- 879BKB (Machine monitor system)
Details of
Air conditioner controller detects short circuit in outside air temperature sensor.
failure
Air conditioner controller transmits short circuit information of outside air temperature sensor to ma-
Action of chine monitor by CAN communication.
controller Ignores data of outside air temperature sensor and continues control of air conditioner in automatic
air conditioner mode.
Since air conditioner outside air temperature sensor has short circuit, outside air temperature is not
Phenomenon
considered in automatic air conditioner mode.
on machine
(Air conditioner is not affected in manual mode.)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• Check if this failure code is displayed on electrical system failure record screen in service
mode of machine monitor.

Related • For each connector, see “Installation locations of air conditioner parts and arrangement of
connectors”.
information
• Since air conditioner controller connector ACECU has no T-adapter and has small pins,
perform troubleshooting by using intermediate connector (although intermediate connector
has no T-adapter either, it has large pins).
• When replacing air conditioner harness between air conditioner controller connector ACE-
CU and intermediate connector, replace air conditioner unit.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective fresh air tem- 2. Disconnect connector P18.
1
perature sensor
Between P18 (male) (1) Approx.
Resistance 25 °C
and (2) 1.7 kΩ
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connector AC01.
2
wiring harness
Between AC01 (female) Approx.
Resistance 25 °C
(7) and (8) 1.7 kΩ
If failure code is still displayed after above checks on cause 2, this check is not re-
quired.
Short circuit in wiring har- 1. Turn starting switch to OFF position.
3
ness 2. Disconnect connectors P18 and AC01.

Between AC01 (female) (7) and (8), or between P18

Resistance Min. 1 MΩ
(female) (1) and (2)
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors P18 and AC01.
4
harness
Between ground and AC01 (female) (8) or P18 (fe-
Resistance Min. 1 MΩ
male) (2)
If failure code is still displayed after above checks, air conditioner controller is de-
Defective air conditioner
5 fective. (In case of an internal defect, troubleshooting is impossible as an assembly
controller
Replace whole assembly.)

HB365LC-3 40-195
FAILURE CODE [879BKB] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks, air conditioner unit may be de-
Defective air conditioner
6 fective. (In case of an internal defect, troubleshooting is impossible as an assembly
unit
Replace whole assembly.)

Circuit diagram related to air conditioner fresh air temperature sensor

40-196 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [879CKA]

FAILURE CODE [879CKA] (ALL-K-K560-410-00-B)

Action level Failure code Ventilating sensor Open Circuit

Failure
- 879CKA (Machine monitor system)

Details of
Air conditioner controller detects open circuit in evaporator temperature (frost) sensor.
failure
• Air conditioner controller transmits open circuit information of evaporator temperature
Action of
(frost) sensor to machine monitor by CAN communication.
controller
• Stops air conditioner.
Phenomenon
Air conditioner does not operate because of open circuit in evaporator temperature (frost) sensor.
on machine
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
Related • Check if this failure code is displayed on electrical system failure record screen in SERV-
information ICE MODE of machine monitor.
• Since connector of air conditioner evaporator temperature (frost) sensor cannot be
checked when it is mounted on machine, troubleshooting cannot be performed.

No. Cause Procedure, measuring location, criteria and remarks

Air conditioner controller may be defective.
Defective air conditioner
1 (In case of an internal defect, troubleshooting is impossible as an assembly. Re-
controller
place whole assembly.)
Defective air conditioner Air conditioner unit may be defective. (In case of an internal defect, troubleshooting
2
unit is impossible as an assembly. Replace whole assembly.)

HB365LC-3 40-197
FAILURE CODE [879CKB] 40 TROUBLESHOOTING

FAILURE CODE [879CKB] (ALL-K-K560-410-01-B)

Action level Failure code Ventilating sensor Short Circuit

Failure
- 879CKB (Machine monitor system)
Details of
Air conditioner controller detects short circuit in evaporator temperature (frost) sensor.
failure
• Air conditioner controller transmits short circuit information of evaporator temperature
Action of
(frost) sensor to machine monitor by CAN communication.
controller
• Stops air conditioner.
Phenomenon
Air conditioner does not operate because of short circuit in evaporator temperature (frost) sensor.
on machine
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
Related • Check if this failure code is displayed on electrical system failure record screen in service
information mode of machine monitor.
• Since connector of air conditioner evaporator temperature (frost) sensor cannot be
checked when it is mounted on machine, troubleshooting cannot be performed.

No. Cause Procedure, measuring location, criteria and remarks

Air conditioner controller may be defective.
Defective air conditioner
1 (In case of an internal defect, troubleshooting is impossible as an assembly. Re-
controller
place whole assembly.)
Defective air conditioner Air conditioner unit may be defective. (In case of an internal defect, troubleshooting
2
unit is impossible as an assembly. Replace whole assembly.)

40-198 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [879DKZ]

FAILURE CODE [879DKZ] (ALL-K-K5FP-410-00-B)

Action level Failure code Sunlight Sensor Open Circuit or Short Circuit
Failure
- 879DKZ (Machine monitor system)

Details of
Air conditioner controller detects open or short circuit in sunlight sensor.
failure
• Air conditioner controller transmits open or short circuit information of sunlight sensor to
Action of machine monitor by CAN communication.
controller • Ignores data of sunlight sensor and continues control of air conditioner in automatic air
conditioner mode.
Phenomenon Since air conditioner sunlight sensor has open or short circuit, sunlight intensity is not considered in
on machine automatic air conditioner mode.(Air conditioner is not affected in manual mode.)

• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• Check if this failure code is displayed on electrical system failure record screen in service
mode of machine monitor.
• For each connector, see 80 APPENDIX, “Installation locations of air conditioner parts and
Related arrangement of connectors”.
information • Since air conditioner controller connector ACECU has no T-adapter and has small pins,
perform troubleshooting by using intermediate connector (although intermediate connector
has no T-adapter either, it has large pins).
• When replacing air conditioner harness between air conditioner controller connector ACE-
CU and intermediate connector, replace air conditioner unit.
• T-adapter is not provided for connectors of sunlight sensor.

No. Cause Procedure, measuring location, criteria and remarks

See 80 APPENDIX, “Testing sunlight sensor”.
Approx.
Direct sunlight
0.55 V
1 Defective sunlight sensor Between sunlight sensor Approx.
Voltage Cloudy
terminals 0.45 V
Approx.
Indoor
0.4 V
See “Testing sunlight sensor”.
Open circuit in wiring har- 1. Turn starting switch to OFF position.
ness (wire breakage or 2. Disconnect connector P31 and AC01.
2
defective contact of con-
nector) Between P31 (female) (1) and AC01 (female) (10) Max. 1 Ω
Resistance
Between P31 (female) (2) and AC01 (female) (9) Max. 1 Ω
If failure code is still displayed after above checks, air conditioner controller is de-
Defective air conditioner
3 fective. (In case of an internal defect, troubleshooting is impossible as an assembly
controller
Replace whole assembly.)
If failure code is still displayed after above checks, air conditioner unit may be de-
Defective air conditioner
4 fective. (In case of an internal defect, troubleshooting is impossible as an assembly
unit
Replace whole assembly.)

HB365LC-3 40-199
FAILURE CODE [879DKZ] 40 TROUBLESHOOTING

Circuit diagram related to sunlight sensor

40-200 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [879EMC]

FAILURE CODE [879EMC] (ALL-K-K5FQ-410-00-B)

Action level Failure code Ventilation Damper Malfunction

Failure
L01 879EMC (Machine monitor system)
Details of Air conditioner controller detects no rotation of vent selector (mode) damper servomotor, judging
failure from potentiometer voltage of servomotor.

Action of Air conditioner controller transmits abnormality of vent selector (mode) damper to machine monitor
controller by CAN communication.

Phenomenon
Vent (mode) cannot be selected, but air conditioner operates.
on machine
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
Related • Check if this failure code is displayed on electrical system failure record screen in service
information mode of machine monitor.
• Since connector of vent selector (mode) damper servomotor cannot be checked when it is
mounted on machine, troubleshooting cannot be performed.

No. Cause Procedure, measuring location, criteria and remarks

Air conditioner controller may be defective.
Defective air conditioner
1 (In case of an internal defect, troubleshooting is impossible as an assembly. Re-
controller
place whole assembly.)
Defective air conditioner Air conditioner unit may be defective. (In case of an internal defect, troubleshooting
2
unit is impossible as an assembly. Replace whole assembly.)

HB365LC-3 40-201
FAILURE CODE [879FMC] 40 TROUBLESHOOTING

FAILURE CODE [879FMC] (ALL-K-K56C-410-00-B)

Action level Failure code Air Mix Damper Malfunction

Failure
L01 879FMC (Machine monitor system)
Details of Air conditioner controller detects no rotation of air mix (temperature regulator) damper servomotor,
failure judging from potentiometer voltage of servomotor.

Action of Air conditioner controller transmits abnormality of air mix damper to machine monitor by CAN com-
controller munication.

Phenomenon
Air conditioner does not operate since temperature cannot be regulated.
on machine
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
Related • Check if this failure code is displayed on electrical system failure record screen in service
information mode of machine monitor.
• Since connector of air mix damper servomotor cannot be checked when it is mounted on
machine, troubleshooting cannot be performed.

No. Cause Procedure, measuring location, criteria and remarks

Air conditioner controller may be defective.
Defective air conditioner
1 (In case of an internal defect, troubleshooting is impossible as an assembly. Re-
controller
place whole assembly.)
Defective air conditioner Air conditioner unit may be defective. (In case of an internal defect, troubleshooting
2
unit is impossible as an assembly. Replace whole assembly.)

40-202 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [879GKX]

FAILURE CODE [879GKX] (ALL-K-K5G0-410-00-B)

Action level Failure code Refrigerant Pressure Input Signal Out of Range
Failure
L01 879GKX (Machine monitor system)

Details of
Air conditioner controller detected that dual pressure switch is OFF.
failure
• Air conditioner controller transmits abnormality information of refrigerant pressure to ma-
Action of chine monitor by CAN communication.
controller • Air conditioner controller turns OFF compressor clutch relay since refrigerant pressure is
abnormal.(Air conditioner compressor stops)
Phenomenon
Air conditioner does not function (in cooling mode).
on machine
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• Check if this failure code is displayed on electrical system failure record screen in SERV-
ICE MODE of machine monitor.
• For each connector, see 80 APPENDIX, “Installation locations of air conditioner parts and
Related arrangement of connectors”.
information • Since air conditioner controller connector ACECU has no T-adapter and has small pins,
perform troubleshooting by using intermediate connector (although intermediate connector
has no T-adapter either, it has large pins).
• When replacing air conditioner harness between air conditioner controller connector ACE-
CU and intermediate connector, replace air conditioner unit.
• T-adapter is not provided for connectors of dual pressure switch.

No. Cause Procedure, measuring location, criteria and remarks

See 80 APPENDIX, “TEST (DUSL) PRESSURE SWITCH FOR REFRIGERANT”.
Defective refrigerant (du-
1
al) pressure switch k Before replacing dual pressure switch, collect refrigerant. See 80 AP-
PENDIX, “PRECAUTIONS FOR REFRIGERANT”.
1. Turn starting switch to OFF position.
Open circuit in wiring har-
2. Disconnect connectors AC01 and P17.
ness (wire breakage or
2
defective contact of con- Between P17 (female) (1) and AC01 (female) (6) Max. 1 Ω
nector) Resistance
Between P17 (female) (2) and ground Max. 1 Ω
If failure code is still displayed after above checks, air conditioner controller is de-
Defective air conditioner
3 fective. (In case of an internal defect, troubleshooting is impossible as an assembly
controller
Replace whole assembly.)
If failure code is still displayed after above checks, air conditioner unit may be de-
Defective air conditioner
4 fective. (In case of an internal defect, troubleshooting is impossible as an assembly
unit
Replace whole assembly.)

HB365LC-3 40-203
FAILURE CODE [879GKX] 40 TROUBLESHOOTING

Circuit diagram related to refrigerant (dual) pressure switch

40-204 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [989L00]

FAILURE CODE [989L00] (ALL-K-APE4-410-00-B)

Action level Failure code Engine Controller Lock Caution 1

Failure
- 989L00 (Machine monitor system)
Details of
Engine controller lock up is detected (Factor 1).
failure

Action of ma- • None in particular

chine monitor • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
Engine does not start.
on machine
• If the failure code is displayed after replacing the machine monitor, user password needs
Related to be changed back to the previous one.
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Machine monitor is re- This failure may occur due to machine monitor replacement.
1
placed

HB365LC-3 40-205
FAILURE CODE [989M00] 40 TROUBLESHOOTING

FAILURE CODE [989M00] (ALL-K-APE5-410-00-B)

Action level Failure code Engine Controller Lock Caution 2

Failure
- 989M00 (Machine monitor system)
Details of
Machine monitor detects engine controller lock (Factor 2).
failure

Action of ma- • None in particular

chine monitor • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
Engine does not start.
on machine
• If the failure code is displayed after replacing the machine monitor, user password needs
Related to be changed back to the previous one.
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Machine monitor is re- This failure may occur due to machine monitor replacement.
1
placed
If this failure code appears even when machine monitor is not replaced, machine
Defective machine moni-
2 monitor is defective. (Since this is an internal defect, troubleshooting cannot be per-
tor
formed.)

40-206 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [989N00]

FAILURE CODE [989N00] (ALL-K-APE6-410-00-B)

Action level Failure code Engine Controller Lock Caution 3

Failure
- 989N00 (Machine monitor system)

Details of
Machine monitor detects engine controller lock (Factor 3).
failure
Action of • Tries automatic recovery.
controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
Engine does not start.
on machine

Related After repairing, check if the failure code is cleared by the following procedure.
Procedure: Failure code cannot be reproduced since machine recovers when cause of failure disap-
information pears.

No. Cause Procedure, measuring location, criteria and remarks

Defective engine control- If this repeatedly occurs, engine controller is defective. (Since this is an internal de-
1
ler fect, troubleshooting cannot be performed.)

HB365LC-3 40-207
FAILURE CODE [A1U0N3] 40 TROUBLESHOOTING

FAILURE CODE [A1U0N3] (ALL-K-A9HM-410-30-B)

Action level Failure code Hydrocarbon Desorb Request 1

Failure
L01 A1U0N3 (Engine controller system)
Details of Unburned fuel remains in KDPF because engine has been running at low idle speed or low load for
failure a long time.

Action of Requests an operator to perform manual stationary regeneration (fuel drying). Or informs manual
controller stationary regeneration (fuel drying) is in progress.

Phenomenon Same phenomenon as automatic regeneration occurs. (When the machine is in a safe condition,
on machine machine controls the engine speed to stay up around 1000 rpm.)

k KDPF and KDOC become hot (Min. 500 °C). Be careful not to get burned.
• Temperature detected by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Temperature detected by KDOC outlet temperature sensor can be checked with monitor-
ing function. (Code: 47400 (°C))
• Temperature detected by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when at
low idle speed (KDPF regeneration is not executed) are approximately 100 to 250 °C, and
difference between these temperatures is approximately 10 °C. (KDOC inlet temperature >
KDOC outlet temperature > KDPF outlet temperature)
• When manual stationary regeneration is performed due to the guidance of monitor display-
ing failure code [A1U0N3] or [A1U0N4], fuel dosing is disabled. Accordingly, each temper-
Related ature of KDOC inlet, KDOC outlet, and KDPF outlet reaches to approximately 250 to
information 400 °C.
• When manual stationary regeneration except above is in progress, KDOC inlet tempera-
ture is approximately 250 to 400 °C, and KDOC outlet temperature and KDPF outlet tem-
perature are 450 to 600 °C.
• If there is a significant difference between KDOC inlet temperature and KDOC outlet tem-
perature when KDPF is completely cooled or engine is running at engine low idle speed
(without regenerating KDPF), replace KDOC inlet temperature sensor or KDOC outlet
temperature sensor, whichever is suspected to be defective, judging from KDPF outlet
temperature.
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1 Defective KDPF drying
Defective KDOC inlet
2 cant differences between KDOC inlet temperature and KDOC outlet temperature or
temperature sensor
3 Defective VGT
Perform the manual stationary regeneration by following the instructions on the
monitor (in order to dry KDPF).
If this failure code is cleared after this, repair work is completed.
When KDPF cooled down sufficiently or at idle (non-regeneration), there are signifi-
KDPF outlet temperature, replace the sensor.
If the KDOC inlet temperature is approximately 250 °C or below during manual sta-
tionary regeneration, and if the VGT solenoid current remains approximately
1000 mA even when several hours have passed, and the manual stationary regen-
eration does not complete, the VGT is defective.

40-208 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [A1U0N3]

No. Cause Procedure, measuring location, criteria and remarks

Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-209
FAILURE CODE [A1U0N4] 40 TROUBLESHOOTING

FAILURE CODE [A1U0N4] (ALL-K-A9HM-410-40-B)

Action level Failure code Hydrocarbon Desorb Request 2

Failure
L03 A1U0N4 (Engine controller system)
Details of Unburned fuel remains in KDPF because engine has been running at low idle speed or low load for
failure a long time.

Action of Requests an operator to perform manual stationary regeneration (fuel drying). Or informs manual
controller stationary regeneration (fuel drying) is in progress.

Phenomenon Same phenomenon as automatic regeneration occurs. (When the machine is in a safe condition,
on machine machine controls the engine speed to stay up around 1000 rpm.)

k KDPF and KDOC become hot (Min. 500 °C). Be careful not to get burned.
• Temperature detected by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Temperature detected by KDOC outlet temperature sensor can be checked with monitor-
ing function. (Code: 47400 (°C))
• Temperature detected by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when at
low idle speed (KDPF regeneration is not executed) are approximately 100 to 250 °C, and
difference between these temperatures are approximately 10 °C. (KDOC inlet temperature
> KDOC outlet temperature > KDPF outlet temperature)
• When manual stationary regeneration is performed due to the guidance of monitor display-
ing failure code [A1U0N3] or [A1U0N4], fuel dosing is disabled. Accordingly, each temper-
Related ature of KDOC inlet, KDOC outlet, and KDPF outlet reaches to approximately 250 to
400 °C.
information
• When manual stationary regeneration except above is in progress, KDOC inlet tempera-
ture is approximately 250 to 400 °C, and KDOC outlet temperature and KDPF outlet tem-
perature are approximately 450 to 600 °C.
• If there is a significant difference between KDOC inlet temperature and KDOC outlet tem-
perature when KDPF is completely cooled or engine is running at engine low idle speed
(without regenerating KDPF), replace KDOC inlet temperature sensor or KDOC outlet
temperature sensor, whichever is suspected to be defective, judging from KDPF outlet
temperature.
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.
• After completion of repair, check that this failure code and failure code [A1U0N3] are
cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Perform the manual stationary regeneration by following the instructions on the
1 Defective KDPF drying monitor (in order to dry KDPF).
If this failure code is cleared after this, repair work is completed.
When KDPF cooled down sufficiently or at idle (non-regeneration), there are signifi-
Defective KDOC inlet
2 cant differences between KDOC inlet temperature and KDOC outlet temperature or
temperature sensor
KDPF outlet temperature, replace the sensor.

40-210 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [A1U0N4]

No. Cause Procedure, measuring location, criteria and remarks

If the KDOC inlet temperature is approximately 250 °C or below during manual sta-
tionary regeneration, and if the VGT solenoid current remains approximately
3 Defective VGT
1000 mA even when several hours have passed, and the manual stationary regen-
eration does not complete, the VGT is defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-211
FAILURE CODE [A900FR] 40 TROUBLESHOOTING

FAILURE CODE [A900FR] (ALL-K-AF87-410-00-B)

Action level Failure code Abrupt Engine Stop by Auto Idle Stop 3
Failure
L03 A900FR (Machine monitor system)
Detail of fail- Durability of turbocharger is degraded due to high engine speed before the engine is stopped by
ure auto idle stop function and frequent engine stops.
• Turn the auto-deceleration setting ON.
Action of
• Auto idle stop sudden stop monitor is displayed in red on machine monitor.
controller
• Resets when next auto idle stop countdown starts or starting switch is turned OFF.
Phenomenon
Turbocharger may get damaged.
on machine
• This failure code is displayed when activation of failure code [A900N6] exceeds 2000
times.
• This failure code will be cleared after replacing the turbocharger assembly and resetting
Related the auto idle stop sudden engine stop counter.
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Before resetting the auto idle stop sudden engine stop counter, let the engine
stop by auto idle stop function with auto-deceleration turned OFF and fuel dial set at maxi-
mum.

No. Cause Procedure, measuring location, criteria and remarks

If this repeatedly occurs even when the auto idle stop function is OFF, machine
Defective machine moni-
1 monitor is defective. (Since this is an internal defect, troubleshooting cannot be per-
tor
formed.)

40-212 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [A900N6]

FAILURE CODE [A900N6] (ALL-K-AF87-410-10-B)

Action level Failure code Abrupt Engine Stop by Auto Idle Stop 1
Failure
- A900N6 (Machine monitor system)
Detail of fail-
Engine speed just before the engine is stopped by auto idle stop function is high.
ure
Action of
Turn the auto-deceleration setting ON.
controller
Phenomenon
None in particular
on machine
• This failure code is displayed if auto-deceleration is not OFF and fuel dial is not at mini-
mum when auto idle stop function commands engine stop.
• Engine speed can be checked with monitoring function. (Code: 01002)
Related
• Accumulated counts can be checked with auto idle stop sudden stops counter reset menu.
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Let the engine stop by auto idle stop function with auto-deceleration turned
OFF and fuel dial set at maximum.

No. Cause Procedure, measuring location, criteria and remarks

If this repeatedly occurs even when the auto idle stop function is OFF, machine
Defective machine moni-
1 monitor is defective. (Since this is an internal defect, troubleshooting cannot be per-
tor
formed.)

HB365LC-3 40-213
FAILURE CODE [A900NY] 40 TROUBLESHOOTING

FAILURE CODE [A900NY] (ALL-K-AF87-410-20-B)

Action level Failure code Abrupt Engine Stop by Auto Idling Stop 2
Failure
L01 A900NY (Machine monitor system)
Detail of fail- Accumulated count of abrupt engine stops is high because engine speed just before the engine is
ure stopped by auto idle stop function is high.
• Turn the auto-deceleration setting ON.
Action of
• Auto idle stop sudden stop monitor is displayed in red on machine monitor.
controller
• Resets when next auto idle stop countdown starts or starting switch is turned OFF.
Phenomenon
Turbocharger may get damaged.
on machine
• This failure code is displayed when activation of failure code [A900N6] exceeds 1000
times.
• This failure code is not detected after replacing the turbocharger assembly and performing
Related “Reset Number of Abrupt Engine Stop by AIS”.
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Before resetting the auto idle stop sudden engine stop counter, let the engine
stop by auto idle stop function with auto-deceleration turned OFF and fuel dial set at maxi-
mum.

No. Cause Procedure, measuring location, criteria and remarks

If this repeatedly occurs even when the auto idle stop function is OFF, machine
Defective machine moni-
1 monitor is defective. (Since this is an internal defect, troubleshooting cannot be per-
tor
formed.)

40-214 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [AA10NX]

FAILURE CODE [AA10NX] (ALL-K-A966-410-00-B)

Action level Failure code Air Cleaner Clogging

Failure
L01 AA10NX (Machine monitor system)
Detail of fail- Air cleaner clogging switch signal voltage is not 1 V and below while engine is running, and machine
ure monitor detects clogging of air cleaner (open of sensor contacts).
Action of
Displays air cleaner clogging monitor in yellow on machine monitor.
controller
Phenomenon
If machine is used as it is, engine may be damaged.
on machine
• Input (ON/OFF) from air cleaner clogging switch can be checked with monitoring function.
(Code: 04501)
Related
• After completion of repair, check that the failure code is cleared by the following proce-
information
dure.
Procedure: Start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Air cleaner may be clogged. Check it for clogging and then clean or replace if clog-
1 Clogging of air cleaner
ged.
1. Turn the starting switch to OFF position.
2. Disconnect the connector P23, and connect the T-adapter to male side.
3. Start the engine.
REMARK
Air cleaner suction resistance value
Defective air cleaner
2 *1: -3430 Pa Max. {-350 mmH2O}
clogging sensor
*2: -7470±490 Pa {-762±50 mmH2O}
When air cleaner: is nor-
Max. 1 Ω
Between P23 (male) (1) mal *1
Resistance
and (2) When air cleaner is clog-
Min. 1 MΩ
ged *2
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CM02 and P23, and connect the T-adapter to
Open circuit in wiring har- each female side.
3
ness
Between CM02 (female) (4) and P23 (female) (1) Max. 1 Ω
Resistance
Between P23 (female) (2) and ground Max. 1 Ω
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
4
tor an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-215
FAILURE CODE [AA10NX] 40 TROUBLESHOOTING

CIRCUIT DIAGRAM (AIR CLEANER CLOGGING SENSOR)

40-216 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [AB00KE]

FAILURE CODE [AB00KE] (ALL-K-AKJ0-410-00-B)

Action level Failure code

Failure Charge Voltage Low (Machine monitor system)
L03 AB00KE
Details of While engine is running, voltage from alternator drops, and machine monitor detects charge voltage
failure low.

Action of ma-
Displays the charge level monitor in red on machine monitor.
chine monitor
Phenomenon
If machine continues to be operated, battery may not be charged.
on machine
• Battery power supply can be checked with monitoring function. (Code: 04300 battery
Related charge voltage)
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

Loose alternator terminal 1. Turn the starting switch to OFF position.

1
or open circuit at terminal 2. Check terminal.
1. Start the engine.
2 Defective alternator Between ground and alter- Engine speed in medium 27.5 to
Voltage
nator terminal R and above 29.5 V
1. Turn the starting switch to OFF position.
2. Disconnect the diode D01, and connect the T-adapter to male side.
REMARK
3 Defective diode Measure it with diode range.
No continui-
Between D01 (male) (2)(+) and (6)(-)
Continuity ty
Between D01 (male) (6)(+) and (2)(-) Continuity
1. Turn the starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect the connector CM01 and alternator terminal R, and connect
4
ness the T-adapter to female side of connector CM01.
Resistance Between CM01 (female) (16) and alternator terminal R Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connector CM01 and connect the T-adapter to female side.
Ground fault in wiring 3. Disconnect the connectors, terminals, and fuses of all the devices which
5
harness branch out from connector CM01 (16).
Between ground and either CM01 (female) (16) or al-
Resistance Min. 1 MΩ
ternator terminal R
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
6
tor an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-217
FAILURE CODE [AB00KE] 40 TROUBLESHOOTING

CIRCUIT DIAGRAM (BATTERY CHARGE)

40-218 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [AQ10N3]

FAILURE CODE [AQ10N3] (ALL-K-A9H2-410-60-B)

Action level Failure code Manual Stationary Regeneration Request

Failure (KDOC Face Plugging)
L01 AQ10N3
(Engine controller system)
The Manual Stationary Regeneration Request (KDOC) requires the user to perform “manual station-
ary regeneration” to recover the efficiency effectively because the efficiency of KDOC (catalyst ac-
Detail of fail-
tion) (The soot in KCSF does not burn normally because the KDOC inlet temperature in regenera-
ure
tion is normally approximately 250 to 400 °C and the KDOC outlet temperature is normally approxi-
mately 450 to 600 °C but the KDOC outlet temperature does not rise).
Action of • EGR valve closed.
controller • Fuel dosing stops.
Phenomenon
• None
on machine
k KDOC and KDPF become hot (Min. 500 °C). Be careful not to get burned.
• Temperature in KDOC inlet temperature sensor can be checked with monitoring function
(Code: 47300(°C))
• Temperature in KDOC outlet temperature sensor can be checked with monitoring function
(Code: 47400(°C))
• Temperature in KDPF outlet temperature sensor can be checked with monitoring function
(Code: 47200(°C))
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.
• As to procedure for accessing KDPF temperature sensor, see “50 DISASSEMBLY AND
ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEMBLY”.
• After turning starting switch to OFF position, engine controller performs AdBlue/DEF purg-
ing (for Max. 6 minutes) and then stops. To restart engine, wait until system operating
lamp goes off after turning starting switch to OFF position, and then turn starting switch to
ON position.
Related • All of KDOC inlet temperature, KDOC outlet temperature and KDPF outlet temperature
information during idle (non-regeneration) are approximately 100 to 250 °C. Each temperature differ-
ence is approximately 10 °C (KDOC inlet temperature > KDOC outlet temperature > KDPF
outlet temperature).
• During manual stationary regeneration, KDOC inlet temperature is approximately 250 to
400 °C, and both KDOC outlet temperature and KDPF outlet temperature are approxi-
mately 450 to 600 °C.
• The manual stationary regeneration (KDOC Face Plugging) does not perform fuel dozing
to recover the KDOC efficiently, so all of KDOC inlet temperature, KDOC outlet tempera-
ture, and KDPF outlet temperature become approximately 250 to 400 °C.
• The failure code [CA2637] is displayed while this failure code is displayed.
How to perform manual stationary regeneration
1. Start the engine.
2. From service menu of machine monitor, display “Diagnostic Tests” screen, open “02 Active
Regeneration for Service”, and then perform “Manual Stationary Regeneration”.
REMARK
The manual stationary regeneration time of the Manual Stationary Regeneration Request (KDOC
Face Plugging) is approximately one and a half hours.

HB365LC-3 40-219
FAILURE CODE [AQ10N3] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If this failure code is not cleared from the machine monitor for several hours after
Defective engine control-
1 the manual stationary regeneration, engine controller is defective. (Since this is an
ler
internal defect, troubleshooting cannot be performed.)

40-220 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [AS00N3]

FAILURE CODE [AS00N3] (ALL-K-A9H2-410-50-B)

Action level Failure code Manual Stationary Regeneration Request (SCR)

Failure
L01 AS00N3 (Engine controller systems)
Manual Stationary Regeneration Request (SCR) requires the user to perform “manual stationary re-
Detail of fail-
generation” to clear urea deposit effectively when the efficiency (catalyst action) of KDOC decreas-
ure
es or the KDOC outlet temperature in regeneration does not rise.
Action of
• Normal operation
controller
Phenomenon
None
on machine

k Since KDPF and KDOC are heated to 500 °C or above, be careful not to get burned.
• Temperature in KDOC inlet temperature sensor can be checked with monitoring function
(Code: 47300(°C))
• Temperature in KDOC outlet temperature sensor can be checked with monitoring function
(Code: 47400(°C))
• Temperature in KDPF outlet temperature sensor can be checked with monitoring function
(Code: 47200(°C))
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.
• As to procedure for accessing KDPF temperature sensor, see “50 DISASSEMBLY AND
ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEMBLY”.
• After turning starting switch to OFF position, engine controller performs AdBlue/DEF purg-
ing (for Max. 6 minutes) and then stops. To restart engine, wait until system operating
lamp goes off after turning starting switch to OFF position, and then turn starting switch to
ON position.
• All of KDOC inlet temperature, KDOC outlet temperature and KDPF outlet temperature
Related during idle (non-regeneration) are approximately 100 to 250 °C. Each temperature differ-
ence is approximately 10 °C (KDOC inlet temperature > KDOC outlet temperature > KDPF
information
outlet temperature).
• During manual stationary regeneration, KDOC inlet temperature is approximately 280 to
400 °C, and both KDOC outlet temperature and KDPF outlet temperature are approxi-
mately 450 to 600 °C.
• During manual stationary regeneration (SCR), KDOC inlet temperature is approximately
250 to 400 °C, and both KDOC outlet temperature and KDPF outlet temperature are ap-
proximately 350 to 600 °C to clear urea deposit.
• Even if regeneration is not implemented normally, the failure code [AS00N3] may disap-
pear.
• The failure code [CA3568], [CA3582] may be displayed while this failure code is displayed.
How to perform manual stationary regeneration
1. Start the engine.
2. From service menu of machine monitor, display “Diagnostic Tests” screen, open “02 Active
Regeneration for Service”, and then perform “Manual Stationary Regeneration”.
REMARK
The manual stationary regeneration time of the Manual Stationary Regeneration Request (SCR) is
approximately an hour.

HB365LC-3 40-221
FAILURE CODE [AS00N3] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

When KDPF cooled down sufficiently or at idle (non-regeneration), there are signifi-
Defective KDOC inlet
1 cant differences between KDOC inlet temperature and KDOC outlet temperature or
temperature sensor
KDPF outlet temperature, replace the sensor.
If the KDOC inlet temperature is approximately 250 °C or below during manual sta-
tionary regeneration, and if the VGT solenoid current remains approximately
2 Defective VGT
1000 mA even when several hours have passed, and the manual stationary regen-
eration does not complete, the VGT is defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

40-222 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [AS00R2]

FAILURE CODE [AS00R2] (ALL-K-AF00-410-30-B)

Action level Failure code Warning 2 (SCR Device Abnormality)

Failure
L01 AS00R2 (Engine controller system)

• A certain time has passed since an abnormality of SCR System occurs.

Detail of fail-
ure • An abnormality of SCR system has occurred again within a certain time since abnormality
repair of SCR system. (EU specification)
Action of • The information related to this failure code is displayed on the monitor screen.
controller • [AS00R3] occurs and operates with restricted output after a certain time.
Phenomenon
The engine power deration after a certain time.
on machine
Related
This failure code is detected during engine operation.
information

No. Cause Procedure, measuring location, criteria and remarks

Since the failure code of SCR device abnormality is displayed, perform trouble-
1 Abnormal SCR device
shooting for that failure code.
If any other failure codes than SCR device abnormality are displayed, perform trou-
2 Abnormal engine system
bleshooting for them.

HB365LC-3 40-223
FAILURE CODE [AS00R3] 40 TROUBLESHOOTING

FAILURE CODE [AS00R3] (ALL-K-AF00-410-40-B)

Action level Failure code Inducement 1 (SCR device abnormality)

Failure
L03 AS00R3 (Engine controller system)

• A certain time has passed since [AS00R2] occurs.

Detail of fail-
ure • An abnormality of SCR equipment has occurred again within a certain time since abnor-
mality repair of SCR device (EU specifications).
• Displays the information related to this failure code on the monitor screen.
Action of • Engine power deration.
controller • [AS00R4] occurs and derates engine power for operation largely after a certain time.
• Derates hybrid system for operation.
• Engine output is reduced.
Phenomenon
• The engine output is reduced heavily after a certain time.
on machine
• Swing output limitation lowers swing speed.
• This failure code is detected during engine operation.
• If this failure code remains displayed after SCR devices are repaired and the engine con-
troller is shut down, run the engine for 1 minute to clear the failure code.
• After this failure code is cleared, engine power deration continues until the starting switch
Related is turned to OFF position.
information • The hybrid caution lamp appears due to derated hybrid system for operation.
REMARK
It is displayed until engine power deration is canceled.
• If failure code related to hybrid system is also displayed, perform troubleshooting for this
failure code first.

No. Cause Procedure, measuring location, criteria and remarks

Since the failure code of SCR device abnormality is displayed, perform trouble-
1 Abnormal SCR device
shooting for that failure code.
If any other failure codes than SCR device abnormality are displayed, perform trou-
2 Abnormal engine system
bleshooting for them.

40-224 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [AS00R4]

FAILURE CODE [AS00R4] (ALL-K-AF00-410-50-B)

Action level Failure code Inducement 2 (SCR device abnormality)

Failure
L04 AS00R4 (Engine controller system)

• A certain time has passed since [AS00R3] occurs.

Detail of fail-
ure • An abnormality of SCR equipment has occurred again within a certain time since abnor-
mality repair of SCR device (North America and EU specifications).
• Displays the information related to this failure code on the monitor screen.
Action of • Derates engine power for operation largely.
controller • [AS00R5] occurs and operates with engine output is fixed at low idle after a certain time.
• Derates hybrid system for operation.
• Engine output is reduced heavily.
Phenomenon
• Engine speed is fixed at low idle after a certain time.
on machine
• Swing output limitation lowers swing speed.
• From the machine monitor, it is possible to perform a “temporary restoration from induce-
ment” to clear engine output low temporarily.
• This failure code is detected during engine operation.
• If this failure code remains displayed after SCR devices are repaired and the engine con-
troller is shut down, run the engine for 1 minute to clear the failure code.
Related • After this failure code is cleared, engine power deration continues until the starting switch
information is turned to OFF position.
• The hybrid caution lamp appears due to derated hybrid system for operation.
REMARK
It is displayed until engine power deration is canceled.
• If failure code related to hybrid system is also displayed, perform troubleshooting for this
failure code first.

No. Cause Procedure, measuring location, criteria and remarks

Since the failure code of SCR device abnormality is displayed, perform trouble-
1 Abnormal SCR device
shooting for that failure code.
If any other failure codes than SCR device abnormality are displayed, perform trou-
2 Abnormal engine system
bleshooting for them.

HB365LC-3 40-225
FAILURE CODE [AS00R5] 40 TROUBLESHOOTING

FAILURE CODE [AS00R5] (ALL-K-AF00-410-60-B)

Action level Failure code Inducement 3 (SCR device abnormality)

Failure
L04 AS00R5 (Engine controller system)

Detail of fail- • A certain time has passed since AS00R4 occurs (North America and domestic specifica-
ure tions).
• Displays the information related to this failure code on the monitor screen.
• Operates with engine speed is fixed at low idle after a certain time.
Action of
• Neither Manual Stationary Regeneration nor Active Regeneration for Service can be per-
controller
formed.
• Stops hybrid system.
Phenomenon • Engine speed is fixed at low idle.
on machine • Swing cannot be performed.
• This failure code is detected during engine operation.
• If this failure code remains displayed after SCR devices are repaired and the engine con-
troller is shut down, run the engine for 1 minute to clear the failure code.
• After this failure code is cleared, engine power deration continues until the starting switch
is turned to OFF position.
Related • The hybrid caution lamp appears since hybrid system is stopped.
information REMARK
It is displayed until engine power deration is canceled.
• If failure code related to hybrid system is also displayed, perform troubleshooting for this
failure code first.
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Since the failure code of SCR device abnormality is displayed, perform trouble-
1 Abnormal SCR device
shooting for that failure code.
If any other failure codes than SCR device abnormality are displayed, perform trou-
2 Abnormal engine system
bleshooting for them.

40-226 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [AS00R6]

FAILURE CODE [AS00R6] (ALL-K-AF00-410-70-B)

Action level Failure code Temporary restoration from inducement

Failure
- AS00R6 (Engine controller system)

Detail of fail- • Temporary restoration from inducement has been performed from the machine monitor
ure while severe inducement is activated and failure code [CA3547] or [AS00R4] is displayed.
• Cancels engine power deration temporarily.
Action of
• Cancels hybrid system power deration temporarily.
controller
• Displays the information related to this failure code on the monitor screen.
Phenomenon • Engine power deration is cleared temporarily.
on machine • Cancels hybrid system power deration temporarily.
• This failure code is not failure but caution to display that temporary restoration from in-
ducement has been performed on “Abnormality Record screen” and KOMTRAX on the
Related
machine monitor.
information
• For 20 seconds after temporary restoration, “E” is displayed in this failure code on “Abnor-
mality Record” screen to indicate this failure is occurring currently.

HB365LC-3 40-227
FAILURE CODE [AS00ZK] 40 TROUBLESHOOTING

FAILURE CODE [AS00ZK] (ALL-K-AFG0-410-E0-B)

Action level Failure code AdBlue/DEF level low error 5

Failure
L04 AS00ZK (Engine controller system)
Detail of fail- A certain time has passed since AdBlue/DEF tank level is lowered and failure code [CA3547] occurs
ure (North America and domestic specifications).
• Displays the information related to this failure code on the monitor screen.
• Derates engine power to low idle for operation.
Action of
• Neither Manual Stationary Regeneration nor Active Regeneration for Service can be per-
controller
formed.
• Stops hybrid system.
Phenomenon • Engine speed is fixed at low idle.
on machine • Swing cannot be performed.
• AdBlue/DEF level ≤ 0.0 % is continued for 1 hour.
• After this failure code is cleared, engine power deration continues until the starting switch
is turned to OFF position.
• The hybrid caution lamp appears since hybrid system is stopped.
Related REMARK
information It is displayed until engine power deration is canceled.
• If failure code related to hybrid system is also displayed, perform troubleshooting for this
failure code first.
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. See the sight gauge, and check that a sufficient amount of AdBlue/DEF is
in the AdBlue/DEF tank.
1 Low AdBlue/DEF level 3. Refill AdBlue/DEF if the level is low.
4. Turn the starting switch to ON position.
If this failure code is not displayed, AdBlue/DEF has been insufficient.
1. Check the sensor connector for stain or damage.
2. Turn the starting switch to OFF position.
Defective AdBlue/DEF 3. Replace the AdBlue/DEF tank sensor.
2
tank sensor 4. Turn the starting switch to ON position.
If this failure code is not displayed, the original AdBlue/DEF tank sensor is defec-
tive. (Since this is an internal defect, troubleshooting cannot be performed.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

40-228 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [AS10KM]

FAILURE CODE [AS10KM] (ALL-K-AFJ1-410-30-B)

Action level Failure code AdBlue/DEF injector overheat warning

Failure
L01 AS10KM (Machine monitor system)
Detail of fail-
Failure code [AS10NT] is detected 150 times or more.
ure
Action of Displays caution symbol for engine stop due to high temperature of AdBlue/DEF system on ma-
controller chine monitor.

Phenomenon
Injection failure of AdBlue/DEF may occur when engine starts operation again.
on machine
• Pre-defined Monitoring (6/28) Aftertreatment related devices
1. 47000 KDPF Outlet Pressure
Related 2. 47100 KDPF Differential Pressure
3. 47200 KDPF 1 Outlet Temperature
information 4. 47300 KDOC 1 Inlet Temperature
5. 47400 KDOC 1 Outlet Temperature
6. 36400 Common Rail Pressure

No. Cause Procedure, measuring location, criteria and remarks

Instruct the operator to stop the engine after performing low idling for approximately
1 Operation mistake
5 minutes.

HB365LC-3 40-229
FAILURE CODE [AS10NR] 40 TROUBLESHOOTING

FAILURE CODE [AS10NR] (ALL-K-AFJ1-410-20-B)

Action level Failure code AdBlue/DEF injector high temperature warning

Failure
- AS10NR (Engine controller system)
Detail of fail- The temperature of AdBlue/DEF injector may become so high that it is damaged, so the output is
ure limited.
Action of • Changes to output limitation.
controller • Derates hybrid system for operation.
Phenomenon • Engine power deration.
on machine • Swing output limitation lowers swing speed.
• This may occur if a heavy load operation is performed for a long time during AdBlue/DEF
thawing.
• This may occur if a heavy load operation is performed for a long time when an error relat-
ed to SCR equipment occurs.
• If the engine coolant temperature is high, the cooling capability of AdBlue/DEF injector is
degraded and a warning may appear.
• If the ambient temperature sensor and the engine room temperature sensor show abnor-
Related mal values (significantly low compared to the actual temperature), unnecessary thawing
control may be enabled and a warning may appear.
information
• This failure code is a warning for equipment protection and does not indicate any failures.
• Both failure code and output limitation are cleared by turning off and on the starting switch.
• The hybrid caution lamp appears due to derated hybrid system for operation.
REMARK
It is displayed until engine power deration is canceled.
• If failure code related to hybrid system is also displayed, perform troubleshooting for this
failure code first.

No. Cause Procedure, measuring location, criteria and remarks

Error related to SCR de- Check if AdBlue/DEF injection stop error is displayed. If it is displayed, perform
1 vice (AdBlue/DEF injec- clearing of that error.
tion stop error)
Check the condition of radiator.
High coolant temperature • Does the radiator shutter prevent the coolant from working properly?
2 (deterioration of radiator
performance) • Is the radiator clogged?
Clean so that the radiator cooling capability is sufficient.
Turn the starting switch to ON position.
Defective ambient tem-
3 If the temperature sensed by ambient temperature sensor is significantly low com-
perature sensor
pared to the actual temperature, the ambient temperature sensor is defective.
1. Turn the starting switch to ON position.
2. Open the pump side cover and wait for 5 minutes.
Defective engine room
4
temperature sensor If the temperature sensed by engine room temperature sensor is significantly low
compared to the actual temperature, the engine room temperature sensor is defec-
tive.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)

40-230 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [AS10NT]

FAILURE CODE [AS10NT] (ALL-K-AFJ1-410-40-B)

Action level Failure code AdBlue/DEF Injector Overheat Caution

Failure
- AS10NT (Machine monitor system)

• Engine is stopped abruptly when engine and aftertreatment devices are at high tempera-
Details of ture. Engine may have been stopped without sufficient running at low idle. This event does
not instantly cause the failure, but if it is repeated, it slowly damages AdBlue/DEF injector.
failure AdBlue/DEF injector will be damaged eventually, and it may cause defective injection or
leakage of AdBlue/DEF.
Action of
None in particular (No error is displayed on the machine monitor.)
controller
Phenomenon
Defective injection of AdBlue/DEF may occur when engine starts operation again.
on machine
• On the Pre-defined Monitoring screen, aftertreatment devices related for engine are used
(the numbers below denote monitoring codes).
47000 KDPF Outlet Pressure
47100 KDPF Differential Pressure
47200 KDPF 1 Outlet Temperature
47300 KDOC 1 Inlet Temperature
47400 KDOC 1 Outlet Temperature
• This failure code is displayed for the purpose of recording that aftertreatment devices of
the engine were stopped in the state of high temperature at the time of last operation stop.
It is not necessary to troubleshoot and replace parts when this failure code is displayed
Related alone.
information • After this failure code is recorded, a warning related to the engine stop is displayed on the
monitor when turning off the key next time.
• This failure code indicates that aftertreatment devices of the engine were stopped in the
state of high temperature at the time of last operation stop (stop during regeneration or
stop immediately after high load operation). Repeatedly doing this will lead to damage to
the AdBlue / DEF injector, so if it is displayed more than once, instruct the operator to stop
the engine after approximately 5 minutes of low idling. If stop the engine during regenera-
tion (regeneration lamp is lit) is required, after stopping the regeneration (see Operation
and Maintenance Manual “PROCEDURE FOR AFTERTREATMENT DEVICES REGEN-
ERATION DISABLE SETTING”), instruct the operator to stop the engine after approxi-
mately 5 minutes of low idling.
• Failure code [AS10KM] is displayed after this failure code has been detected 150 times or
more.

No. Cause Procedure, measuring location, criteria and remarks

Instruct the operator to stop the engine after performing low idling for approximately
1 Operation mistake
5 minutes.

HB365LC-3 40-231
FAILURE CODE [B@BAZG] 40 TROUBLESHOOTING

FAILURE CODE [B@BAZG] (ALL-K-AB00-410-60-B)

Action level Failure code Engine oil pressure low

Failure
L03 B@BAZG (Engine controller system)
Detail of fail- Signal voltage from engine oil pressure sensor drops while engine is running, and engine controller
ure detects engine oil pressure abnormality.
• Displays engine oil pressure monitor on machine monitor in red.
Action of
• Engine power deration.
controller
• Derates hybrid system for operation.
• Engine output is reduced.
Phenomenon
• If machine is used as it is, engine may be seized.
on machine
• Swing output limitation lowers swing speed.
• Engine controller inputs the signal voltage of engine oil pressure sensor and transmits the
information to machine monitor through CAN communication system.
• Engine oil pressure can be checked with monitoring function. (Code: 37200)
• The hybrid caution lamp appears due to derated hybrid system for operation.
Related REMARK
information It is displayed until engine power deration is canceled.
• If failure code related to hybrid system is also displayed, perform troubleshooting for this
failure code first.
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Since engine oil pressure low is detected, check engine oil pressure.
2. Perform TROUBLESHOOTING, “OIL PRESSURE DROPS” in S mode.
1 Low engine oil pressure
3. When engine oil consumption is large, perform “ENGINE OIL CONSUMP-
TION IS EXCESSIVE” in S mode.

40-232 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [B@BAZK]

FAILURE CODE [B@BAZK] (ALL-K-AB44-410-01-B)

Action level Failure code Eng Oil Level Low

Failure
L01 B@BAZK (machine monitor system)
Detail of fail- When the starting switch is turned ON, the signal voltage from the engine oil level switch becomes
ure higher than 1 V and the machine monitor detected engine oil level low (oil level switch OPEN).
Action of
Lights up engine oil level in yellow on machine monitor.
controller
Phenomenon
If machine is used as it is, engine may be seized.
on machine
• Input (ON/OFF) from engine oil level switch can be checked with monitoring function
Related (Code: 04501 Monitor input 2).
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Since engine oil level low is detected, check engine oil level.
2. Perform TROUBLESHOOTING, “OIL PRESSURE DROPS” in S mode.
1 Low engine oil level
3. When engine oil consumption is large, perform “ENGINE OIL CONSUMP-
TION IS EXCESSIVE” in S mode.
1. Turn the starting switch to OFF position.
2. Disconnect the connector P44, and connect the T-adapter to male side.
Defective engine oil level
2
sensor Engine oil level normal Max. 1 Ω
Between P44 (male) (1)
Resistance
and ground Engine oil level low Min. 1 MΩ
1. Turn the starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect the connectors CM02 and P44, and connect the T-adapter to
3
ness each female side.
Resistance Between CM02 (female) (2) and P44 (female) (1) Max. 1 Ω
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
4
tor an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-233
FAILURE CODE [B@BAZK] 40 TROUBLESHOOTING

Circuit diagram related to engine oil level

40-234 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [B@BCNS]

FAILURE CODE [B@BCNS] (ALL-K-AC00-410-01-B)

Action level Failure code Engine Coolant Overheat

Failure
L02 B@BCNS (Engine controller system)
Details of Engine controller determines engine coolant temperature overheat when voltage from engine cool-
failure ant temperature sensor drops while engine is running.

Action of • Lights up engine coolant temperature monitor in red on machine monitor.

controller • Engine power deration.
Phenomenon • Engine power deration.
on machine • If machine is used as it is, engine may be seized.
• Signal voltage of engine coolant temperature sensor is input to engine controller that
transmits information to machine monitor through CAN communication system.
Related
• Engine coolant temperature can be checked with monitoring function (Code: 04107)
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

Overheat of engine cool- Engine coolant may overheat. Remove the cause of failure if coolant overheats.
1
ant
Defective engine coolant If failure code is still displayed after above checks on cause 1, engine coolant tem-
2 temperature sensor sys- perature sensor system may be defective. Perform troubleshooting for failure codes
tem [CA144] and [CA145].

HB365LC-3 40-235
FAILURE CODE [B@BCZK] 40 TROUBLESHOOTING

FAILURE CODE [B@BCZK] (ALL-K-AC40-410-00-B)

Action level Failure code Eng Water Level Low

Failure
L01 B@BCZK (Machine monitor system)
Details of Signal circuit of radiator coolant level switch is "OPEN" (disconnected from GND) when the engine
failure is stopped.

Action of ma-
None in particular
chine monitor
Phenomenon
Machine is used when coolant level is low, engine may overheat.
on machine
• Operation of radiator coolant level switch can be becked with (Code: 04500).
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Check if radiator coolant level is normal.

1 Low radiator coolant level NOTICE

If radiator coolant level is lowered, check periphery of engine and radiator for
leakage before refilling.
1. Since the float may be stuck by clogging of dirt, check and clean the radia-
tor coolant level sensor directly.
2. Turn the starting switch to OFF position.
Defective radiator coolant 3. Disconnect the connector P24, and connect the T-adapter to male side.
2
level sensor
Radiator coolant level is
Max. 1 Ω
Between P24 (male) (1) normal
Resistance
and ground Radiator coolant level is
Min. 1 MΩ
low
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CM02 and P24, and connect the T-adapter to
Open circuit in wiring har- each female side.
3
ness
Between CM02 (female) (3) and P24 (female) (1) Max. 1 Ω
Resistance
Between P24 (female) (2) and ground Max. 1 Ω
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
4
tor an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to radiator coolant level switch

40-236 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [B@HANS]

FAILURE CODE [B@HANS] (ALL-K-L200-410-00-B)

Action level Failure code Hydraulic Oil Overheat

Failure
L02 B@HANS (Engine controller system)
Detail of fail- Pump controller detects overheating of hydraulic oil temperature (approximately 102 °C or above)
ure by signal voltage of hydraulic oil temperature sensor while engine is running.
Action of • Displays hydraulic oil temperature monitor on machine monitor in red.
controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
If machine is used as it is, hydraulic component may be damaged.
on machine
• Signal from hydraulic oil temperature sensor is input to pump controller and then data is
transmitted to machine monitor through CAN communication system.
• Hydraulic oil temperature can be checked with monitoring function. (Code: 04401 "Hy-
draulic Oil Temperature")
Related
• See troubleshooting for “HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES
information
NOT MOVE FROM MINIMUM OR MAXIMUM” and “DISPLAY OF HYDRAULIC OIL TEM-
PERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE” in E mode.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

1 Hydraulic Oil Overheat Hydraulic oil may overheat. Remove the cause of failure if hydraulic oil overheats.

HB365LC-3 40-237
FAILURE CODE [CA115] 40 TROUBLESHOOTING

FAILURE CODE [CA115] (ALL-K-AG30-410-00-B)

Action level Failure code Engine NE and Backup Speed Sensor Error (Engine controller sys-
Failure
L04 CA115 tem)

Details of
Errors occur simultaneously in signal circuits of Ne speed sensor and Bkup speed sensor.
failure
Action of
Stops engine.
controller
Phenomenon • Stopped engine cannot be started.
on machine • Running engine stops.
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective connection of Since connection of connector between NE speed sensor and Bkup speed sensor
1
sensor connector may be defective (incorrect connection), check it.
Defective Ne speed sen- Perform troubleshooting for failure code [CA689].
2
sor system
Defective Bkup speed Perform troubleshooting for failure code [CA778].
3
sensor system
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

40-238 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA122]

FAILURE CODE [CA122] (ALL-K-AAM0-410-00-B)

Action level Failure code

Failure Charge Air Pressure Sensor High Error (Engine controller system)
L03 CA122
Details of
High voltage occurs in signal circuit of charge pressure sensor (boost pressure sensor).
failure
• Sets charge pressure (boost pressure) to fixed value (400 kPa {4.1 kg/cm2} ) for operation.
Action of • EGR valve closes and fully opens VGT.
controller • Engine power deration
• Regeneration control stops.
Phenomenon • Engine acceleration performance is poor.
on machine • Engine power deration
• Signal voltage from charge pressure sensor (boost pressure sensor) can be checked by
monitoring function. (Code: 36501 (V))
• Pressure (boost pressure) by charge pressure sensor (boost pressure sensor) can be
checked by monitoring function. (Code: 36500 (kPa))
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn starting switch to ON position.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note the engine power deration is not canceled right after the failure
code is cleared).

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
Defective sensor power If failure code [CA352] or [CA386] is also displayed, perform troubleshooting these
2
supply system first.
1. Turn starting switch to OFF position.
2. Disconnect connector BOOST PRESS & IMT.
3. Turn starting switch to ON position.
If failure code changes from [CA122] to [CA123], charge pressure (boost pressure)
sensor is defective.
Defective charge (boost) Reference
3
pressure sensor 1. Turn starting switch to OFF position.
2. Insert T-adapter into connector ECM J1 or BOOST PRESS & IMT.
3. Turn starting switch to ON position.
Between ECM J1 (45) and
Voltage (54), or between BOOST Sensor output 0.3 to 4.7 V
PRESS & IMT (1) and (4)
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and connect
ness (ground line break-
4 T-adapters to each female side.
age or defective contact
of connector) Between ECM J1 (female) (54) and BOOST PRESS &
Resistance Max. 10 Ω
IMT (female) (4)

HB365LC-3 40-239
FAILURE CODE [CA122] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Short circuit in wiring har- 2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and connect
5
ness T-adapter to female side of ECM J1.
Resistance Between ECM J1 (female) (45) and (78) Min. 100 kΩ
1. Turn starting switch to OFF position.
2. Disconnect connector BOOST PRESS & IMT and connect T-adapter to fe-
male side, or insert T-adapter into connector ECM J1.
Hot short circuit in wiring
6 3. Turn starting switch to ON position (with connector BOOST PRESS & IMT
harness
disconnected).
Between BOOST PRESS & IMT (1) and (4), or be-
Voltage Max. 1 V
tween ECM J1 (female) (45) and (54)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to charge air pressure sensor

40-240 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA123]

FAILURE CODE [CA123] (ALL-K-AAM0-410-10-B)

Action level Failure code

Failure Charge Air Pressure Sensor Low Error (Engine controller system)
L03 CA123
Details of
Low voltage occurs in signal circuit of charge pressure sensor (boost pressure sensor).
failure
• Sets charge pressure (boost pressure) to fixed value (400 kPa {4.1 kg/cm2} ) for operation.
Action of • EGR valve closes and fully opens VGT.
controller • Engine power deration
• Regeneration control stops.
Phenomenon • Engine acceleration performance is poor.
on machine • Engine power deration
• Signal voltage from charge pressure sensor (boost pressure sensor) can be checked by
monitoring function. (Code: 36501 (V))
• Pressure (boost pressure) by charge pressure sensor (boost pressure sensor) can be
checked by monitoring function. (Code: 36500 (kPa))
Related • After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.
• This failure code is displayed if sensor connector is disconnected.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note the engine power deration is not canceled right after the failure
code is cleared).

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
If failure code [CA352] or [CA386] is also displayed, perform troubleshooting these
first.
1. Turn starting switch to OFF position.
Defective power supply
system of charge pres- 2. Disconnect connector BOOST PRESS & IMT and connect T-adapter to fe-
2
sure sensor (boost pres- male side.
sure sensor) 3. Switch ON
Between BOOST PRESS 4.75 to
Voltage Power supply
& IMT (female) (1) and (2) 5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and connect
T-adapters to each female side.
Open circuit in wiring har-
Between ECM J1 (female) (45) and BOOST PRESS &
ness (wire breakage or Max. 10 Ω
3 IMT (female) (1)
defective contact of con-
nector) Between ECM J1 (female) (62) and BOOST PRESS &
Resistance Max. 10 Ω
IMT (female) (3)
Between ECM J1 (female) (78) and BOOST PRESS &
Max. 10 Ω
IMT (female) (2)

HB365LC-3 40-241
FAILURE CODE [CA123] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and connect
Short circuit in wiring har-
4 T-adapter to either female side.
ness
Between ECM J1 (female) (45) and (54), or between
Resistance Min. 100 kΩ
BOOST PRESS & IMT (female) (1) and (4)
1. Turn starting switch to OFF position to perform troubleshooting.
Ground fault in wiring 2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and connect
5 harness (contact with T-adapter to either female side.
ground circuit)
Between ground and ECM J1 (female) (45) or BOOST
Resistance Min. 100 kΩ
PRESS & IMT (female) (1)
If failure code is still displayed after above checks on causes 1 to 5 and any failure
is found by checks on cause 6, sensor is defective.
1. Turn starting switch to OFF position.
Defective charge (boost) 2. Insert T-adapter into connector ECM J1 or BOOST PRESS & IMT.
6
pressure sensor 3. Turn starting switch to ON position.
Between ECM J1 (45) and
Voltage (54), or between BOOST Sensor output 0.3 to 4.7 V
PRESS & IMT (1) and (4)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to charge air pressure sensor

40-242 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA131]

FAILURE CODE [CA131] (ALL-K-AEX0-410-00-B)

Action level Failure code Throttle sensor high error

Failure
L03 CA131 (Engine controller system)
Detail of fail-
High voltage occurs in signal circuit of fuel dial sensor.
ure
• If error occurs while starting switch is ON, controller sets to fixed value used before the
Action of error has been detected and runs engine.
controller • If starting switch is turned to ON position after the error has occurred, controller uses a
value of 100%.
Phenomenon
Engine speed cannot be controlled by using fuel control dial.
on machine
• Signal voltage from fuel control dial can be checked with monitoring function. (Code:
Related 03000)
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
Defective throttle sensor If failure code [CA2185] or [CA2186] are displayed at the same time, perform trou-
2
power supply system bleshooting these first.
1. Turn starting switch to OFF position.
2. Disconnect connector P20, and connect T-adapter to male side.
4.0 to
Between P20 (male) (1) and (3)
Defective fuel dial (throt- 6.0 kΩ
3
tle sensor)
0.25 to
Resistance Between P20 (male) (2) and (3)
5.0 kΩ
0.25 to
Between P20 (male) (1) and (2)
5.0 kΩ
1. Starting switch: OFF
2. Disconnect connector ECM J2, and connect T-adapter to female side.
Open or short circuit in 4.0 to
4 Between ECM J2 (female) (9) and (33)
wiring harness 6.0 kΩ
Resistance
0.25 to
Between ECM J2 (female) (9) and (10)
5.0 kΩ
If failure code is still displayed after above checks on cause 4, this check is not re-
quired.
1. Starting switch: OFF
Short circuit in wiring har-
5 2. Disconnect connectors ECM J2 and P20, and connect T-adapter to either
ness
female side.
Between ECM J2 (female) (9) and (10), or between
Resistance Min. 100 kΩ
P20 (female) (1) and (2)

HB365LC-3 40-243
FAILURE CODE [CA131] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector P20 and connect T-adapter to female side.
6 harness (contact with
3. Turn starting switch to ON position.
24 V circuit)
Voltage Between P20 (female) (2) and ground Max. 1 V
If no failure is found by above checks, engine controller is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)
1. Starting switch: OFF
2. Insert T-adapter into connector ECM J2.
Defective engine control- 3. Starting switch: ON
7
ler 4. Operate fuel dial and perform troubleshooting.
Between ECM J2 (9) and 4.75 to
Power supply
(33) 5.25 V
Voltage
Between ECM J2 (10) and
Sensor output 0.5 to 4.5 V
(33)

Circuit diagram related to throttle sensor

40-244 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA132]

FAILURE CODE [CA132] (ALL-K-AEX0-410-10-B)

Action level Failure code Throttle Sensor Low Error

Failure
L03 CA132 (Engine controller system)
Detail of fail-
Low voltage occurs in signal circuit of fuel dial sensor.
ure
• If error occurs while starting switch is ON, controller sets to fixed value used before the
Action of error has been detected and runs engine.
controller • If starting switch is turned to ON position after the error has occurred, controller uses a
value of 100%.
Phenomenon
Engine speed cannot be controlled by using fuel control dial.
on machine
• Signal voltage from fuel control dial can be checked with monitoring function. (Code:
Related 03000)
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
Defective throttle sensor If failure code [CA2185] or [CA2186] are displayed at the same time, perform trou-
2
power supply system bleshooting these first.
1. Turn starting switch to OFF position.
2. Disconnect connector P20, and connect T-adapter to male side.
4.0 to
Between P20 (male) (1) and (3)
Defective fuel dial (throt- 6.0 kΩ
3
tle sensor)
0.25 to
Resistance Between P20 (male) (2) and (3)
5.0 kΩ
0.25 to
Between P20 (male) (1) and (2)
5.0 kΩ
1. Starting switch: OFF
2. Disconnect connector ECM J2, and connect T-adapter to female side.
Open or short circuit in 4.0 to
4 Between ECM J2 (female) (9) and (33)
wiring harness 6.0 kΩ
Resistance
0.25 to
Between ECM J2 (female) (10) and (33)
5.0 kΩ
If failure code is still displayed after above checks on cause 4, this check is not re-
quired.
1. Starting switch: OFF
Open circuit in wiring har- 2.
Disconnect connectors ECM J2 and P20, and connect T-adapter to each
ness (wire breakage or
5 female side.
defective contact of con-
nector) Between ECM J2 (female) (9) and P20 (female) (1) Max. 10 Ω
Resistance Between ECM J2 (female) (10) and P20 (female) (2) Max. 10 Ω
Between ECM J2 (female) (33) and P20 (female) (3) Max. 10 Ω

HB365LC-3 40-245
FAILURE CODE [CA132] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Starting switch: OFF
Ground fault in wiring 2. Disconnect connectors ECM J2 and P20, and connect T-adapter to either
6 harness (contact with female side.
ground circuit)
Between ground and ECM J2 (female) (10) or P20 (fe-
Resistance Min. 100 kΩ
male) (2)
If failure code is still displayed after above checks on cause 4, this check is not re-
quired.
1. Starting switch: OFF
Short circuit in wiring har-
7 2. Disconnect connectors ECM J2 and P20, and connect T-adapter to either
ness
female side.
Between ECM J2 (female) (10) and (33), or between
Resistance Min. 100 kΩ
P20 (female) (2) and (3)
If no failure is found by above checks, engine controller is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)
1. Starting switch: OFF
2. Insert T-adapter into connector ECM J2.
Defective engine control- 3. Starting switch: ON
8
ler 4. Operate fuel dial and perform troubleshooting.
Between ECM J2 (9) and 4.75 to
Power supply
(33) 5.25 V
Voltage
Between ECM J2 (10) and
Sensor output 0.5 to 4.5 V
(33)

Circuit diagram related to throttle sensor

40-246 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA144]

FAILURE CODE [CA144] (ALL-K-ACA0-410-00-B)

Action level Failure code

Failure Coolant Temperature Sensor High Error (Engine controller system)
L01 CA144
Details of
High voltage occurs in signal circuit of engine coolant temperature sensor.
failure
Action of
Sets coolant temperature to fixed value for operation.
controller
Phenomenon • Engine startability becomes poor in low temperature.
on machine • Overheat prevention function does not operate.
• Signal voltage from engine coolant temperature sensor can be checked by monitoring
function. (Code: 04105 (V))
• Temperature in engine oil coolant sensor can be checked by monitoring function. (Code:
04107 (°C))
• After repairing, check if the failure code is cleared by the following procedure.
Related Procedure: Turn starting switch to ON position.
information • This failure code is displayed when temperature sensor connector is disconnected.
• Because female connector alone is provided in “Socket” for troubleshooting for this sen-
sor, socket cannot be connected to female connector on wiring harness side of sensor and
check for wire breakage cannot be performed (T-adapter is not provided).
k Do not work at high coolant temperature, when testing and replacing coolant temper-
ature sensor.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “c: Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector COOLANT TEMP and connect socket to male side.
REMARK
Regard coolant temperature sensor as normal if its resistance is 700 Ω to 37 kΩ
when coolant temperature is min. 0 °C.
0 °C 30 to 37 kΩ
9.3 to
25 °C
Defective coolant tem- 10.7 kΩ
2 Between COOLANT
perature sensor 3.2 to
TEMP (male) (A) and (B) 50 °C
3.8 kΩ
Coolant temperature char-
Resistance acteristics 1.0 to
80 °C
1.3 kΩ
700 to
95 °C
800 Ω
Between COOLANT
All coolant temperature
TEMP (male) (B) and Min. 100 kΩ
range
ground

HB365LC-3 40-247
FAILURE CODE [CA144] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1, and connect T-adapter to female side.

REMARK
Open or short circuit in
3 Use coolant temperature sensor resistance charac-
wiring harness
Resistance teristics table for check on cause 2 as criteria for re- 700 Ω to
sistance 37 kΩ
between ECM J1 (female) (83) and (54) (coolant tem-
perature: Min. 0 °C).
1. Turn starting switch to OFF position.
2. Disconnect connector COOLANT TEMP.
Hot short circuit in wiring 3.
4 Insert T-adapter into connector ECM J1.
harness
4. Turn starting switch to ON position.
Voltage Between ECM J1 (83) and (54) Max. 5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and COOLANT TEMP, and connect T-
Short circuit in wiring har-
5 adapter to female side of ECM J1.
ness
Between ECM J1 (female) (83) and each pin other No continui-
Continuity
than pin (83) ty
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

Electrical circuit diagram related to coolant temperature sensor

40-248 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA145]

FAILURE CODE [CA145] (ALL-K-ACA0-410-10-B)

Action level Failure code

Failure Coolant Temperature Sensor Low Error (Engine controller system)
L01 CA145
Details of
Low voltage occurs in signal circuit of engine coolant temperature sensor.
failure
Action of
Sets coolant temperature to fixed value for operation.
controller
Phenomenon • Engine startability becomes poor in low temperature.
on machine • Overheat prevention function does not operate.
• Signal voltage from engine coolant temperature sensor can be checked by monitoring
function. (Code: 04105 (V))
• Temperature in engine oil coolant sensor can be checked by monitoring function. (Code:
04107 (°C))
Related • After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.
• When temperature sensor connector is removed, failure code for High Error [CA144] is
displayed instead of this failure code.
k Do not work at high coolant temperature, when testing and replacing coolant temper-
ature sensor.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “c: Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector COOLANT TEMP and connect socket to male side.
REMARK
Regard coolant temperature sensor as normal if its resistance is 700 Ω to 37 kΩ
when coolant temperature is min. 0 °C.
0 °C 30 to 37 kΩ
9.3 to
25 °C
Defective coolant tem- 10.7 kΩ
2 Between COOLANT
perature sensor 3.2 to
TEMP (male) (A) and (B) 50 °C
3.8 kΩ
Coolant temperature char-
Resistance acteristics 1.0 to
80 °C
1.3 kΩ
700 to
95 °C
800 Ω
Between COOLANT
All coolant temperature
TEMP (male) (B) and Min. 100 kΩ
range
ground

HB365LC-3 40-249
FAILURE CODE [CA145] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Ground fault in wiring
3 harness (contact with
ground circuit)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and COOLANT TEMP, and connect T-
adapter to female side of ECM J1.
Resistance Between ECM J1 (female) (83) and ground Min. 100 kΩ
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1, and connect T-adapter to female side.

REMARK
Short circuit in wiring har-
4 Use coolant temperature sensor resistance charac-
ness
Resistance teristics table for check on cause 2 as criteria for re- 700 Ω to
sistance 37 kΩ
between ECM J1 (female) (83) and (54) (coolant tem-
perature: Min. 0 °C).
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)

Electrical circuit diagram related to coolant temperature sensor

40-250 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA153]

FAILURE CODE [CA153] (ALL-K-AAM1-410-00-B)

Action level Failure code Charge Air Temperature Sensor High Error (Engine controller sys-
Failure
L03 CA153 tem)

Details of
High voltage occurs in signal circuit of charge (boost) temperature sensor.
failure
• Sets charge temperature (boost temperature) to fixed value (70 °C) for operation.
Action of • EGR valve closed.
controller • Engine power deration
• Regeneration control stops.
Phenomenon • Engine startability becomes poor in low temperature.
on machine • Engine power deration
• Signal voltage from charge temperature sensor (boost temperature sensor) can be
checked by monitoring function. (Code: 18501 (V))
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be
checked with monitoring function. (Code: 18500 (°C))
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
Related
• Because female connector alone is provided in “Socket” for troubleshooting for this sen-
information
sor, socket cannot be connected to female connector on wiring harness side of sensor and
check for wire breakage cannot be performed (T-adapter is not provided).
• This failure code is displayed when temperature sensor connector is disconnected.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note the engine power deration is not canceled right after the failure
code is cleared).

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “c: Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.

HB365LC-3 40-251
FAILURE CODE [CA153] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector BOOST PRESS & IMT and connect socket to male
side.
REMARK
Regard charge temperature sensor as normal if its resistance is 80 Ω to 48 kΩ.
-40 °C 41 to 48 kΩ
-20 °C 14 to 16 kΩ
Defective charge temper-
2 5.4 to
ature sensor 0 °C
6.1 kΩ
Between BOOST PRESS
& IMT (male) (3) and (4) 1.6 to
30 °C
Resistance 1.8 kΩ
Charge thermal character-
istics 500 to
60 °C
600 Ω
230 to
90 °C
250 Ω
130 °C 80 to 90 Ω
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1, and connect T-adapter to female side.

Open or short circuit in REMARK

3
wiring harness Use charge temperature sensor resistance charac- 80 Ω to
Resistance teristics table for check on cause 2 as criteria for re- 48 kΩ
sistance
between ECM J1 (female) (62) and (54).
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector BOOST PRESS & IMT.
4
harness 3. Insert T-adapter into connector ECM J1.
Voltage Between ECM J1 (62) and (54) Max. 5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and BOOST PRESS & IMT, and connect
Short circuit in wiring har-
5 T-adapter to female side of ECM J1.
ness
Between ECM J1 (female) (62) and each pin other No continui-
Continuity
than pin (62) ty
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

40-252 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA153]

Circuit diagram related to charge temperature sensor

HB365LC-3 40-253
FAILURE CODE [CA154] 40 TROUBLESHOOTING

FAILURE CODE [CA154] (ALL-K-AAM1-410-10-B)

Action level Failure code

Failure Charge Air Temperature Sensor Low Error (Engine controller system)
L03 CA154
Details of
Low voltage occurs in signal circuit of charge (boost) temperature sensor.
failure
• Sets charge temperature (boost temperature) to fixed value (70 °C) for operation.
Action of • EGR valve closed.
controller • Engine power deration
• Regeneration control stops.
Phenomenon • Engine startability becomes poor in low temperature.
on machine • Engine power deration
• Signal voltage from charge temperature sensor (boost temperature sensor) can be
checked by monitoring function. (Code: 18501 (V))
• Temperature sensed by charge temperature sensor (boost temperature sensor) can be
checked with monitoring function. (Code: 18500 (°C))

Related • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
information
• When temperature sensor connector is removed, failure code for High Error [CA153] is
displayed instead of this failure code.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note the engine power deration is not canceled right after the failure
code is cleared).

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “c: Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.

40-254 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA154]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector BOOST PRESS & IMT and connect socket to male
side.
REMARK
Regard charge temperature sensor as normal if its resistance is 80 Ω to 48 kΩ.
-40 °C 41 to 48 kΩ
-20 °C 14 to 16 kΩ
5.4 to
0 °C
Defective charge temper- REMARK 6.1 kΩ
2
ature sensor Charge thermal charac- 1.6 to
30 °C
teristics 1.8 kΩ

Resistance between BOOST PRESS 500 to

60 °C
& IMT (male) (3) and (4) 600 Ω
230 to
90 °C
250 Ω
130 °C 80 to 90 Ω
Between BOOST PRESS
& IMT (male) (3) and All range Min. 100 kΩ
ground
1. Turn starting switch to OFF position.
Ground fault in wiring
3 harness (contact with 2. Disconnect connector ECM J1, and connect T-adapter to female side.
ground circuit)
Resistance Between ECM J1 (female) (62) and ground Min. 100 kΩ
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1, and connect T-adapter to female side.

Short circuit in wiring har- REMARK

4
ness Use charge temperature sensor resistance charac- 80 Ω to
Resistance teristics table for check on cause 2 as criteria for re- 48 kΩ
sistance
between ECM J1 (female) (62) and (54).
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-255
FAILURE CODE [CA154] 40 TROUBLESHOOTING

Circuit diagram related to charge temperature sensor

40-256 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA187]

FAILURE CODE [CA187] (ALL-K-AG1P-410-00-B)

Action level Failure code Sensor 2 Supply Voltage Low Error

Failure
L03 CA187 (Engine controller system)
Details of
Low voltage occurs in sensor 2 supply (5 V) circuit.
failure
• Ignores signals from EGR valve lift sensor and VGT position sensor, and fixes values be-
Action of
fore detecting error for operation.
controller
• Engine power deration
Phenomenon
Engine power deration.
on machine
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
Related
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
information
ure code is cleared (note the engine power deration is not canceled right after the failure
code is cleared).

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “c: Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. Each time troubleshooting is finished, return to step 1.
If this failure code is cleared, disconnected sensor or engine wiring harness is de-
fective.
Defective sensor or wir-
2 REMARK
ing harness
Other failure codes are also displayed. This is because connector is discon-
nected. Ignore all failure codes except for [CA187].
EGR valve lift sensor SEGR
Connector VGT position sensor SVGT
Engine wiring harness ECM J1
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1, and connect T-adapter to male side.
3. Turn starting switch ON with connector ECM J1 disconnected.
4. If no failure is found by this check, perform troubleshooting again from
Defective engine control-
3 cause 1 before replacing the engine controller.
ler
4.75 to
Voltage Between ECM J1 (male) (81) and (57)
5.25 V
If no failure is found by above checks, engine controller is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-257
FAILURE CODE [CA187] 40 TROUBLESHOOTING

Circuit diagram related to sensor 2 supply circuit

40-258 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA221]

FAILURE CODE [CA221] (ALL-K-AAP0-410-00-B)

Action level Failure code Ambient Pressure Sensor High Error

Failure
L03 CA221 (Engine controller system)
Detail of fail-
High voltage occurs in signal circuit of ambient pressure sensor.
ure
• Sets ambient pressure to fixed value (52.44 kPa {0.53 kg/cm2}) and runs engine.
Action of • EGR valve closes and fully opens VGT.
controller • Engine power deration.
• Stops KDPF regeneration control.
Phenomenon
Engine power deration
on machine
• Signal voltage from ambient pressure sensor can be checked with monitoring function.
(Code: 37401 (V))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
Related function. (Code: 37400 (kPa))
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• Engine power deration is canceled when this failure code is cleared and the starting switch
is turned to OFF position (not canceled only by deactivation of the failure code).

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “c: Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
Defective ambient pres- If failure code [CA352] or [CA386] is displayed, perform troubleshooting these first.
2 sure sensor power sup-
ply system
1. Turn starting switch to OFF position.
2. Disconnect connector AMB.AIR PRESSURE.
3. Turn starting switch to ON position.
If failure code [CA221] changes to [CA222], sensor is defective.

Defective ambient pres- Reference

3 1. Turn starting switch to OFF position.
sure sensor
2. Insert T-adapter into connector ECM J1 and AMB.AIR PRESSURE.
3. Turn starting switch to ON position.
Between (54) and ECM J1
Voltage (44), or between (2) and Sensor output 0.3 to 4.7 V
AMB.AIR PRESSURE (3)
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors ECM J1 and AMB.AIR PRESSURE and connect T-
ness (wire breakage of
4 adapters to each female side.
ground line or defective
contact of connector) Between ECM J1 (female) (54) and AMB.AIR PRES-
Resistance Max. 10 Ω
SURE (female) (2)

HB365LC-3 40-259
FAILURE CODE [CA221] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and AMB.AIR PRESSURE, and connect
Short circuit in wiring har-
5 T-adapter to either female side.
ness
Between ECM J1 (female) (78) and (44), or between
Resistance Min. 100 kΩ
AMB.AIR PRESSURE (female) (1) and (3)
1. Turn starting switch to OFF position.
2. Disconnect connector AMB.AIR PRESSURE, and connect T-adapter to fe-
Hot short circuit in wiring male side.
6
harness
3. Turn starting switch to ON position.
Voltage Between (2) and AMB.AIR PRESSURE (female) (3) Max. 1 V
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)

CIRCUIT DIAGRAM (AMBIENT PRESSURE SENSOR)

40-260 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA222]

FAILURE CODE [CA222] (ALL-K-AAP0-410-10-B)

Action level Failure code Ambient Pressure Sensor Low Error

Failure
L03 CA222 (Engine controller system)

Details of
Low voltage occurs in signal circuit of ambient pressure sensor.
failure
• Sets ambient pressure to fixed value (52.44 kPa) for operation.
Action of • EGR valve closed.
controller • Engine power deration
• Regeneration control stops.
Phenomenon
Engine power deration
on machine
• Signal voltage sensed by ambient pressure sensor can be checked with monitoring func-
tion. (Code: 37401 (V))
• Ambient pressure sensed by ambient pressure sensor can be checked with monitoring
function. (Code: 37400 (kPa))
Related • After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.
• This failure code is displayed if sensor connector is disconnected.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note the engine power deration is not canceled right after the failure
code is cleared).

No. Cause Procedure, measuring location, criteria and remarks

Defective wiring harness
1
connector
Defective ambient pres-
2 sure sensor power sup-
ply system
Short circuit in wiring har-
3 T-adapter to either female side.
ness
Ground fault in wiring
4 harness (contact with
ground circuit)
1. See descriptions of wiring harness and connectors in “c: Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
FORMATION ON TROUBLESHOOTING”, and check it.
2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
If failure code [CA352] or [CA386] is displayed, perform troubleshooting these first.
1. Turn starting switch to OFF position.
2. Disconnect connector AMB.AIR PRESSURE, and connect T-adapter to fe-
male side.
3. Switch ON
Between (2) and AMB.AIR 4.75 to
Voltage Turn power supply ON.
PRESSURE (female) (1) 5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connectors AMB.AIR PRESSURE and ECM J1, and connect
Between (54) and ECM J1 (female) (44), or between
Resistance Min. 100 kΩ
(2) and AMB.AIR PRESSURE (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors AMB.AIR PRESSURE and ECM J1, and connect
T-adapter to either female side.
Between ground and ECM J1 (female) (44) or
Resistance Min. 100 kΩ
AMB.AIR PRESSURE (female) (3)

HB365LC-3 40-261
FAILURE CODE [CA222] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors AMB.AIR PRESSURE and ECM J1 and connect T-
adapters to each female side.
Between ECM J1 (female) (44) and AMB.AIR PRES-
Open circuit in wiring har- Max. 10 Ω
5 SURE (female) (3)
ness
Between ECM J1 (female) (54) and AMB.AIR PRES-
Resistance Max. 10 Ω
SURE (female) (2)
Between ECM J1 (female) (78) and AMB.AIR PRES-
Max. 10 Ω
SURE (female) (1)
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector ECM J1 or AMB.AIR PRESSURE.
Defective ambient pres- 3. Turn starting switch to ON position.
6
sure sensor
Between (54) and ECM J1
Voltage (44), or between (2) and Sensor output 0.3 to 4.7 V
AMB.AIR PRESSURE (3)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)

CIRCUIT DIAGRAM (AMBIENT PRESSURE SENSOR)

40-262 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA227]

FAILURE CODE [CA227] (ALL-K-AG1P-410-10-B)

Action level Failure code

Failure Sensor 2 Supply Voltage High Error (Engine controller system)
L03 CA227
Detail of fail-
High voltage occurs in sensor power supply 2 (5 V) circuit.
ure
• Ignores signals from EGR valve lift sensor and VGT position sensor, and fixes values be-
Action of
fore detecting error for operation.
controller
• Engine power deration
Phenomenon
Engine power deration
on machine
• After repairing, check if the failure code is cleared by the following procedure.
Related Procedure: Turn starting switch to ON position.
information • Engine power deration is canceled when this failure code is cleared and the starting switch
is turned to OFF position (not canceled only by deactivation of the failure code).

No. Cause Procedure, measuring location, criteria and remarks

Defective sensor 2 sup- Perform troubleshooting for failure code [CA187].
1
ply system

HB365LC-3 40-263
FAILURE CODE [CA234] 40 TROUBLESHOOTING

FAILURE CODE [CA234] (ALL-K-A000-410-00-B)

Action level Failure code Engine Overspeed

Failure
L02 CA234 (Engine controller system)
Details of
Engine speed exceeds operating range.
failure
Action of
Restricts fuel injection rate until speed is lowered within operating range.
controller
Phenomenon
Engine speed varies.
on machine
• If other failure codes are also displayed, perform troubleshooting for them.
Related • Engine speed can be checked with monitoring function. (Code: 01002 (rpm))
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine and run at high idle speed.

No. Cause Procedure, measuring location, criteria and remarks

1 Improper fuel is used. Fuel used may be improper. Check it.
Defective relevant sys- If other failure codes are also displayed, perform troubleshooting for them.
2
tem
Method of using machine may be improper, so instruct operator on how to use ma-
3 Improper machine usage
chine properly.
If failure code is still displayed after above checks on causes 1 to 2, engine control-
Defective engine control-
4 ler is defective. (In case of an internal defect, troubleshooting is impossible as an
ler
assembly. Replace whole assembly.)

40-264 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA238]

FAILURE CODE [CA238] (ALL-K-AG41-410-00-B)

Action level Failure code NE Speed Sensor Supply Voltage Error

Failure
L01 CA238 (Engine controller system)
Details of
Error occurs in NE speed sensor power supply (5 V) circuit.
failure
Action of
Controls by Bkup speed sensor signal.
controller
Phenomenon • Running engine stops (when Bkup speed sensor is also defective).
on machine • Stopped engine cannot be started (when Bkup speed sensor is also defective).
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Start the engine.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect following connectors one by one and turn starting switch to ON po-
sition each time.
3. Each time troubleshooting is finished at one connector , return to step 1.
and troubleshoot next connector.
If this code is not displayed, disconnected sensor or engine wiring harness is de-
fective.
Defective sensor or wir-
2
ing harness REMARK
Many of other failure codes are displayed at the same time. This is because of
connector being disconnected. So ignore other codes than this failure code
[CA238].
CRANK
NE speed sensor
Connector SENSOR
Engine wiring harness ECM J1
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1, and connect T-adapter to male side.
3. Turn starting switch ON with engine wiring harness disconnected.
Defective engine control- 4.75 to
3 Voltage Between ECM J1 (male) (79) and (55)
ler 5.25 V
If failure code is still displayed after above checks, engine controller may be defec-
tive. Replace engine controller. (In case of an internal defect, troubleshooting is im-
possible as an assembly. Replace whole assembly.)

HB365LC-3 40-265
FAILURE CODE [CA238] 40 TROUBLESHOOTING

CIRCUIT DIAGRAM (Ne SPEED SENSOR)

40-266 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA239]

FAILURE CODE [CA239] (ALL-K-AG41-410-10-B)

Action level Failure code NE Speed Sensor Supply Voltage High Error
Failure
L01 CA239 (Engine controller system)
Details of
High voltage occurs in power supply (5 V) circuit of NE speed sensor.
failure
Action of
Controls by Bkup speed sensor signal.
controller
Phenomenon • Running engine stops (when Bkup speed sensor is also defective).
on machine • Stopped engine cannot be started (when Bkup speed sensor is also defective).
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Start the engine.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector CRANK SENSOR.
Defective NE speed sen-
2 3. Turn starting switch to ON position.
sor
If this code is not displayed, disconnected sensor or engine wiring harness is de-
fective.
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1.
3. Turn starting switch to ON position.

3 Defective wiring harness If this failure code is cleared, wiring harness is defective.
REMARK
Many of other failure codes are displayed at the same time. This is because of
connector being disconnected. So ignore other codes than this failure code
[CA239].
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1, and connect T-adapter to male side.
3. Turn starting switch ON with engine wiring harness disconnected.
Defective engine control- 4.75 to
4 Voltage Between ECM J1 (male) (79) and (55)
ler 5.25 V
If failure code is still displayed after above checks, engine controller may be defec-
tive. Replace engine controller. (In case of an internal defect, troubleshooting is im-
possible as an assembly. Replace whole assembly.)

HB365LC-3 40-267
FAILURE CODE [CA239] 40 TROUBLESHOOTING

CIRCUIT DIAGRAM (Ne SPEED SENSOR)

40-268 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA249]

FAILURE CODE [CA249] (ALL-K-AFKE-410-00-B)

Action level Failure code Ambient Air Temp Sensor High Error
Failure
L01 CA249 (Engine controller system)
Detail of fail-
High voltage occurs in signal circuit of ambient temperature sensor.
ure
• Operates substituting the ambient temperature with the intake temperature.
Action of (If there are any abnormalities in the intake air temperature sensor, operates with the am-
controller bient temperature set to the default value (25 °C))
• Advances to Inducement strategy. (EU Specification)
• AdBlue/DEF line stops thawing.
Phenomenon • The NOx emission increases because the AdBlue/DEF injection becomes improper, or the
on machine AdBlue/DEF line cannot be thawed at low temperature.
• Engine power deration according to inducement strategy. (EU Specification)
• This failure code is displayed when ambient temperature sensor connector is disconnect-
Related ed.
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check them.
1
connector 2. Turn the starting switch to ON position.
If this failure code is not displayed, the wiring harness connector is defective.
1. Turn the starting switch to OFF position.
2. Disconnect connector P65 and connect socket to male side.
REMARK
If a resistance value of the ambient temperature sensor ranges from 280 Ω to
382 kΩ, the ambient temperature sensor is considered to be normal.
291 to
-40 °C
382 kΩ
85 to
-20 °C
Defective ambient tem- 109 kΩ
2
perature sensor
0 °C 29 to 36 kΩ
7.3 to
Between P65 (male) (A) 30 °C
Resistance 8.8 kΩ
and (B)
2.3 to
60 °C
2.7 kΩ
860 to
90 °C
970 Ω
280 to
130 °C
320 Ω

HB365LC-3 40-269
FAILURE CODE [CA249] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector J2, and connect the T-adapter to female side.
REMARK
Open or short circuit in
3 Use charge temperature sensor resistance characteristics table for check on
wiring harness
cause 2 as resistance criteria.
280 Ω to
Resistance Between J2 (female) (56) and (32)
382 kΩ
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Insert T-adapter into connector J2.
4
harness 3. Turn the starting switch to ON position.
Voltage Between J2 (56) and (32) Max. 4.96 V
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to ambient air temperature sensor

40-270 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA256]

FAILURE CODE [CA256] (ALL-K-AFKE-410-10-B)

Action level Failure code Ambient Air Temp Sensor Low Error
Failure
L01 CA256 (Engine controller system)
Detail of fail-
Low voltage occurs in signal circuit of ambient temperature sensor.
ure
• Operates substituting the ambient temperature with the intake temperature.
Action of (If there are any abnormalities in the intake air temperature sensor, operates with the am-
controller bient temperature set to the default value (25 °C))
• Advances to Inducement strategy. (EU Specification)
• AdBlue/DEF line stops thawing.
Phenomenon • The NOx emission increases because the AdBlue/DEF injection becomes improper, or the
on machine AdBlue/DEF line cannot be thawed at low temperature.
• Engine power deration according to inducement strategy. (EU Specification)
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check them.
1
connector 2. Turn the starting switch to ON position.
If this failure code is not displayed, the wiring harness connector is defective.
1. Turn the starting switch to OFF position.
2. Disconnect connector P65 and connect socket to male side.
REMARK
If a resistance value of the ambient temperature sensor ranges from 280 Ω to
382 kΩ, the ambient temperature sensor is considered to be normal.
291 to
-40 °C
382 kΩ
85 to
-20 °C
109 kΩ
0 °C 29 to 36 kΩ
7.3 to
Defective ambient tem- Between P65 (male) (A) 30 °C
2 8.8 kΩ
perature sensor Resistance and (B)
2.3 to
60 °C
2.7 kΩ
860 to
90 °C
970 Ω
280 to
130 °C
320 Ω
Between P65 (male) (B) and ground Min. 100 kΩ
1. Turn the starting switch to OFF position.
2. Disconnect connectors J2 and P65 and connect T-adapter to female side
of J2.
Resistance Between J2 (female) (56) and ground Min. 100 kΩ

HB365LC-3 40-271
FAILURE CODE [CA256] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector J2, and connect the T-adapter to female side.
REMARK
Open or short circuit in
3 Use charge temperature sensor resistance characteristics table for check on
wiring harness
cause 2 as resistance criteria.
280 Ω to
Resistance Between J2 (female) (56) and (32)
382 kΩ
1. Turn the starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors J2 and P65 and connect T-adapter to female side
4
harness of J2.
Resistance Between J2 (female) (56) and ground Min. 100 kΩ
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to ambient air temperature sensor

40-272 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA271]

FAILURE CODE [CA271] (ALL-K-AD81-410-02-B)

Action level Failure code IMV or PCV 1 short circuit

Failure
L03 CA271 (Engine controller system)
Detail of fail-
Short circuit is detected in supply pump actuator (IMV) drive circuit.
ure
Action of • Engine power deration.
controller • Closes EGR valve.
• Engine speed does not increase from low idle speed.
Phenomenon • Engine output is reduced.
on machine • Engine startability becomes poor.
• Common rail fuel pressure is higher than the command value.
• While engine is running normally, approximately 24 V of pulse voltage is supplied to IMV.
Because it is pulse voltage, it cannot be measured by using multimeter.
Related • After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Start the engine.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared. (This deration is not canceled by simply failure code being cleared.)

No. Cause Procedure, measuring location, criteria and remarks

1. Check according to sections related to wiring harnesses and connectors in
“TROUBLESHOOTING-RELATED INFORMATION”, “CHECKS BEFORE
Defective wiring harness TROUBLESHOOTING”, “c Electrical equipment”.
1
connector 2. Start engine.
If this failure code goes out, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector INLET METERING VALVE, and connect socket to
Defective supply pump male side.
2 PCV1 (internal short cir-
cuit) Resistance Between INLET METERING VALVE (male) (1) and (2) 2.3 to 5.3 Ω
Between INLET METERING VALVE (male) (1) and
Resistance Min. 100 kΩ
ground
1. Turn starting switch to OFF position.
Short circuit in wiring har- 2. Disconnect connector ECM J1, and connect T-adapter to female side.
3
ness
Between ECM J1 (female) (10) and (11) (INLET ME-
Resistance 2.3 to 5.3 Ω
TERING VALVE resistance)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and INLET METERING VALVE, and con-
Ground fault in wiring
4 harness (contact with nect T-adapter to female side of ECM J1.
ground circuit) Between ECM J1 (female) (10) and ground Min. 100 kΩ
Resistance
Between ECM J1 (female) (11) and ground Min. 100 kΩ
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Insert T-adapter into connector ECM J1.
5
harness 3. Turn starting switch to ON position.
Voltage Between ECM J1 (10) and ground Max. 1 V
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-273
FAILURE CODE [CA271] 40 TROUBLESHOOTING

Circuit diagram related to IMV/PCV1

40-274 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA272]

FAILURE CODE [CA272] (ALL-K-AD81-410-11-B)

Action level Failure code IMV or PCV 1 open circuit

Failure
L03 CA272 (Engine controller system)
Detail of fail-
Open circuit is detected in supply pump actuator (IMV) drive circuit.
ure
Action of • Engine power deration.
controller • Closes EGR valve.
• Engine output is reduced.
Phenomenon • Engine startability becomes poor.
on machine • Engine does not run stably.
• Common rail fuel pressure is higher than the command value.
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Start the engine.
• While engine is running normally, approximately 24 V of pulse voltage is supplied to IMV.
Because it is pulse voltage, it cannot be measured by using multimeter.
Related
• Because female connector alone is provided in “Socket” for troubleshooting for this sen-
information
sor, socket cannot be connected to female connector on wiring harness side of sensor,
and check for wire breakage cannot be performed (T-adapter is not provided).
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared. (This deration is not canceled by simply failure code being cleared.)

No. Cause Procedure, measuring location, criteria and remarks

1. Check according to sections related to wiring harnesses and connectors in
“TROUBLESHOOTING-RELATED INFORMATION”, “CHECKS BEFORE
Defective wiring harness TROUBLESHOOTING”, “c Electrical equipment”.
1
connector 2. Start engine.
If this failure code goes out, wiring harness connector is defective.
1. Turn starting switch to OFF position.
Defective supply pump 2. Disconnect connector INLET METERING VALVE, and connect socket to
2 PCV1 (internal short cir-
male side.
cuit)
Resistance Between INLET METERING VALVE (male) (1) and (2) 2.3 to 5.3 Ω
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connector ECM J1, and connect T-adapter to female side.
3
wiring harness
Between ECM J1 (female) (10) and (11) (INLET ME-
Resistance 2.3 to 5.3 Ω
TERING VALVE resistance)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-275
FAILURE CODE [CA272] 40 TROUBLESHOOTING

Circuit diagram related to IMV/PCV1

40-276 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA281]

FAILURE CODE [CA281] (ALL-K-AD70-410-00-B)

Action level Failure code Supply Pump Pressure Balance Error

Failure
L03 CA281 (Engine controller system)
Details of
Response of fuel force feed is poor due to high pressure pump mechanical system error.
failure
Action of
None in particular
controller
Phenomenon • Engine does not start. Engine runs but its speed does not stabilize.
on machine • The pressure of high-pressure fuel differs between front and rear side of supply pump.
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

Bleed air from the fuel circuit. For detail, see Testing and adjusting,“Bleeding air
1 Mixing of air in fuel circuit
from fuel circuit”.
1. Check according to sections related to wiring harnesses and connectors in
“TROUBLESHOOTING-RELATED INFORMATION”, “CHECKS BEFORE
Defective wiring harness TROUBLESHOOTING”, “c Electrical equipment”.
2
connector 2. Start engine.
If this failure code goes out, wiring harness connector is defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-277
FAILURE CODE [CA322] 40 TROUBLESHOOTING

FAILURE CODE [CA322] (ALL-K-AE81-410-00-B)

Action level Failure code Injector #1 (L#1) Open Circuit Error or Short Circuit Error (Engine
Failure
L03 CA322 controller system)

Details of
Open or short circuit is detected in #1 injector circuit.
failure
Action of
None in particular
controller
Phenomenon • Engine power deration
on machine • Engine does not run stably.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.
Related • While engine is running normally, approximately 65 V of pulse voltage is supplied to injec-
information tor (+) side. Because it is pulse voltage, it cannot be measured by using multimeter.
• If ground fault or hot short circuit is detected, failure codes [CA322], [CA331] and [CA324]
appear simultaneously.

No. Cause Procedure, measuring location, criteria and remarks

1. See “RELATED INFORMATION ON TROUBLESHOOTING”, “CHECKS
BEFORE TROUBLESHOOTING”, “Electrical equipment”, and check them
Defective wiring harness according to the descriptions of wiring harness and connectors.
1
connector 2. Start the engine.
If this failure code is not displayed, the wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 1 & 2, and connect T-adapter to
2 Defective injector #1 male side.
Between INJECTOR CYL 1 & 2 (male) (3) and (4) Max. 2 Ω
Resistance
Between INJECTOR CYL 1 & 2 (male) (3) and ground Min. 100 kΩ
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1, and connect T-adapter to female side.
Open circuit or ground
3
fault in wiring harness Between ECM J1 (female) (25) and (1) Max. 2 Ω
Resistance
Between ECM J1 (female) (25) and ground Min. 100 kΩ
If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and connect
ness (wire breakage or T-adapter to each female side.
4
defective contact of con-
nector) Between ECM J1 (female) (25) and INJECTOR CYL 1
Max. 2 Ω
& 2 (female) (3)
Resistance
Between ECM J1 (female) (1) and INJECTOR CYL 1 &
Max. 2 Ω
2 (female) (4)

40-278 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA322]

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.

Ground fault in wiring
5 harness (contact with
ground circuit)
2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and connect
T-adapter to each female side.
Between ground and ECM J1 (female) (25) or INJEC-
Min. 100 kΩ
TOR CYL 1 & 2 (female) (3)
Resistance
Between ground and ECM J1 (female) (1) or INJEC-
Min. 100 kΩ
TOR CYL 1 & 2 (female) (4)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and connect
T-adapter to female side of ECM J1.

Short circuit in wiring har- No continui-

6 Between ECM J1 (female) (25) and each pin other
ness ty (no sound
than pin (25)
is heard)
Continuity
No continui-
Between ECM J1 (female) (1) and each pin other than
ty (no sound
pin (1)
is heard)
1. Turn starting switch to OFF position.
2. Insert T-adapter to connector ECM J1.
3. Turn starting switch to ON position.
Hot short circuit in wiring Voltage Between ECM J1 (25) and ground Max. 6 V
7
harness
If measured voltage is abnormal, disconnect connector INJECTOR CYL 1 & 2 and
measure the voltage at the same point again.
If the abnormality persists, a positive (+) line is defective.
If the voltage is restored back to a normal range, a negative (-) line is defective.
Defective another cylin- When failure code for abnormality in multiple injectors is displayed, perform trouble-
8 der's injector or wiring shooting these first.
harness
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
9
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to injector #1

HB365LC-3 40-279
FAILURE CODE [CA323] 40 TROUBLESHOOTING

FAILURE CODE [CA323] (ALL-K-AE84-410-00-B)

Action level Failure code Injector #5 (L#5) Open Circuit Error or Short Circuit Error (Engine
Failure
L03 CA323 controller system)

Details of
Open or short circuit is detected in #5 injector circuit.
failure
Action of
None in particular
controller
Phenomenon • Engine power deration
on machine • Engine does not run stably.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.
Related • If ground fault or hot short circuit is detected, failure codes [CA323], [CA325] and [CA332]
information appear simultaneously.
• While engine is running normally, approximately 65 V of pulse voltage is supplied to injec-
tor (+) side. Because it is pulse voltage, it cannot be measured by using multimeter.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Start the engine.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 5 & 6, and connect T-adapter to
2 Defective injector #5 male side.
Between INJECTOR CYL 5 & 6 (male) (3) and (4) Max. 2 Ω
Resistance
Between INJECTOR CYL 5 & 6 (male) (3) and ground Min. 100 kΩ
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1, and connect T-adapter to female side.
Open circuit or ground
3
fault in wiring harness Between ECM J1 (female) (50) and (74) Max. 2 Ω
Resistance
Between ECM J1 (female) (50) and ground Min. 100 kΩ
If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors ECM J1 and INJECTOR CYL 5 & 6, and connect
ness (wire breakage or T-adapter to each female side.
4
defective contact of con-
nector) Between ECM J1 (female) (50) and INJECTOR CYL 5
Max. 2 Ω
& 6 (female) (3)
Resistance
Between ECM J1 (female) (74) and INJECTOR CYL 5
Max. 2 Ω
& 6 (female) (4)

40-280 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA323]

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.

Ground fault in wiring
5 harness (contact with
ground circuit)
2. Disconnect connectors ECM J1 and INJECTOR CYL 5 & 6, and connect
T-adapter to each female side.
Between ground and ECM J1 (female) (50) or INJEC-
Min. 100 kΩ
TOR CYL 5 & 6 (female) (3)
Resistance
Between ground and ECM J1 (female) (74) or INJEC-
Min. 100 kΩ
TOR CYL 5 & 6 (female) (4)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and INJECTOR CYL 5 & 6, and connect
T-adapter to female side of ECM J1.

Short circuit in wiring har- No continui-

6 Between ECM J1 (female) (50) and each pin other
ness ty (no sound
than pin (50)
is heard)
Continuity
No continui-
Between ECM J1 (female) (74) and each pin other
ty (no sound
than pin (74)
is heard)
1. Turn starting switch to OFF position.
2. Insert T-adapter to connector ECM J1.
3. Turn starting switch to ON position.
Hot short circuit in wiring Voltage Between ECM J1 (50) and ground Max. 6 V
7
harness
If measured voltage is abnormal, disconnect connector INJECTOR CYL 5 & 6 and
measure the voltage at the same point again.
If the abnormality persists, a positive (+) line is defective.
If the voltage is restored back to a normal range, a negative (-) line is defective.
Defective another cylin- When failure code for abnormality in multiple injectors is displayed, perform trouble-
8 der's injector or wiring shooting these first.
harness
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
9
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to injector #5

HB365LC-3 40-281
FAILURE CODE [CA324] 40 TROUBLESHOOTING

FAILURE CODE [CA324] (ALL-K-AE87-410-00-B)

Action level Failure code Injector #3 (L#3) Open Circuit Error or Short Circuit Error (Engine
Failure
L03 CA324 controller system)

Details of
Open or short circuit is detected in #3 injector circuit.
failure
Action of
None in particular
controller
Phenomenon • Engine power deration
on machine • Engine does not run stably.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine
Related • If ground fault or hot short circuit is detected, failure codes [CA322], [CA331] and [CA324]
information appear simultaneously.
• While engine is running normally, approximately 65 V of pulse voltage is supplied to injec-
tor (+) side. Because it is pulse voltage, it cannot be measured by using multimeter.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “c: Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Start the engine.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 3 & 4, and connect T-adapter to
2 Defective injector #3 male side.
Between INJECTOR CYL 3 & 4 (male) (3) and (4) Max. 2 Ω
Resistance
Between INJECTOR CYL 3 & 4 (male) (3) and ground Min. 100 kΩ
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1, and connect T-adapter to female side.
Open circuit or ground
3
fault in wiring harness Between ECM J1 (female) (27) and (3) Max. 2 Ω
Resistance
Between ECM J1 (female) (27) and ground Min. 100 kΩ
If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors ECM J1 and INJECTOR CYL 3 & 4, and connect
ness (wire breakage or T-adapter to each female side.
4
defective contact of con-
nector) Between ECM J1 (female) (27) and INJECTOR CYL 3
Max. 2 Ω
& 4 (female) (3)
Resistance
Between ECM J1 (female) (3) and INJECTOR CYL 3 &
Max. 2 Ω
4 (female) (4)

40-282 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA324]

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.

Ground fault in wiring
5 harness (contact with
ground circuit)
2. Disconnect connectors ECM J1 and INJECTOR CYL 3 & 4, and connect
T-adapter to either female side.
Between ground and ECM J1 (female) (27) or INJEC-
Min. 100 kΩ
TOR CYL 3 & 4 (female) (3)
Resistance
Between ground and ECM J1 (female) (3) or INJEC-
Min. 100 kΩ
TOR CYL 3 & 4 (female) (4)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and INJECTOR CYL 3 & 4, and connect
T-adapter to female side of ECM J1.

Short circuit in wiring har- No continui-

6 Between ECM J1 (female) (27) and each pin other
ness ty (no sound
than pin (27)
is heard)
Continuity
No continui-
Between ECM J1 (female) (3) and each pin other than
ty (no sound
pin (3)
is heard)
1. Turn starting switch to OFF position.
2. Insert T-adapter to connector ECM J1.
3. Turn starting switch to ON position.
Hot short circuit in wiring Voltage Between ECM J1 (27) and ground Max. 6 V
7
harness
If measured voltage is abnormal, disconnect connector INJECTOR CYL 3 & 4 and
measure the voltage at the same point again.
If the abnormality persists, a positive (+) line is defective.
If the voltage is restored back to a normal range, a negative (-) line is defective.
Defective another cylin- When failure code for abnormality in multiple injectors is displayed, perform trouble-
8 der's injector or wiring shooting these first.
harness
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
9
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to injector #3

HB365LC-3 40-283
FAILURE CODE [CA325] 40 TROUBLESHOOTING

FAILURE CODE [CA325] (ALL-K-AE8A-410-00-B)

Action level Failure code Injector #6 (L#6) Open Circuit Error or Short Circuit Error (Engine
Failure
L03 CA325 controller system)

Details of
Open or short circuit is detected in #6 injector circuit.
failure
Action of
None in particular
controller
Phenomenon • Engine power deration
on machine • Engine does not run stably.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.
Related • If ground fault or hot short circuit is detected, failure codes [CA323], [CA325] and [CA332]
information appear simultaneously.
• While engine is running normally, approximately 65 V of pulse voltage is supplied to injec-
tor (+) side. Because it is pulse voltage, it cannot be measured by using multimeter.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Start the engine.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 5 & 6, and connect T-adapter to
2 Defective injector #6 male side.
Between INJECTOR CYL 5 & 6 (male) (1) and (2) Max. 2 Ω
Resistance
Between INJECTOR CYL 5 & 6 (male) (1) and ground Min. 100 kΩ
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1, and connect T-adapter to female side.
Open circuit or ground
3
fault in wiring harness Between ECM J1 (female) (51) and (75) Max. 2 Ω
Resistance
Between ECM J1 (female) (51) and ground Min. 100 kΩ
If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors ECM J1 and INJECTOR CYL 5 & 6, and connect
ness (wire breakage or T-adapter to each female side.
4
defective contact of con-
nector) Between ECM J1 (female) (51) and INJECTOR CYL 5
Max. 2 Ω
& 6 (female) (2)
Resistance
Between ECM J1 (female) (75) and INJECTOR CYL 5
Max. 2 Ω
& 6 (female) (1)

40-284 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA325]

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.

Ground fault in wiring
5 harness (contact with
ground circuit)
2. Disconnect connectors ECM J1 and INJECTOR CYL 5 & 6, and connect
T-adapter to either female side.
Between ground and ECM J1 (female) (51) or INJEC-
Min. 100 kΩ
TOR CYL 5 & 6 (female) (2)
Resistance
Between ground and ECM J1 (female) (75) or INJEC-
Min. 100 kΩ
TOR CYL 5 & 6 (female) (1)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and INJECTOR CYL 5 & 6, and connect
T-adapter to female side of ECM J1.

Short circuit in wiring har- No continui-

6 Between ECM J1 (female) (51) and each pin other
ness ty (no sound
than pin (51)
is heard)
Continuity
No continui-
Between ECM J1 (female) (75) and each pin other
ty (no sound
than pin (75)
is heard)
1. Turn starting switch to OFF position.
2. Insert T-adapter to connector ECM J1.
3. Turn starting switch to ON position.
Hot short circuit in wiring Voltage Between ECM J1 (51) and ground Max. 6 V
7
harness
If measured voltage is abnormal, disconnect connector INJECTOR CYL 5 & 6 and
measure the voltage at the same point again.
If the abnormality persists, a positive (+) line is defective.
If the voltage is restored back to a normal range, a negative (-) line is defective.
Defective another cylin- When failure code for abnormality in multiple injectors is displayed, perform trouble-
8 der's injector or wiring shooting these first.
harness
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
9
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to injector #6

HB365LC-3 40-285
FAILURE CODE [CA331] 40 TROUBLESHOOTING

FAILURE CODE [CA331] (ALL-K-AE8D-410-00-B)

Action level Failure code Injector #2 (L#2) Open Circuit Error or Short Circuit Error (Engine
Failure
L03 CA331 controller system)

Details of
Open or short circuit is detected in #2 injector circuit.
failure
Action of
None in particular
controller
Phenomenon • Engine power deration
on machine • Engine does not run stably.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.
Related • If ground fault or hot short circuit is detected, failure codes [CA322], [CA331] and [CA324]
information appear simultaneously.
• While engine is running normally, approximately 65 V of pulse voltage is supplied to injec-
tor (+) side. Because it is pulse voltage, it cannot be measured by using multimeter.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “c: Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Start the engine.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 1 & 2, and connect T-adapter to
2 Defective injector #2 male side.
Between INJECTOR CYL 1 & 2 (male) (1) and (2) Max. 2 Ω
Resistance
Between INJECTOR CYL 1 & 2 (male) (1) and ground Min. 100 kΩ
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1, and connect T-adapter to female side.
Open circuit or ground
3
fault in wiring harness Between ECM J1 (female) (26) and (2) Max. 2 Ω
Resistance
Between ECM J1 (female) (26) and ground Min. 100 kΩ
If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and connect
ness (wire breakage or T-adapter to each female side.
4
defective contact of con-
nector) Between ECM J1 (female) (26) and INJECTOR CYL 1
Max. 2 Ω
& 2 (female) (2)
Resistance
Between ECM J1 (female) (2) and INJECTOR CYL 1 &
Max. 2 Ω
2 (female) (1)

40-286 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA331]

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.

Ground fault in wiring
5 harness (contact with
ground circuit)
2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and connect
T-adapter to either female side.
Between ground and ECM J1 (female) (26) or INJEC-
Min. 100 kΩ
TOR CYL 1 & 2 (female) (1)
Resistance
Between ground and ECM J1 (female) (2) or INJEC-
Min. 100 kΩ
TOR CYL 1 & 2 (female) (2)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and INJECTOR CYL 1 & 2, and connect
T-adapter to female side of ECM J1.

Short circuit in wiring har- No continui-

6 Between ECM J1 (female) (26) and each pin other
ness ty (no sound
than pin (26)
is heard)
Continuity
No continui-
Between ECM J1 (female) (2) and each pin other than
ty (no sound
pin (2)
is heard)
1. Turn starting switch to OFF position.
2. Insert T-adapter to connector ECM J1.
3. Turn starting switch to ON position.
Hot short circuit in wiring Voltage Between ECM J1 (26) and ground Max. 6 V
7
harness
If measured voltage is abnormal, disconnect connector INJECTOR CYL 1 & 2 and
measure the voltage at the same point again.
If the abnormality persists, a positive (+) line is defective.
If the voltage is restored back to a normal range, a negative (-) line is defective.
Defective another cylin- When failure code for abnormality in multiple injectors is displayed, perform trouble-
8 der's injector or wiring shooting these first.
harness
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
9
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to injector #2

HB365LC-3 40-287
FAILURE CODE [CA332] 40 TROUBLESHOOTING

FAILURE CODE [CA332] (ALL-K-AE8G-410-00-B)

Action level Failure code Injector #4 (L#4) Open Circuit Error or Short Circuit Error (Engine
Failure
L03 CA332 controller system)

Details of
Open or short circuit is detected in #4 injector circuit.
failure
Action of
None in particular
controller
Phenomenon • Engine power deration
on machine • Engine does not run stably.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.
Related • While engine is running normally, approximately 65 V of pulse voltage is supplied to injec-
information tor (+) side. Because it is pulse voltage, it cannot be measured by using multimeter.
• If ground fault or hot short circuit is detected, failure codes [CA323], [CA325] and [CA332]
appear simultaneously.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “c: Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Start the engine.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector INJECTOR CYL 3 & 4, and connect T-adapter to
2 Defective injector #4 male side.
Between INJECTOR CYL 3 & 4 (male) (1) and (2) Max. 2 Ω
Resistance
Between INJECTOR CYL 3 & 4 (male) (1) and ground Min. 100 kΩ
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1, and connect T-adapter to female side.
Open circuit or ground
3
fault in wiring harness Between ECM J1 (female) (49) and (73) Max. 2 Ω
Resistance
Between ECM J1 (female) (49) and ground Min. 100 kΩ
If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors ECM J1 and INJECTOR CYL 3 & 4, and connect
ness (wire breakage or T-adapter to each female side.
4
defective contact of con-
nector) Between ECM J1 (female) (49) and INJECTOR CYL 3
Max. 2 Ω
& 4 (female) (2)
Resistance
Between ECM J1 (female) (73) and INJECTOR CYL 3
Max. 2 Ω
& 4 (female) (1)

40-288 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA332]

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.

Ground fault in wiring
5 harness (contact with
ground circuit)
2. Disconnect connectors ECM J1 and INJECTOR CYL 3 & 4, and connect
T-adapter to either female side.
Between ground and ECM J1 (female) (49) or INJEC-
Min. 100 kΩ
TOR CYL 3 & 4 (female) (1)
Resistance
Between ground and ECM J1 (female) (73) or INJEC-
Min. 100 kΩ
TOR CYL 3 & 4 (female) (2)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and INJECTOR CYL 3 & 4, and connect
T-adapter to female side of ECM J1.

Short circuit in wiring har- No continui-

6 Between ECM J1 (female) (49) and each pin other
ness ty (no sound
than pin (49)
is heard)
Continuity
No continui-
Between ECM J1 (female) (73) and each pin other
ty (no sound
than pin (73)
is heard)
1. Turn starting switch to OFF position.
2. Insert T-adapter to connector ECM J1.
3. Turn starting switch to ON position.
Hot short circuit in wiring Voltage Between ECM J1 (49) and ground Max. 6 V
7
harness
If measured voltage is abnormal, disconnect connector INJECTOR CYL 3 & 4 and
measure the voltage at the same point again.
If the abnormality persists, a positive (+) line is defective.
If the voltage is restored back to a normal range, a negative (-) line is defective.
Defective another cylin- When failure code for abnormality in multiple injectors is displayed, perform trouble-
8 der's injector or wiring shooting these first.
harness
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
9
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to injector #4

HB365LC-3 40-289
FAILURE CODE [CA343] 40 TROUBLESHOOTING

FAILURE CODE [CA343] (ALL-K-AP70-410-00-B)

Action level Failure code

Failure Engine Controller Internal Failure (Engine controller system)
L04 CA343
Details of
Internal defect is detected in engine controller.
failure
Action of
None in particular
controller
Phenomenon Engine runs normally. However, engine may be stopped during operation or stopped engine may
on machine not be started.

• Battery voltage of engine controller can be checked by monitoring function. (Code: 03203)
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective engine control- Perform troubleshooting for failure code [CA441].
1
ler system

40-290 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA351]

FAILURE CODE [CA351] (ALL-K-AP50-410-00-B)

Action level Failure code

Failure Injectors Drive Circuit Error (Engine controller system)
L03 CA351
Details of
Error occurs in injector drive circuit
failure
Action of
Restricts engine output for operation (restricts common rail pressure).
controller
Phenomenon
Engine power deration
on machine
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective relevant sys- If other failure codes (for injector system) are also displayed, perform troubleshoot-
1
tem ing for them.
Defective engine control- Perform troubleshooting for failure code [CA441].
2
ler system

HB365LC-3 40-291
FAILURE CODE [CA352] 40 TROUBLESHOOTING

FAILURE CODE [CA352] (ALL-K-AAQ9-410-00-B)

Action level Failure code

Failure Sensor 1 Supply Voltage Low Error (Engine controller system)
L03 CA352
Details of
Low voltage occurs in sensor power supply 1 (5 V) circuit.
failure
• Ignores signal from Bkup speed sensor, and operates by NE speed sensor signal.
• Ignores signal from ambient pressure sensor, and fixes ambient pressure value to
(52.44 kPa {0.53 kg/cm2} ) for operation.
• Ignores signal from charge (boost) pressure sensor, and fixes charge (boost) pressure val-
Action of ue to (400 kPa {4.1 kg/cm2} ) for operation.
controller • Ignores signal from crankcase pressure sensor, and fixes crankcase pressure value to
(0 kPa {0 kg/cm2} ) for operation.
• EGR valve closes and fully opens VGT.
• Engine power deration
• Regeneration control stops.
Phenomenon
Engine power deration
on machine
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
Related
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
information
ure code is cleared (note the engine power deration is not canceled right after the failure
code is cleared).

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “c: Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.

40-292 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA352]

No. Cause Procedure, measuring location, criteria and remarks

1. Starting switch: OFF
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. Each time troubleshooting is finished, return to step 1.
If this failure code is cleared, disconnected sensor or engine wiring harness is de-
fective.
REMARK
Other failure codes are also displayed. This is because connector is discon-
nected. Ignore all failure codes except for [CA352].
Defective sensor or wir-
2 CAM SEN-
ing harness Bkup speed sensor
SOR
BOOST
PRESS &
Charge (Boost) pressure sensor
TEMPERA-
Connector TURE
AMB.AIR
Ambient pressure sensor
PRESSURE
Crank case pressure sensor P57
Engine wiring harness ECM J1
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1, and connect T-adapter to male side.
3. Turn starting switch ON with connector ECM J1 disconnected.
4. If no failure is found by this check, perform troubleshooting again from
Defective engine control-
3 cause 1 before replacing the engine controller.
ler
4.75 to
Voltage Between ECM J1 (male) (78) and (54)
5.25 V
If no failure is found by above checks, engine controller is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-293
FAILURE CODE [CA352] 40 TROUBLESHOOTING

Circuit diagram related to sensor 1 supply circuit

40-294 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA356]

FAILURE CODE [CA356] (ALL-K-A96G-410-00-B)

Action level Failure code

Failure MAF Sensor High Error (Engine controller system)
L03 CA356
Details of
High frequency input error is detected in signal circuit of mass air flow sensor.
failure
• Sets mass air flow to fixed value (10 kg/min) for operation.
Action of • EGR valve closed.
controller • Engine power deration
• Regeneration control stops.
Phenomenon
Engine power deration
on machine
• Because sensor output is approximately 5 V of pulse waveform, it is not measured by us-
ing multimeter.
• Mass air flow sensor and intake air temperature sensor are provided as a unit.
Related • After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note the engine power deration is not canceled right after the failure
code is cleared).

No. Cause Procedure, measuring location, criteria and remarks

1. Perform checkup referring to descriptions of wiring harness and connec-
tors in “c Electric equipment ”of “CHECKS BEFORE TROUBLESHOOT-
Defective wiring harness ING” in “RELATED INFORMATION ON TROUBLESHOOTING”.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector P55.
Defective mass air flow
2 3. Turn starting switch to ON position.
sensor (internal defect)
If this failure code changes to failure code [CA357], mass air flow sensor is defec-
tive.
Defective sensor power If failure code [CA3419] or [CA3421] are displayed at the same time, perform trou-
3
supply system bleshooting these first.
1. Perform preparation when starting switch is in OFF position.
2. Disconnect connector P55 and connect T-adapter to female side.
Defective sensor power
4 3. Turn starting switch to ON position.
supply system
Between P55 (female) (2) Approx.
Voltage Power supply
and (3) 12 V

HB365LC-3 40-295
FAILURE CODE [CA356] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks on cause 4, this check is not re-
quired.
1. Turn the starting switch to OFF position.
Open circuit in wiring har-
2. Disconnect connectors ECM J1 and P55, and connect T-adapters to each
ness (wire breakage of
5 female side.
ground line or defective
contact of connector) REMARK
Open circuit in GND line
Resistance Between ECM J1 (female) (56) and P55 (female) (3) Max. 10 Ω
1. Starting switch: OFF
2. Disconnect connectors ECM J1 and P55, and connect T-adapter to female
Short circuit in wiring har- side of ECM J1.
6
ness Check by using multimeter in continuity mode.
Between ECM J1 (female) (32) and each pin other No continui-
Continuity
than (32) pin. ty
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)

CIRCUIT DIAGRAM (MASS AIR FLOW SENSOR)

40-296 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA357]

FAILURE CODE [CA357] (ALL-K-A96G-410-10-B)

Action level Failure code

Failure Mass Air Flow Sensor Low Error (Engine controller system)
L03 CA357
Details of
Low frequency input error is detected in signal circuit of mass air flow sensor.
failure
• Sets mass air flow sensor to fixed value (10 kg/min) for operation.
Action of • EGR valve closed.
controller • Engine power deration
• Regeneration control stops.
Phenomenon
Engine power deration
on machine
• Because sensor output is approximately. 5 V of pulse waveform, it is not measured by us-
ing multimeter.
• Mass air flow sensor and intake air temperature sensor are provided as a unit.
• This failure code and failure code [CA691] are displayed simultaneously if sensor connec-
Related tor is removed.
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note the engine power deration is not canceled right after the failure
code is cleared).

No. Cause Procedure, measuring location, criteria and remarks

1. Perform checkup referring to descriptions of wiring harness and connec-
tors in “c Electric equipment ”of “CHECKS BEFORE TROUBLESHOOT-
Defective wiring harness ING” in “RELATED INFORMATION ON TROUBLESHOOTING”.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
Defective sensor power If failure code [CA3419] or [CA3421] are displayed at the same time, perform trou-
2
supply system bleshooting these first.
1. Turn starting switch to OFF position.
Defective mass air flow 2. Replace mass air flow sensor.
3
sensor (internal defect) 3. Turn starting switch to ON position.
If this failure code is cleared, originally-provided mass air flow sensor is defective.
1. Perform preparation when starting switch is in OFF position.
2. Disconnect connector P55 and connect T-adapter to female side.
Defective sensor power
4 3. Turn starting switch to ON position.
supply system
Between P55 (female) (2) Approx.
Voltage Power supply
and (3) 12 V

HB365LC-3 40-297
FAILURE CODE [CA357] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Starting switch: OFF
2. Disconnect connectors ECM J1 and P55, and connect T-adapter to either
female side.

Open circuit in wiring har- If failure code is still displayed after above checks on
ness (wire breakage or cause 4, this check is not required. Max. 10 Ω
5
defective contact of con- Between ECM J1 (female) (80) and P55 (female) (2)
nector)
Resistance If failure code is still displayed after above checks on
cause 4, this check is not required. Max. 10 Ω
Between ECM J1 (female) (56) and P55 (female) (3)
Between ECM J1 (female) (32) and P55 (female) (1) Max. 10 Ω
1. Starting switch: OFF
Ground fault in wiring 2. Disconnect connectors ECM J1 and P55, and connect T-adapter to either
6 harness (contact with female side.
ground circuit)
Between ground and ECM J1 (female) (32) or P55 (fe-
Resistance Min. 100 kΩ
male) (1)
1. Starting switch: OFF
2. Disconnect connectors ECM J1 and P55, and connect T-adapter to female
Short circuit in wiring har- side of ECM J1.
7
ness Check by using multimeter in continuity mode.
Between ECM J1 (female) (32) and each pin other No continui-
Continuity
than (32) pin. ty
1. Perform preparation when starting switch is in OFF position.
Hot short circuit in wiring 2. Disconnect connector P55 and connect T-adapter to female side.
8
harness 3. Turn starting switch to ON position.
Voltage Between P55 (female) (1) and (3) Max. 1 V
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
9
ler an internal defect, troubleshooting cannot be performed.)

CIRCUIT DIAGRAM (MASS AIR FLOW SENSOR)

40-298 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA386]

FAILURE CODE [CA386] (ALL-K-AAQ9-410-10-B)

Action level Failure code

Failure Sensor 1 Supply Voltage High Error (Engine controller system)
L03 CA386
Details of
High voltage occurs in sensor power supply 1 (5 V) circuit.
failure
• Ignores signal from Bkup speed sensor, and operates by NE speed sensor signal.
• Ignores signal from ambient pressure sensor, and fixes ambient pressure value to
(52.44 kPa {0.53 kg/cm2} ) for operation.
• Ignores signal from charge (boost) pressure sensor, and fixes charge (boost) pressure val-
Action of ue to (400 kPa {4.1 kg/cm2} ) for operation.
controller • Ignores signal from crankcase pressure sensor, and fixes crankcase pressure value to
(0 kPa {0 kg/cm2} ) for operation.
• EGR valve closed.
• Engine power deration
• Regeneration control stops.
Phenomenon
Engine power deration
on machine
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
Related
• Engine power deration is canceled by turning starting switch to OFF position after this the
information
failure code is cleared (note that the engine power deration is not canceled right after the
failure code is cleared).

No. Cause Procedure, measuring location, criteria and remarks

Defective sensor 1 sup- Perform troubleshooting for failure code [CA352].
1
ply system

HB365LC-3 40-299
FAILURE CODE [CA428] 40 TROUBLESHOOTING

FAILURE CODE [CA428] (ALL-K-AEB5-410-00-B)

Action level Failure code Water in Fuel Sensor High Error

Failure
L01 CA428 (Engine Controller System)
Detail of fail-
High voltage is detected in signal circuit of water-in-fuel sensor installed to fuel prefilter.
ure
Action of
None in particular
controller
Phenomenon
Water separator monitor is not displayed properly
on machine
• State (ON/OFF) of water-in-fuel sensor signal can be checked with monitoring function.
Related (Code: 18800 State of WIF sensor)
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “c: Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
FORMATION ON TROUBLESHOOTING”, and check it.
Defective wiring harness 2. Turn starting switch to ON position.
1
connector
If this failure code is cleared, wiring harness connector is defective.
REMARK
If this failure code is displayed, perform following.
1. Starting switch: OFF
2. Disconnect connector P47 and connect T-adapter to male side.
Defective water-in-fuel
REMARK
2 sensor installed to fuel
prefilter If water is in fuel prefilter, drain it.
10 to
Resistance Between P47 (male) (1) and (2)
100 kΩ
1. Turn starting switch to OFF position.
Short circuit or ground 2. Disconnect connector ECM J2 and connect T-adapter to female side.
3
fault in wiring harness
Between ECM J2 (female) (13) and (32) (Water sensor 10 to
Resistance
resistance) 100 kΩ

REMARK
If failure code is still displayed after above checks on cause 3, this check is not
required.
Open circuit in wiring har-
ness (wire breakage or 1. Perform preparation when starting switch is in OFF position.
4
defective contact of con- 2. Disconnect connectors ECM J2 and P47, and connect T-adapter to female
nector) side of ECM J2 and female side of P47.
Between ECM J2 (female) (13) and P47 (female) (2) Max. 10 Ω
Resistance
Between ECM J2 (female) (32) and P47 (female) (1) Max. 10 Ω

40-300 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA428]

No. Cause Procedure, measuring location, criteria and remarks

1. Starting switch: OFF
2. Disconnect connectors ECM J2 and P47, and connect T-adapter to female
Short circuit in wiring har- side of ECM J2.
5
ness
No continui-
Between ECM J2 (female) (13) and each pin other
Continuity ty (no
than pin (13)
sound)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to water-in-fuel sensor

HB365LC-3 40-301
FAILURE CODE [CA429] 40 TROUBLESHOOTING

FAILURE CODE [CA429] (ALL-K-AEB5-410-01-B)

Action level Failure code

Failure Water in Fuel Sensor Low Error (Engine Controller System)
L01 CA429
Detail of fail-
Low voltage is detected in signal circuit of water-in-fuel sensor installed to fuel prefilter.
ure
Action of
None in particular
controller
Phenomenon
Water separator monitor is not displayed properly
on machine
• State (ON/OFF) of water-in-fuel sensor signal can be checked with monitoring function.
Related (Code: 18800 State of WIF sensor)
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “c: Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
FORMATION ON TROUBLESHOOTING”, and check it.
Defective wiring harness 2. Turn starting switch to ON position.
1
connector
If this failure code is cleared, wiring harness connector is defective.
REMARK
If this failure code is displayed, perform following.
1. Starting switch: OFF
2. Disconnect connector P47 and connect T-adapter to male side.

Defective water-in-fuel REMARK

2 sensor installed to fuel If water is in fuel prefilter, drain it.
prefilter
10 to
Between P47 (male) (1) and (2)
Resistance 100 kΩ
Between P47 (male) (1) and ground Min. 100 kΩ
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J2 and connect T-adapter to female side of
Short circuit or ground connector.
3
fault in wiring harness Between ECM J2 (female) (13) and (32) (water-in-fuel 10 to
Resistance sensor resistance) 100 kΩ
Between ECM J2 (female) (13) and ground Min. 1 Ω
1. Starting switch: OFF
2. Disconnect connectors ECM J2 and P47, and connect T-adapter to female
Short circuit in wiring har- side of ECM J2.
4
ness
No continui-
Between ECM J2 (female) (13) and each pin other
Continuity ty (no
than pin (13)
sound)

40-302 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA429]

No. Cause Procedure, measuring location, criteria and remarks

REMARK
If failure code is still displayed after above checks on cause 3, this check is not
required.
Ground fault in wiring
1. Starting switch: OFF
5 harness (contact with
ground circuit) 2. Disconnect connectors ECM J2 and P47, and connect T-adapter to either
of female side of ECM J2 or female side of P47
Between ground and ECM J2 (female) (13) or P47 (fe-
Resistance Min. 100 kΩ
male) (2)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to water-in-fuel sensor

HB365LC-3 40-303
FAILURE CODE [CA435] 40 TROUBLESHOOTING

FAILURE CODE [CA435] (ALL-K-ABKC-410-00-B)

Action level Failure code Engine Oil Pressure SW Error

Failure
L01 CA435 (Engine controller system)
Details of
Failure occurs in engine oil pressure switch signal circuit.
failure
Action of
None in particular.
controller
Phenomenon • Protection function based on engine oil pressure does not work.
on machine • Engine oil pressure monitor is not displayed normally.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position or start engine.
• Engine oil pressure switch is in CLOSED (ON) when oil pressure is low (when engine is
stopped), but is in OPEN (OFF) when oil pressure is high (when engine is running).
• To generate this failure code, engine controller checks whether engine oil pressure switch
Related is in CLOSED (ON) only when engine is stopped, that is, whether signal voltage is zero or
information not.
• Failure of engine oil pressure switch when engine is running is indicated by failure code
[B@BAZG].
REMARK
When performing checking and replacement of engine oil pressure switch, open oil filler port,
and check that engine oil temperature cools down enough not to get scalded.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
FORMATION ON TROUBLESHOOTING”, and check it.
Defective harness con- 2. Turn starting switch to ON position.
1
nector
If this failure code is cleared, wiring harness connector is defective.
REMARK
If this failure code is displayed, perform following.
1. Turn starting switch to OFF position.
2. Disconnect connector OIL PRESSURE SWITCH and connect Tadapters to
Defective engine oil pres-
2 male side.
sure switch
Between OIL PRESSURE SWITCH (male) (1) and
Resistance Max. 10 Ω
ground
1. Turn starting switch to OFF position.
Open circuit or ground 2.
3 Disconnect connector ECM J1 and connect T-adapters to female side.
fault in wiring harness
Resistance Between ECM J1 (female) (52) and ground Max. 10 Ω
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

40-304 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA435]

Circuit diagram related to engine oil pressure switch

HB365LC-3 40-305
FAILURE CODE [CA441] 40 TROUBLESHOOTING

FAILURE CODE [CA441] (ALL-K-AP40-410-00-B)

Action level Failure code Power Voltage Low Error

Failure
L04 CA441 (Engine controller system)
Detail of fail-
Low voltage occurs in power supply circuit of controller.
ure
Action of
Operates at fixed value (approximately 6.0 V) of battery voltage.
controller
Phenomenon Engine runs normally. However, engine may be stopped during operation or stopped engine may
on machine not be started.

• Battery voltage of engine controller can be checked by monitoring function. (Code: 03203)
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn engine starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Loose or corroded bat- Battery terminal may be loose or corroded. Check it directly.
1
tery terminal

Loose terminal or partial 1. Turn starting switch to OFF position.

2
open circuit at terminal Check terminals of the alternator, battery, ground terminal (T12), etc.
1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
3
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Perform troubleshooting with starting switch at OFF position and when starting
4 Improper battery voltage engine.
Voltage Between battery (+) and (-). 20 to 30 V
1. Turn starting switch to OFF position.
5 Defective alternator 2. Start engine. (Engine speed: Medium or higher)
Voltage alternator terminal M18 and ground 26 to 30.5 V
If no failure is found by above checks, engine controller is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)
1. Turn starting switch to OFF position, and turn battery disconnect switch to
OFF position.
2. Insert T-adapter into connector ECM J2.
3. Turn battery disconnect switch to ON position.
Defective engine control- 4. Measure voltage with starting switch at OFF position and when starting en-
6
ler gine.
Between ECM J2 (1) and (73) 20 to 30 V
Between ECM J2 (25) and (49) 20 to 30 V
Voltage Between ECM J2 (26) and (50) 20 to 30 V
Between ECM J2 (27) and (51) 20 to 30 V
Between ECM J2 (28) and (52) 20 to 30 V

40-306 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA441]

CIRCUIT DIAGRAM (ENGINE CONTROLLER POWER SUPPLY)

HB365LC-3 40-307
FAILURE CODE [CA442] 40 TROUBLESHOOTING

FAILURE CODE [CA442] (ALL-K-AP40-410-10-B)

Action level Failure code Battery voltage high error

Failure
L04 CA442 (Engine controller system)
Detail of fail-
High voltage (Min. 36 V) occurs in power supply circuit of controller.
ure
Action of
Operates at fixed value (approximately 36 V) of battery voltage.
controller
Phenomenon Engine runs normally. However, engine may be stopped during operation or stopped engine may
on machine not be started.

• After repairing, check if the failure code is cleared by the following procedure.
Related
Procedure: Turn starting switch to ON position.
information
• Battery voltage of engine controller can be checked by monitoring function. (Code: 03203)

No. Cause Procedure, measuring location, criteria and remarks

Defective engine control- Perform troubleshooting for failure code [CA441].
1
ler power supply system

40-308 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA449]

FAILURE CODE [CA449] (ALL-K-AE20-410-00-B)

Action level Failure code Common Rail Pressure High Error 2

Failure
L03 CA449 (Engine controller system)
Details of
High pressure error (exceeding specified maximum level) has occurred in common rail pressure.
failure
Action of
• Restricts engine output for operation.
controller
Phenomenon
Engine power deration
on machine
• Signal voltage from common rail pressure sensor can be checked by monitoring function.
(Code: 36401 (V))
Related • Common rail pressure in common rail pressure sensor can be checked by monitoring
information function. (Code: 36400 (MPa))
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective relevant sys- If other failure codes are also displayed, perform troubleshooting for them.
1
tem
Air may be in low-pressure circuit. Check it according to the following procedure.
1. Remove pressure pickup plug (outlet side) of fuel main filter.
2. Operate feed pump of fuel prefilter.
2 Air in low-pressure circuit 3. Check pressure pickup plug for leakage of fuel and air.
If this error occurs during air bleeding after fuel filter is replaced, air may remain in
fuel circuit. Keep running engine at low idle speed for approximately 3 minutes. As
air is bled from fuel circuit, engine speed is stabilized, and error display disappears.

HB365LC-3 40-309
FAILURE CODE [CA449] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

• For check of pressure in fuel low pressure circuit, see TESTING AND AD-
JUSTING, “TEST FUEL PRESSURE”.
• Measured at fuel filter outlet side.
Pressure of Min.
fuel low At high idle 0.48 MPa
pressure cir- (if engine can be started) {Min.
cuit 4.9 kg/cm2}
• For check of pressure in fuel low pressure circuit, see TESTING AND AD-
JUSTING, “TEST FUEL PRESSURE”.
• Measured at fuel filter inlet and outlet sides.
• Pressure drop in fuel low-pressure circuit = Fuel filter inlet pressure - Fuel
filter outlet pressure
Pressure Max.
drop in fuel 0.08 MPa
At high idle
low-pres- {Max.
Defective fuel low-pres- sure circuit 0.8 kg/cm2}
3
sure circuit component
• For check of pressure in fuel low pressure circuit, see TESTING AND AD-
JUSTING, “TEST FUEL PRESSURE”.
• Measure at gear pump fuel inlet side of supply pump.
Fuel suction Min.
circuit pres- -33.9 kPa
sure At high idle {Min.
(gear pump -254 mmHg}
side)
For check of pressure in fuel low pressure circuit, see TESTING AND ADJUSTING,
“TEST FUEL PRESSURE”.
Fuel suction Min.
circuit pres- -27.1 kPa
sure At high idle {Min.
(fuel con- -203 mmHg}
nector side)
Directly check for fuel leakage from fuel tube of fuel cooler, O-ring, seal washer
4 Defective fuel cooler
damage, and check valve clogging or damage.
1. Turn starting switch to ON position.
2. Display monitoring code: 36400 with monitoring function of machine moni-
tor.
Defective common rail
5 0
pressure sensor
Common ± 0.39 MPa
rail pressure When engine is stopped
36400 {0
± 4 kg/cm2}
See descriptions of wiring harness and connectors in “c. METHOD FOR CHECK-
Defective wiring harness
6 ING ELECTRIC EQUIPMENT” in “CHECKS BEFORE TROUBLESHOOTING” of
connector
“RELATED INFORMATION ON TROUBLESHOOTING”, and check it.
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J2, and connect T-adapter to female side.
Defective GND harness
7 Check terminal GND20 for looseness and rust.
of engine controller
Between ground and each of ECM J2 (female) (49),
Resistance Max. 10 Ω
(50), (51), (52), and (73)

40-310 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA449]

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks on Causes 1 to 9, supply pump
8 Defective supply pump
may be defective.

Related circuit diagram to engine controller ground

HB365LC-3 40-311
FAILURE CODE [CA451] 40 TROUBLESHOOTING

FAILURE CODE [CA451] (ALL-K-AE24-410-00-B)

Action level Failure code Common Rail Pressure Sensor High Error
Failure
L03 CA451 (Engine controller system)

Details of
High voltage occurs in signal circuit of common rail pressure sensor.
failure
• Engine power deration
Action of
• Restricts common rail pressure.
controller
• Close EGR valve.
Phenomenon
Engine power deration
on machine
• Signal voltage from common rail pressure sensor can be checked by monitoring function.
(Code: 36401 (V))
• Common rail pressure in common rail pressure sensor can be checked by monitoring
function. (Code: 36400 (MPa))
Related • This failure code is displayed if connector of common rail pressure sensor is disconnected.
information • Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note the engine power deration is not canceled right after failure code
is cleared).
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equipment” in
“CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
Defective wiring harness TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, harness connector is defective.
If failure code [CA515] or [CA516] is also displayed, perform troubleshooting these
first.
1. Turn starting switch to OFF position.
Defective common rail 2. Disconnect connector FUEL RAIL PRESS and connect T-adapter to fe-
2 pressure sensor power male side.
supply system 3. Turn starting switch to ON position.
Between FUEL RAIL
4.75 to
Voltage PRESS (female) (A) and Power supply
5.25 V
(B)

40-312 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA451]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector FUEL RAIL PRESS and ECM J1, and connect T-
adapters to each female side.
If power supply input in check on cause 2 is normal,
this check is not required.
Open circuit in wiring har- Max. 10 Ω
Between ECM J1 (female) (82) and FUEL RAIL
ness (wire breakage or
3 PRESS (female) (A)
defective contact of con-
nector) If power supply input in check on cause 2 is normal,
Resistance
this check is not required.
Max. 10 Ω
Between ECM J1 (female) (58) and FUEL RAIL
PRESS (female) (B)
Between ECM J1 (female) (42) and FUEL RAIL
Max. 10 Ω
PRESS (female) (C) (sensor output)
1. Turn starting switch to OFF position.
2. Disconnect connectors FUEL RAIL PRESS and ECM J1, and connect T-
Short circuit in wiring har-
4 adapter to either female side.
ness
Between ECM J1 (female) (42) and (82), or between
Resistance Min. 100 kΩ
FUEL RAIL PRESS (A) and (C)
1. Turn starting switch to OFF position.
2. Disconnect connector FUEL RAIL PRESS.
3. Connect T-adapter to female side of connector FUEL RAIL PRESS, or in-
sert T-adapter into connector ECM J1.
Hot short circuit in wiring 4. Turn starting switch to ON position.
5
harness
REMARK
ECM J1 (42) pin is connected to 5 V source through resistor in engine controller.
Between FUEL RAIL PRESS (female) (C) and (B), or Approxi-
Voltage
between ECM J1 (42) and (58) mately 5 V
If failure code is still displayed after above checks on causes 1 to 5 and any failure
is found by checks on cause 6, sensor is defective.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector FUEL RAIL PRESS or ECM J1.
Defective common rail
6 3. Turn starting switch to ON position.
pressure sensor
Between FUEL RAIL
PRESS (female) (C) and
Voltage Sensor output 0.2 to 4.6 V
(B), or between ECM J1
(42) and (58)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-313
FAILURE CODE [CA451] 40 TROUBLESHOOTING

Circuit diagram related to common rail pressure sensor

40-314 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA452]

FAILURE CODE [CA452] (ALL-K-AE24-410-10-B)

Action level Failure code Common Rail Pressure Sensor Low Error
Failure
L03 CA452 (Engine controller system)

Details of
Low voltage occurs in signal circuit of common rail pressure sensor.
failure
• Engine power deration
Action of
• Restricts common rail pressure.
controller
• Close EGR valve.
Phenomenon
Engine power deration
on machine
• Signal voltage from common rail pressure sensor can be checked by monitoring function.
(Code: 36401 (V))
• Common rail pressure in common rail pressure sensor can be checked by monitoring
function. (Code: 36400 (MPa))

Related • If temperature sensor connector is removed even in normal condition, failure code for High
Error [CA451] is displayed instead of this failure code.
information
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note the engine power deration is not canceled right after failure code
is cleared).
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equipment” in
“CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
Defective wiring harness TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, harness connector is defective.
If failure code [CA515] or [CA516] is also displayed, perform troubleshooting these
first.
1. Turn starting switch to OFF position.
Defective common rail 2. Disconnect connector FUEL RAIL PRESS and connect T-adapter to fe-
2 pressure sensor power male side.
supply system 3. Turn starting switch to ON position.
Between FUEL RAIL
4.75 to
Voltage PRESS (female) (A) and Power supply
5.25 V
(B)

HB365LC-3 40-315
FAILURE CODE [CA452] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector FUEL RAIL PRESS.
3. Turn starting switch to ON position.
If failure code [CA452] changes to [CA451], sensor is defective.
Reference
Defective common rail 1. Turn starting switch to OFF position.
3
pressure sensor
2. Insert T-adapter into connector FUEL RAIL PRESS or ECM J1.
3. Turn starting switch to ON position.
Between FUEL RAIL
PRESS (C) and (B), or be-
Voltage Sensor output 0.2 to 4.6 V
tween ECM J1 (42) and
(58)
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors ECM J1 and FUEL RAIL PRESS, and connect T-
ness (5 V line breakage
4 adapters to each female side.
or defective contact of
connector) Between ECM J1 (female) (82) and FUEL RAIL
Resistance Max. 10 Ω
PRESS (female) (A)
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors ECM J1 and FUEL RAIL PRESS, and connect T-
5 harness (contact with adapter to either female side.
ground circuit)
Between ground and FUEL RAIL PRESS (female) (C)
Resistance Min. 100 kΩ
or ECM J1 (female) (42)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and FUEL RAIL PRESS, and connect T-
Short circuit in wiring har-
6 adapter to either female side.
ness
Between FUEL RAIL PRESS (female) (B) and (C), or
Resistance Min.100 kΩ
between ECM J1 (female) (42) and (58)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to common rail pressure sensor

40-316 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA488]

FAILURE CODE [CA488] (ALL-K-AA09-410-01-B)

Action level Failure code Charge Air Temperature High Torque Derate
Failure
L03 CA488 (Engine controller system)
Details of Temperature signal from boost pressure & temperature sensor exceeds upper limit of control tem-
failure perature.

Action of
Restricts engine output and allows engine to run.
controller
Phenomenon
Engine power deration
on machine
• Boost temperature can be checked with monitoring function. (Code: 18500)
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

Aftercooler cooling performance may be degraded. Check for following points:
Drop of cooling perform- • Defective fan rotation
1
ance of aftercooler • Insufficient cooling air
• Clogged aftercooler fins
Unusual rise of turbo- Outlet temperature of turbocharger may be unusually high. Check related parts.
2 charger outlet tempera-
ture
Defective boost tempera- Perform troubleshooting for failure codes [CA153] and [CA154].
3
ture sensor system

HB365LC-3 40-317
FAILURE CODE [CA515] 40 TROUBLESHOOTING

FAILURE CODE [CA515] (ALL-K-AE25-410-00-B)

Action level Failure code Common Rail Pressure Sensor Supply Voltage High Error (Engine
Failure
L03 CA515 controller system)

Details of
High voltage occurs in power supply (5 V) of common rail pressure sensor.
failure
Action of • Engine power deration
controller • Restricts common rail pressure.
Phenomenon
Engine power deration
on machine
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equipment” in
“CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
Defective wiring harness TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector FUEL RAIL PRESS.
3. Turn starting switch to ON position.
Defective common rail
2 pressure sensor (internal If this failure code is cleared any more, sensor is defective.
defect)
REMARK
Other failure codes are displayed at the same time. This happens because the
connector is disconnected. So ignore other codes than this failure code.
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1.
3. Turn starting switch to ON position.

3 Defective wiring harness If this failure code is cleared, wiring harness system may be defective. perform fol-
lowing diagnosis.
REMARK
Many other failure codes appear at same time because of disconnected con-
nector. Ignore failure codes other than this.
If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector FUEL RAIL PRESS, and connect T-adapter to fe-
4
harness male side.
3. Turn starting switch to ON position.
4.75 to
Voltage Between FUEL RAIL PRESS (female) (A) and (B)
5.25 V

40-318 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA515]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1, and connect T-adapter to male side.
3. Turn starting switch to ON position.
Defective engine control-
5 4.7 to
ler Voltage Between ECM J1 (male) (82) and (58)
5.25 V
If no failure is found by above checks, engine controller is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to common rail pressure sensor

HB365LC-3 40-319
FAILURE CODE [CA516] 40 TROUBLESHOOTING

FAILURE CODE [CA516] (ALL-K-AE25-410-10-B)

Action level Failure code Common Rail Pressure Sensor Supply Voltage Low Error (Engine
Failure
L03 CA516 controller system)

Details of
Low voltage occurs in power supply (5 V) of common rail pressure sensor.
failure
Action of • Engine power deration
controller • Restricts common rail pressure.
Phenomenon
Engine power deration
on machine
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equipment” in
“CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
Defective wiring harness TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector FUEL RAIL PRESS.
3. Turn starting switch to ON position.
Defective common rail
2 pressure sensor (internal If this failure code is cleared any more, sensor is defective.
defect)
REMARK
Other failure codes are displayed at the same time. This happens because the
connector is disconnected. So ignore other codes than this failure code.
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1.
3. Turn starting switch to ON position.

3 Defective wiring harness
Ground fault in wiring
4 harness (contact with
ground circuit)
If this failure code is cleared, wiring harness system may be defective. perform fol-
lowing diagnosis.
REMARK
Many other failure codes appear at same time because of disconnected con-
nector. Ignore failure codes other than this.
If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and FUEL RAIL PRESS, and connect T-
adapter to either female side.
Between ground and ECM J1 (female) (82) or FUEL
Resistance Min. 100 kΩ
RAIL PRESS (female) (A)

40-320 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA516]

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.
Short circuit in wiring har-
5 2. Disconnect connectors ECM J1 and FUEL RAIL PRESS, and connect T-
ness
adapter to either female side.
Between ECM J1 (female) (58) and (82), or between
Resistance Min. 100 kΩ
FUEL RAIL PRESS (female) (A) and (B)
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1, and connect T-adapter to male side.
3. Turn starting switch to ON position.
Defective engine control-
6 4.7 to
ler Voltage Between ECM J1 (male) (82) and (58)
5.25 V
If no failure is found by above checks, engine controller is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to common rail pressure sensor

HB365LC-3 40-321
FAILURE CODE [CA553] 40 TROUBLESHOOTING

FAILURE CODE [CA553] (ALL-K-AE20-410-10-B)

Action level Failure code

Failure Common Rail Pressure High Error 1 (Engine controller system)
L01 CA553
Details of
Common rail pressure high error 1 (indicated pressure is higher than that which is assumed)
failure
Action of
None in particular
controller
Phenomenon
Engine power deration
on machine
• Signal voltage from common rail pressure sensor can be checked by monitoring function.
(Code: 36401 (V))
Related • Common rail pressure in common rail pressure sensor can be checked by monitoring
information function. (Code: 36400 (MPa))
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective relevant sys- If other failure codes are also displayed, perform troubleshooting for them.
1
tem
2 Improper fuel is used. Fuel used may be improper. Check it.
Ground terminal may be connected defectively. Check following terminals directly.
• Ground terminal of machine ((-) terminal of battery)
Defective connection of • Ground terminal of engine
3
ground terminal
• Ground terminal of engine controller
• Ground terminal of starting motor
Defective electrical sys- Since common rail pressure sensor may have electrical defect, perform trouble-
4 tem of common rail pres- shooting for following failure codes. [CA451], [CA452]
sure sensor
Defective mechanical Common rail pressure sensor may have mechanical trouble. Check it.
5 system of common rail
pressure sensor
Overflow valve spring may be broken, seat may be worn, and ball may be stuck.
6 Defective overflow valve
Check them.
7 Clogged overflow piping Overflow piping may be clogged. Check it.
8 Defective pressure limiter Pressure limiter may be defective mechanically. Check it.

40-322 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA555]

FAILURE CODE [CA555] (ALL-K-A300-410-01-B)

Action level Failure code Crankcase Pressure High Error 2

Failure
L01 CA555 (Engine controller system)
Details of
High pressure error (level 1) in crankcase pressure is detected.
failure
Action of
None in particular
controller
Phenomenon
None in particular
on machine
• Signal voltage from crankcase pressure sensor can be checked by monitoring function.
(Code: 48401 (V))
• Pressure in crankcase pressure sensor can be checked by monitoring function. (Code:
Related
48400 (kPa))
information
• This failure code is cleared when failure code [CA1942] is displayed.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

1 Clogged KCCV filter Replace the KCCV filter.
If an error persists after replacement of the KCCV filter and emulsions are detected
Blocked KCCV gas pip-
2 inside KCCV, blocked emulsions may be suspected in KCCV blow by gas piping.
ing
Check that there is no coolant leakage.
Defective crankcase Crankcase pressure sensor system may be defective. Perform troubleshooting for
3
pressure sensor failure codes [CA1843] and [CA1844].
The error does not disappear after replacing KCCV filter, and “Crankcase Pressure
High Error 1” or “Crankcase Pressure High Error 2” is also displayed, piston ring
4 Increase of blowby gas may be worn or broken, or oil from VGT may be leaked, valve guide and stem seal
may be worn or damaged. Perform troubleshooting “TROUBLESHOOTING OF EN-
GINE (S MODE)”, “Engine oil consumption is excessive”.

HB365LC-3 40-323
FAILURE CODE [CA556] 40 TROUBLESHOOTING

FAILURE CODE [CA556] (ALL-K-A300-410-02-B)

Action level Failure code Crankcase Pressure High Error 2

Failure
L03 CA556 (Engine controller system)
Details of
High pressure error (level 2) in crankcase pressure is detected.
failure
Action of
Engine power deration
controller
Phenomenon • Engine power deration.
on machine • Oil may leak from seals or gauge.
• Signal voltage from crankcase pressure sensor can be checked by monitoring function.
(Code: 48401 (V))
• Pressure in crankcase pressure sensor can be checked by monitoring function. (Code:
Related
48400 (kPa))
information
• This failure code is cleared when failure code [CA1942] is displayed.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

1 Clogged KCCV filter Replace the KCCV filter.
If an error persists after replacement of the KCCV filter and emulsions are detected
Blocked KCCV gas pip-
2 inside KCCV, blocked emulsions may be suspected in KCCV blow by gas piping.
ing
Check that there is no coolant leakage.
Defective crankcase Crankcase pressure sensor system may be defective. Perform troubleshooting for
3
pressure sensor failure codes [CA1843] and [CA1844].
The error does not disappear after replacing KCCV filter, and “Crankcase Pressure
High Error 1” or “Crankcase Pressure High Error 2” is also displayed, piston ring
4 Increase of blowby gas may be worn or broken, or oil from VGT may be leaked, valve guide and stem seal
may be worn or damaged. Perform troubleshooting “TROUBLESHOOTING OF EN-
GINE (S MODE)”, “Engine oil consumption is excessive”.

40-324 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA559]

FAILURE CODE [CA559] (ALL-K-AD00-410-00-B)

Action level Failure code Common Rail Pressure Low Error 1

Failure
L01 CA559 (Engine controller system)
Details of
No-pressure error (level 1) is detected in supply pump.
failure
• Engine power deration.
Action of
• Close EGR valve.
controller
• Stop regeneration control.
Phenomenon
Engine power deration
on machine
• Common rail pressure in common rail pressure sensor can be checked by monitoring
function. (Code: 36400 (MPa))

Related • Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note the engine power deration is not canceled right after failure code
information is cleared).
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

1 Non-fuel Check the remaining quantity of fuel
Defective fuel tank Fuel tank breather may be clogged. Check it directly
2
breather
Fuel may be leaking to outside. Check it directly (Check visually while running en-
3 Fuel leakage to outside
gine at low idle)

HB365LC-3 40-325
FAILURE CODE [CA559] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

• For check of pressure in fuel low pressure circuit, see TESTING AND AD-
JUSTING, “TEST FUEL PRESSURE”.
• Measure at fuel filter inlet side.
• Cranking speed: Min. 150 rpm
Min.
Pressure of
0.105 MPa
fuel low
At cranking {Min.
pressure cir-
1.07 kg/cm2
cuit
}
• For check of pressure in fuel low pressure circuit, see TESTING AND AD-
JUSTING, “TEST FUEL PRESSURE”.
• Measured at fuel filter outlet side.
Pressure of Min.
fuel low 0.48 MPa
At high idle
pressure cir- {Min.
cuit 4.9 kg/cm2}
• For check of pressure in fuel low pressure circuit, see TESTING AND AD-
JUSTING, “TEST FUEL PRESSURE”.
• Measured at fuel filter inlet and outlet sides.
• Pressure drop in fuel low-pressure circuit = Fuel filter inlet pressure - Fuel
Defective low-pressure
4 filter outlet pressure
circuit component
Pressure Max.
drop in fuel 0.08 MPa
At high idle
low-pres- {Max.
sure circuit 0.8 kg/cm2}
• For check of pressure in fuel low pressure circuit, see TESTING AND AD-
JUSTING, “TEST FUEL PRESSURE”.
• Measure at gear pump fuel inlet side of supply pump.
Fuel suction Min.
circuit pres- -33.9 kPa
sure At high idle {Min.
(gear pump -254 mmHg}
side)
• For check of pressure in fuel low pressure circuit, see TESTING AND AD-
JUSTING, “TEST FUEL PRESSURE”.
• Measure at fuel connector side.
Fuel suction Min.
circuit pres- -27.1 kPa
sure At high idle {Min.
(fuel con- -203 mmHg}
nector side)

40-326 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA559]

No. Cause Procedure, measuring location, criteria and remarks

For check of return rate from injector, see TESTING AND ADJUSTING, “METHOD
FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE”.

At cranking Max.
300 cc/45
Fuel leakage from inlet (if engine cannot be started) sec
Return rate
5 connector (inside head)
from injector Max.
(note 2) At low idle
100 cc/30
(if engine can be started) sec
When fuel return rate is high, check the tightening of connecting part of high-pres-
sure pipes according to “note 2”.
For check of return rate from injector, see TESTING AND ADJUSTING, “METHOD
FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE”.

At cranking Max.
300 cc/45
6 Defective injector (if engine cannot be started)
Return rate sec
from injector Max.
At low idle
100 cc/30
(if engine can be started) sec
For check of return rate from supply pump, see TESTING AND ADJUSTING,
“METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE”.

At cranking Max.
320 cc/30
7 Defective supply pump Return rate (if engine cannot be started) sec
from supply
pump At low idle Max.
350 cc/30
(if engine can be started) sec
For details of testing pressure limiter leakage amount, see TESTING AND AD-
JUSTING “METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAK-
AGE”.
8 Defective pressure limiter
Leakage
Max. 30
from pres- At low idle
drops/min.
sure limiter
Air may be in low-pressure circuit. Check it according to the following procedure.
1. Remove pressure pickup plug (outlet side) of fuel main filter.
2. Operate feed pump of fuel prefilter.
9 Air in low-pressure circuit 3. Check pressure pickup plug for leakage of fuel and air.
If this error occurs during air bleeding after fuel filter is replaced, air may remain in
fuel circuit. Keep running engine at low idle speed for approximately 3 minutes. As
air is bled from fuel circuit, engine speed is stabilized, and error display disappears.

Note 1: When low-pressure circuit equipment is detective, check the following.

1. Clogging of fuel tank breather
2. Clogging of check valve (3) installed to cooling plate (2) on engine controller (1).
3. Leakage from or clogging of low-pressure fuel piping
4. Clogging of fuel prefilter
5. Clogging of fuel main filter
6. Replace fuel filter when problem is not removed even if no clogging is found.

HB365LC-3 40-327
FAILURE CODE [CA559] 40 TROUBLESHOOTING

Note 2

High-pressure pipe from common rail is connected to the injector through inlet connection (11) in the cylinder
head.
Inlet connection (11) is fastened by retainer (10), so re-tighten retainer (10).
3 Retainer:
50 ± 4 Nm {5± 0.4 kgm}

40-328 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA595]

FAILURE CODE [CA595] (ALL-K-AA09-410-00-B)

Action level Failure code Turbocharger Speed High Error 2

Failure
L01 CA595 (Engine controller system)
Details of
Turbocharger rotates at abnormally high speed.
failure
Action of
Runs turbocharger speed at fixed value of 125000 rpm.
controller
Phenomenon
None in particular
on machine
• Turbocharger speed in turbocharger speed sensor can be checked by monitoring function.
(Code: 48100 (rpm))
Related
• Because sensor output is pulse waveform, it is not measured by using multimeter.
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

Increase of turbocharger Since turbocharger speed may increase, check it.
1
speed
2 Defective turbocharger Turbocharger may have a failure. Check it.
Defective turbocharger If no failure is found in cause 1, the turbocharger speed sensor system may be de-
3
speed sensor fective. Perform troubleshooting for failure code [CA687].

HB365LC-3 40-329
FAILURE CODE [CA687] 40 TROUBLESHOOTING

FAILURE CODE [CA687] (ALL-K-AA09-410-10-B)

Action level Failure code Turbocharger Speed Low Error

Failure
L01 CA687 (Engine controller system)
Details of
Turbocharger turbine blade rotates at abnormal low speed.
failure
Action of
Runs turbocharger speed at fixed value of 125000 rpm.
controller
Phenomenon
on machine

k VGT is heated to 500 °C and above. Be careful not to get burn injury.
• Because sensor output is pulse waveform, it is not measured by using multimeter.
• Turbocharger speed in turbocharger speed sensor can be checked by monitoring function.
(Code: 48100 (rpm))
Related • Engine speed can be checked by monitoring function. (Code: 01002 (rpm))
information • Pressure (boost pressure) by charge pressure sensor (boost pressure sensor) can be
checked by monitoring function. (Code: 36500 (kPa))
• This failure code is displayed if VGT speed sensor connector is disconnected.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine and sets engine speed to 1200 rpm or higher, and set charge
pressure sensor (boost pressure sensor) to approximately 120 kPa or higher.

No. Cause Procedure, measuring location, criteria and remarks

1 Defective turbocharger
Defective wiring harness
2
connector
Defective VGT speed
3
sensor (internal defect)
Open circuit and short
circuit in wiring harness
4 (short circuit, wire break-
age or defective contact
of connector)
Open circuit in wiring har-
5
ness
Turbocharger may have a failure. Check it.
1. See descriptions of wiring harness and connectors in “c: Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
FORMATION ON TROUBLESHOOTING”, and check it.
2. Run engine at high idle speed.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector VGT REV. and connect T-adapter to female side.
600 to
Resistance Between VGT REV. (female) (1) and (2)
1600 Ω
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1, and connect T-adapter to female side.
600 to
Resistance Between ECM J1 (female) (17) and (16)
1600 Ω
If failure code is still displayed after above checks on open circuit and short circuit
in wiring harness, this check is not required.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and VGT REV., and connect T-adapters to
each female side.
Between ECM J1 (female) (17) and VGT REV. (fe-
Max. 10 Ω
male) (1)
Resistance
Between ECM J1 (female) (16) and VGT REV. (fe-
Max. 10 Ω
male) (2)

40-330 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA687]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and VGT REV., and connect T-adapter to
Ground fault in wiring either female side.
6 harness (contact with Between ground and ECM J1 (female) (17) or VGT
ground circuit) Resistance Min. 100 kΩ
REV. (female) (1)
Between ground and ECM J1 (female) (16) or VGT
Resistance Min. 100 kΩ
REV. (female) (2)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and VGT REV., and connect T-adapter to
Short circuit in wiring har-
7 either female side.
ness
Between ECM J1 (female) (17) and (16), or between
Resistance Min. 100 kΩ
VGT REV. (female) (1) and (2)
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector ECM J1, and connect T-adapter to female side.
8
harness 3. Turn starting switch to ON position.
Voltage Between ECM J1 (female) (17) and ground Max. 1 V
Defective sensor installa- Defective VGT speed sensor (looseness) or defective parts for speed detection
9 tion or defective parts for (VGT internal parts) (including deformation by heat) may be suspected. Check it.
speed detection
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
10
ler an internal defect, troubleshooting cannot be performed.)

CIRCUIT DIAGRAM (TURBO SPEED SENSOR)

HB365LC-3 40-331
FAILURE CODE [CA689] 40 TROUBLESHOOTING

FAILURE CODE [CA689] (ALL-K-AG40-410-00-B)

Action level Failure code

Failure Engine NE Speed Sensor Error (Engine controller system)
L01 CA689
Detail of fail-
Error occurs in the signal from engine NE speed sensor.
ure
Action of
Operates by signal from engine Bkup speed sensor.
controller
• Running engine stops (when Bkup (CAM) speed sensor is also defective).
Phenomenon • Stopped engine cannot be started (when Bkup (CAM) speed sensor is also defective).
on machine • Engine hunts.
• Engine startability is poor.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.
• Because internal speed sensor consists of hole sensor and electronic circuit instead of
coil, whether speed sensor is normal or not cannot be determined even if resistance of
Related
speed sensor is measured by using multimeter.
information
• Since output of normal speed sensor is 5 V pulse voltage, it cannot be measured by using
multimeter.
• Speed sensor detects tooth missing part of rotation speed sensing wheel installed on
crankshaft.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Start the engine.
If this failure code is cleared, wiring harness connector is defective.
Defective NE speed sen- If failure code [CA238] or [CA239] is displayed, perform troubleshooting for the
2
sor power supply system code first.
Engine NE speed sensor Engine NE speed sensor may be broken or installed improperly (loosened). Check
3 broken or installed im- it.
properly (loosened)
1. Turn starting switch to OFF position.
2. Disconnect connector NE, and connect T-adapter to female side.
Defective NE speed sen-
4 3. Turn starting switch to ON position.
sor power supply system
Between CRANK SEN- 4.75 to
Voltage Power supply
SOR (female) (1) and (2) 5.25 V

40-332 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA689]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and NE, and connect T-adapters to each
female side.
If failure code is still displayed after above checks on
cause 4, this check is not required.
Open circuit in wiring har- Max. 10 Ω
Between ECM J1 (female) (79) and CRANK SENSOR
ness (wire breakage or
5 (female) (1)
defective contact of con-
nector) If failure code is still displayed after above checks on
Resistance
cause 4, this check is not required.
Max. 10 Ω
Between ECM J1 (female) (55) and CRANK SENSOR
(female) (2)
Between ECM J1 (female) (31) and CRANK SENSOR
Max. 10 Ω
(female) (3)
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors ECM J1 and NE, and connect T-adapter to either
6 harness (contact with female side.
ground circuit)
Between ground and ECM J1 (female) (31) or CRANK
Resistance Min. 100 kΩ
SENSOR (female) (3)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and NE, and connect T-adapter to either
female side.
Short circuit in wiring har-
7 Between ECM J1 (female) (79) and (31), or between
ness Min. 100 kΩ
CRANK SENSOR (female) (1) and (3)
Resistance
Between ECM J1 (female) (55) and (31), or between
Min. 100 kΩ
CRANK SENSOR (female) (2) and (3)
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector NE, and connect T-adapter to female side.
8
harness 3. Turn starting switch to ON position.
Voltage Between CRANK SENSOR (female) (3) and ground Max. 1 V
1. Remove NE speed sensor (crankshaft sensor).
Breakage or looseness of 2. Check rotation speed sensing wheel (R) from sensor mounting hole direct-
9 rotation speed sensed ly.
wheel Rotation speed sensing wheel (R) has tooth missing part (A) to sense rotation.
When rotation speed sensing wheel (R) is loose, see “Reference”.
If failure code is still displayed after above checks, the engine Ne speed sensor
Defective engine NE
10 may be defective. (In case of an internal defect, troubleshooting is impossible as an
speed sensor
assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
11
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-333
FAILURE CODE [CA689] 40 TROUBLESHOOTING

CIRCUIT DIAGRAM (Ne SPEED SENSOR)

Reference: Check of crankshaft speed sensing wheel for loose installation (Engine model 114)
Remove the damper, flywheel, flywheel housing and outer main cap, and check the crankshaft speed sensing
wheel for loose installation.
REMARK
• When replacing the crankshaft speed sensing wheel, the crankshaft must be removed.
• Prepare the rear seal, gasket and liquid gasket LG-6 and LG-7 on hand.
Removal
1. Remove the engine. For details, see DISASSEMBLY AND ASSEMBLY, “REMOVE AND INSTALL ENGINE
ASSEMBLY”.
2. Remove the following parts. For details, see DISASSEMBLY AND ASSEMBLY, “Removal and installation of
engine rear seal”.
1) Damper
2) Flywheel
3) Flywheel housing
4) Rear seal housing
3. Remove the oil pan.
4. Remove mounting bolts (2) of main cap (1).
5. Insert mounting bolts (2) into the bolt holes of main cap (1) and remove main cap (1) while shaking it.
REMARK
Check that embossed letters “BACK” on side (A) of main cap (1) face the rear of the cylinder block.

40-334 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA689]

(3): Rotation speed sensing wheel

6. Check that mounting bolts (4) of NE speed (crank) sensing wheel (3) are not loose.
REMARK
• If the bolts are loose, replace them with new ones.
• Tighten all the bolts evenly.
3 Mounting bolt (4):
8 ± 2 Nm {0.8 ± 0.2 kgm}
5): Crankshaft

Installation
REMARK
For drawings, see the "Removal".
1. Install main cap (1) with the embossed letters “BACK” facing toward the rear of the cylinder block.
2 Crankshaft journal surface:
Engine oil (EO15W-40)
REMARK
Push it in by hitting it lightly with a plastic hammer or rubber hammer.
2. Install main cap (1) with mounting bolts (2).
3 Main cap mounting bolt (1st time):
50 ± 7 Nm {5.1 ± 0.7 kgm}
Loosen 360 °.
3 Main cap mounting bolt (2nd time):
95 ± 6 Nm {9.7 ± 0.6 kgm}
3 Main cap mounting bolt (3rd time):
60±5 °

HB365LC-3 40-335
FAILURE CODE [CA689] 40 TROUBLESHOOTING

3. Install the oil pan.

3 Mounting bolt:
Tighten the mounting bolts in the order of [1] to [32].

24 ± 4 Nm {2.4 ± 0.4 kgm}

4. Restore it. For details, see DISASSEMBLY AND ASSEMBLY, "Removal and installation of engine rear seal"
and "REMOVE AND INSTALL ENGINE ASSEMBLY".

40-336 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA691]

FAILURE CODE [CA691] (ALL-K-A96G-410-20-B)

Action level Failure code

Failure Intake Air Temperature Sensor High Error (Engine controller system)
L01 CA691
Details of
High voltage occurs in signal circuit of intake air temperature sensor.
failure
Action of
Sets intake air temperature to fixed value (25 °C) for operation.
controller
Phenomenon
None in particular
on machine
• Mass air flow sensor and intake air temperature sensor are provided as a unit.

Related • This failure code and failure code [CA357] are displayed simultaneously if sensor connec-
tor is removed.
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Perform checkup referring to descriptions of wiring harness and connec-
tors in “c Electric equipment ”of “CHECKS BEFORE TROUBLESHOOT-
Defective wiring harness ING” in “RELATED INFORMATION ON TROUBLESHOOTING”.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Starting switch: OFF
2. Disconnect connector P55 and connect T-adapter to male side.
-30 °C 25 to 28 kΩ
5.5 to
0 °C
Between P55 (male) (3) 6.1 kΩ
Defective intake air tem- and (4) 1.9 to
2 perature sensor (internal 25 °C
Characteristic of intake 2.1 kΩ
defect) temperature - resistance
Resistance 1.1 to
value 40 °C
1.2 kΩ
180 to
100 °C
185 Ω
Between P55 (male) (3)
Entire area Min. 100 kΩ
and ground (sensor body)
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1, and connect T-adapter to female side.
Open circuit and short
circuit in wiring harness REMARK
3 (short circuit, wire break- Use intake temperature sensor resistance characteristics table for check on
age or defective contact
cause 2 as an air intake temperature resistance value.
of connector)
180 Ω to
Resistance Between ECM J1 (female) (61) and (56)
28 kΩ

HB365LC-3 40-337
FAILURE CODE [CA691] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Perform preparation when starting switch is in OFF position.
2. Disconnect connector P55.
Hot short circuit in wiring 3. Insert T-adapter into connector ECM J1, or connect T-adapter to female
4
harness side of P55.
Between ECM J1 (32) and (56) or P55 (female) (1) and
Voltage Max. 5.25 V
(3)
1. Starting switch: OFF
2. Disconnect connectors ECM J1 and P55, and connect T-adapter to female
Short circuit in wiring har- side of ECM J1.
5
ness Check by using multimeter in continuity mode.
Between ECM J1 (female) (61) and each pin other
Resistance Min. 100 kΩ
than pin (61)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

CIRCUIT DIAGRAM (MASS AIR FLOW SENSOR)

40-338 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA692]

FAILURE CODE [CA692] (ALL-K-A96G-410-30-B)

Action level Failure code

Failure Intake Air Temperature Sensor Low Error (Engine controller system)
L01 CA692
Details of
Low voltage occurs in signal circuit of intake air temperature sensor.
failure
Action of
Sets intake air temperature to fixed value (25 °C) for operation.
controller
Phenomenon
None in particular
on machine
• Mass air flow sensor and intake air temperature sensor are provided as a unit.
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Perform checkup referring to descriptions of wiring harness and connec-
tors in “c Electric equipment ”of “CHECKS BEFORE TROUBLESHOOT-
Defective wiring harness ING” in “RELATED INFORMATION ON TROUBLESHOOTING”.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Starting switch: OFF
2. Disconnect connector P55.
3. Starting switch: ON
If this failure code changes to failure code [CA691]. intake air temperature sensor is
defective.
1. Starting switch: OFF
2. Disconnect connector P55 and connect T-adapter to male side.

Defective intake air tem- -30 °C 25 to 28 kΩ

2 perature sensor (internal 5.5 to
defect) 0 °C
Between P55 (male) (3) 6.1 kΩ
and (4) 1.9 to
25 °C
Characteristic of intake 2.1 kΩ
Resistance temperature - resistance 1.1 to
value 40 °C
1.2 kΩ
180 to
100 °C
185 Ω
Between P55 (male) (3)
Entire area Min. 100 kΩ
and ground (sensor body)
1. Starting switch: OFF
Ground fault in wiring 2. Disconnect connectors ECM J1 and P55, and connect T-adapter to either
3 harness (contact with female side.
ground circuit)
Between ground and ECM J1 (female) (61) or P55 (fe-
Resistance Min. 100 kΩ
male) (4)

HB365LC-3 40-339
FAILURE CODE [CA692] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Starting switch: OFF
2. Disconnect connectors ECM J1 and P55, and connect T-adapter to female
Short circuit in wiring har- side of ECM J1.
4
ness Check by using multimeter in continuity mode.
Between ECM J1 (female) (61) and each pin other
Resistance Min. 100 kΩ
than pin (61)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)

CIRCUIT DIAGRAM (MASS AIR FLOW SENSOR)

40-340 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA697]

FAILURE CODE [CA697] (ALL-K-AP70-410-10-B)

Action level Failure code Engine Controller Internal Temperature Sensor High Error
Failure
L01 CA697 (Engine controller system)
Details of
High voltage error occurs in signal circuit of engine controller internal temperature sensor.
failure
Action of
None in particular
controller
Phenomenon
None in particular
on machine
• Temperature detected by engine controller internal temperature sensor can be checked
Related with monitoring function. (Code: 18900 (°C))
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Improper use of control- Check that controller is not used in high temperature environment.
1
ler
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
2
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-341
FAILURE CODE [CA698] 40 TROUBLESHOOTING

FAILURE CODE [CA698] (ALL-K-AP70-410-20-B)

Action level Failure code Engine Controller Internal Temperature Sensor Low Error
Failure
L01 CA698 (Engine controller system)
Details of
Low voltage error occurs in signal circuit of engine controller internal temperature sensor.
failure
Action of
None in particular
controller
Phenomenon
None in particular
on machine
• Temperature detected by engine controller internal temperature sensor can be checked
Related with monitoring function. (Code: 18900 (°C))
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Improper use of control- Check that controller is not used in low temperature environment.
1
ler
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
2
ler an internal defect, troubleshooting cannot be performed.)

40-342 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA731]

FAILURE CODE [CA731] (ALL-K-AG60-410-00-B)

Action level Failure code Engine Backup Speed Sensor Phase Error
Failure
L01 CA731 (Engine controller system)
Detail of fail- Engine controller detects phase error by signal from engine Bkup speed sensor. (Compared with
ure signal from NE speed sensor, phase does not fit.)
Action of
Controls by NE speed sensor signal.
controller
• Running engine stops (when NE speed sensor is also defective).
Phenomenon
• Engine cannot start or engine is hard to start.
on machine
• Engine idling speed is unstable.
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

Breakage of engine NE Engine NE speed sensor (CRANK sensor) may be broken. Check it.
1
speed (CRANK) sensor
Breakage of engine Bkup Engine Bkup speed sensor (CAM sensor) may be broken. Check it.
2
speed (CAM) sensor
Rotation speed sensing wheel on crankshaft side may be installed improperly or
damaged. Check it according to the following procedure.
Defective installation or
1. Set No. 1 cylinder to compression top dead center (align stamping mark).
breakage of rotation
3 2.
sensing wheel on crank- Remove NE speed sensor (crankshaft sensor).
shaft 3. If tooth missing part (A) of rotation speed sensing wheel can be seen
through mounting hole of sensor, the wheel is installed normally.
Speed sensing ring on camshaft side is a camshaft gear (CAMG) and may be in-
stalled improperly or damaged. Check it according to the following procedure.
Defective installation or 1. Set No. 1 cylinder to compression top dead center (align stamping mark).
4 breakage of camshaft 2. Remove Bkup speed sensor.
gear
3. Installation is correct if twin groove rib (B) of camshaft gear (CAMG) is visi-
ble through sensor mounting hole.
• Timing of crankshaft and camshaft may be defective. Check it directly.
Defective timing of crank-
5 • Remove engine front cover, and check that matchmarks of crank gear and
shaft and camshaft
cam gear are matched.
Ground terminal may be connected defectively. Check following terminals directly.
• Ground terminal of machine ((-) terminal of battery)
Defective connection of • Ground terminal of engine
6
ground terminal
• Ground terminal of engine controller
• Ground terminal of starting motor

HB365LC-3 40-343
FAILURE CODE [CA731] 40 TROUBLESHOOTING

Engine NE speed (CRANK) sensor

Engine Bkup speed (CAM) sensor

40-344 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA778]

FAILURE CODE [CA778] (ALL-K-AG60-410-10-B)

Action level Failure code Engine Backup Speed Sensor Error

Failure
L01 CA778 (Engine controller system)
Detail of fail-
Error is detected in engine Bkup speed sensor circuit.
ure
Action of
Operates by NE speed sensor signal.
controller
• Running engine stops (when NE speed sensor is also defective).
Phenomenon
• Stopped engine cannot be started (when NE speed sensor is also defective).
on machine
• Engine startability is deteriorated (when NE speed sensor is normal).
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.
• Because internal speed sensor consists of electronic circuit instead of coil, whether speed
Related sensor is normal or not cannot be determined even if resistance of speed sensor is meas-
information ured by using multimeter.
• Because speed sensor output is 5 V of pulse voltage, it cannot be measured by using mul-
timeter.
• Speed sensor detects rotation with 2 ribs on the side face of camshaft gear.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
Defective sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting these
2
supply system first.
Breakage or defective in- Engine Bkup speed (CAM) sensor may be broken or installed improperly (loos-
stallation (looseness) of ened). Check it.
3
engine Bkup speed
(CAM) sensor
1. Turn starting switch to OFF position.
2. Disconnect connector CAM SENSOR and connect T-adapters to female
Defective engine Bkup side.
4 speed sensor power sup-
3. Turn starting switch to ON position.
ply system
Between CAM SENSOR 4.75 to
Voltage Power supply
(female) (1) and (2) 5.25 V

HB365LC-3 40-345
FAILURE CODE [CA778] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position to perform troubleshooting.
2. Disconnect connectors ECM J1 ,CAM SENSOR, and connect T-adapters
to each female side.
If power supply voltage in check on cause 5 is normal,
this check is not required.
Open circuit in wiring har- Max.10 Ω
ness Between ECM J1 (female) (78) and CAM SENSOR
5 (female) (1)
(wire breakage or defec-
tive contact of connector) Resistance If power supply voltage in check on cause 5 is normal,
this check is not required.
Max.10 Ω
Between ECM J1 (female) (54) and CAM SENSOR
(female) (2)
Between ECM J1 (female) (18) and CAM SENSOR
Max.10 Ω
(female) (3)
1. Turn starting switch to OFF position to perform troubleshooting.
2. Disconnect connectors ECM J1, CAM SENSOR, and connect T-adapters
to female side of ECM J1 or CAM SENSOR.
Short circuit in wiring har-
6 Between ECM J1 (female) (78) and (18), or between
ness Min.100 kΩ
CAM SENSOR (female) (1) and (3)
Resistance
Between ECM J1 (female) (54) and (18), or between
Min.100 kΩ
CAM SENSOR (female) (2) and (3)
1. Turn starting switch to OFF position to perform troubleshooting.
Ground fault in wiring
2. Disconnect connectors ECM J1 and G, and connect T-adapters to either
harness
7 female side.
(contact with ground cir-
cuit) Between ground and ECM J1 (female) (18) or CAM
Resistance Min.100 kΩ
SENSOR (female) (3)
1. Turn starting switch to OFF position to perform troubleshooting.
2. Disconnect connectors CAM SENSOR and connect T-adapters to female
Hot short circuit in wiring side of CAM SENSOR.
8
harness 3. Turn starting switch to ON position (with connector BOOST PRESS & IMT
disconnected).
Voltage Between CAM SENSOR (female) (3) and ground Max.1 V
Remove e Bkup speed (CAM) sensor, and check through hole.
9 Loosened camshaft gear REMARK
If the camshaft gear (CAMG) is loose, see “Reference”.
If failure code is still displayed after above checks, engine Bkup speed sensor is
Defective engine Bkup
10 defective. (In case of an internal defect, troubleshooting is impossible as an assem-
speed sensor
bly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
11
ler an internal defect, troubleshooting cannot be performed.)

40-346 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA778]

CIRCUIT DIAGRAM (Bkup (CAMSHAFT) SPEED SENSOR)

Reference: Check of camshaft gear for looseness (Engine model 114)

Remove the pulley, damper, front seal, front cover and housing, and check the camshaft gear for looseness.
REMARK
Prepare the front seal, gasket, liquid gasket LG-7, and front seal tool (795-799-8120) on hand.
Removal
1. Remove the following parts. For details, see DISASSEMBLY AND ASSEMBLY, “Removal and installation of
engine front seal”.
1) Remove compressor belt.
2) Remove pulley (1).
3) Remove damper (2).

HB365LC-3 40-347
FAILURE CODE [CA778] 40 TROUBLESHOOTING

4) Remove carrier assembly (3).

5) Remove dust seal (4) and front seal (5) from carrier assembly (3).
2. Remove front cover (6).
3. Remove housing (7).
(8): Gasket

4. Check that there is no play when moving gear (9) of camshaft (10) by hand.

Installation
REMARK
For drawings, see the "Removal".
1. Fit gasket (8) to housing (7) and install front cover (6) to housing (7).
2 Housing:
Liquid gasket LG-7
2. See DISASSEMBLY AND ASSEMBLY, “Removal and installation of engine front seal” and,
1) Install front seal (5) and dust seal (4) to carrier (3).
2) Install carrier assembly to front cover (6).

40-348 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA778]

3) Install damper (2).

4) Install pulley (1).
5) Install compressor belt.
6) Install the cooling assembly.

HB365LC-3 40-349
FAILURE CODE [CA1117] 40 TROUBLESHOOTING

FAILURE CODE [CA1117] (ALL-K-AP70-410-30-B)

Action level Failure code Engine Controller Partial Data Lost Error
Failure
L04 CA1117 (Engine controller system)
Details of
Internal defect is detected in controller.
failure
Action of
None in particular
controller
• Engine runs normally. However, engine may be stopped during operation or stopped en-
Phenomenon
gine may not be started.
on machine
• Engine controller cannot memorize internal data correctly.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• Engine controller internal data (related to KDPF, AdBlue/DEF Level, etc.) may be lost. Ap-
propriate remedy must be performed after resetting error.

Related • This error code is displayed when power supply is disconnected by battery disconnect
switch, etc. before engine controller is normally exited.
information
NOTICE
Remedy after resetting error
See “TESTING AND ADJUSTING”, “SERVICE MODE” and “METHOD FOR SETTING TESTING
(ACTIVE REGENERATION FOR SERVICE)” in “SETTING AND OPERATION OF MACHINE
MONITOR” to perform “Active Regeneration for Service”.

No. Cause Procedure, measuring location, criteria and remarks

Defective power supply Since the power supply circuit may be defective, perform troubleshooting for failure
1
circuit system code [CA441].
Improper operation of Battery disconnect switch may be operated improperly.
2
battery disconnect switch
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

40-350 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1664]

FAILURE CODE [CA1664] (ALL-K-A9H2-410-00-B)

Action level Failure code KDOC Abnormality

Failure
L03 CA1664 (Engine controller system)
Details of During regeneration, KDOC inlet temperature sensor and KDOC outlet temperature sensor indicate
failure similar values (temperature difference is approximately within 10°C).

• EGR valve closed.

Action of • Engine power deration
controller • Regeneration control stops.
• Fuel dosing stops.
Phenomenon
Engine power deration
on machine

k The temperature of KDPF and KDOC becomes hot (Min. 500 °C). Be careful not to get
burned.
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
(Code: 47300 (°C))
• Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when at
low idle speed (KDPF regeneration is not executed) are 100 to 250 °C, and difference be-
tween these temperatures is approximately 10 °C. (KDOC inlet temperature > KDOC out-
let temperature > KDPF outlet temperature)
• When manual stationary regeneration is in progress, KDOC inlet temperature is 250 to
400 °C, and KDOC outlet temperature and KDPF outlet temperature are 450 to 600 °C.
Related • As to procedure for accessing KDPF temperature sensor, see “50 Disassembly and as-
information sembly”, “Removal and installation of KDPF assembly” and “Disassembly and assembly of
KDPF assembly”.
• Engine controller stops after starting switch is turned to OFF position and AdBlue/DEF is
retracted (for up to 6 minutes). So when you restart engine, wait until the system operating
lamp goes out after starting switch is turned OFF, and then turn the starting switch to ON
position.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note that the engine power deration is not canceled only by the failure
code is cleared).
NOTICE
• This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. Af-
ter investigating the cause of the problem and completing the repair, perform “Load-
ed Diagnostics Operation To Clear Failure Code” to make sure the failure code is
cleared. (This failure code is not cleared by only turning ON the starting switch
again.)
• Before performing “Loaded Diagnostics Operation To Confirm Failure Correction”,
firstly “Setting and operating machine monitor”, Service mode, Testing menu (En-
gine Controller Active Fault Clear) to be performed to clearer this failure code.

HB365LC-3 40-351
FAILURE CODE [CA1664] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Defective KDOC inlet If failure code [CA3313], [CA3314] or [CA3315] is displayed, perform troubleshoot-
1
temperature sensor ing for [CA3313], [CA3314] or [CA3315].
Defective KDOC outlet If failure code [CA3316], [CA3317] or [CA3318] is displayed, perform troubleshoot-
2
temperature sensor ing for [CA3316], [CA3317] or [CA3318].
1. Check if KDPF is correctly attached to the exhaust system.
3 Defective KDOC
2. Check if KDOC is correctly attached to KDPF.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Clear Failure Code

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is cleared after this procedure.)
1. Turn starting switch from OFF position to ON position.
2. Start the engine and run it at low idle for approximately 1 minute.
3. Display KDOC inlet and outlet temperatures with monitoring function.
REMARK
KDOC inlet temperature of 280 °C or higher is a requirement for clearing the failure code.
4. Use the work equipment to raise either track off ground.
5. Set the swing lock switch to ON position and working mode to B.
6. Run that track idle off ground for 15 minutes with fuel control dial at MAX position and travel speed at Hi
setting.
7. If this failure code is cleared after steps 1 to 6 are performed, repair work is completed.

40-352 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1669]

FAILURE CODE [CA1669] (ALL-K-AFG0-410-00-B)

Action level Failure code AdBlue/DEF Level Sensor Voltage High Error
Failure
L01 CA1669 (Engine controller system)
Detail of fail-
Failure of AdBlue/DEF level sensor (Piezoelectric element for level measurement is open)
ure
Action of
Advances to Inducement strategy. (EU Specification)
controller
Phenomenon • Failure to measure AdBlue/DEF level.
on machine • Engine power deration according to inducement strategy. (EU Specification)
• The AdBlue/DEF level sensor is one of the AdBlue/DEF tank sensors integrated with the
AdBlue/DEF temperature sensor and AdBlue/DEF quality sensor performs CAN communi-
cation with the engine controller.
Related
• If the engine controller receives open-circuit information of Piezoelectric element for level
information measurement, this failure code is displayed.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Check the sensor connector for contamination and damage.
2. Turn starting switch to OFF position.
3. Replace the AdBlue/DEF tank sensor.
Defective AdBlue/DEF
2 4. Turn starting switch to ON position.
tank sensor
If this failure code is cleared, any internal parts in the original AdBlue/DEF tank
sensor is defective. (In case of an internal defect, troubleshooting is impossible as
an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-353
FAILURE CODE [CA1673] 40 TROUBLESHOOTING

FAILURE CODE [CA1673] (ALL-K-AFG0-410-10-B)

Action level Failure code AdBlue/DEF Level Low Error 3

Failure
L03 CA1673 (Engine controller system)
Detail of fail-
The AdBlue/DEF tank level lowered. (The tank level becomes 2.5 % or less)
ure
Action of
Engine power deration
controller
Phenomenon
Engine power deration
on machine
• The failure codes of AdBlue/DEF level low are as follows:
When AdBlue/DEF level is 10 % or less [CA3497]
When AdBlue/DEF level is 5 % or less [CA3498]
When AdBlue/DEF level is 2.5 % or less [CA1673]
Related When AdBlue/DEF level is 0.0 %or less [CA3547]
information • CA3547 is displayed and engine output is limited significantly if usage is continued without
refilling AdBlue/DEF and the AdBlue/DEF level becomes 0.0 %.
• After this failure code is cleared, Engine power deration continues until the starting switch
is turned to OFF position.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Check the sight gauge to confirm that there is sufficient amount of
AdBlue/DEF in the AdBlue/DEF tank.
1 Low AdBlue/DEF level 3. Refill AdBlue/DEF if the level is low.
4. Turn starting switch to ON position.
If this failure code is cleared, AdBlue/DEF has been insufficient.
1. Check the sensor connector for contamination and damage.
2. Turn starting switch to OFF position.
3. Replace the AdBlue/DEF tank sensor.
Defective AdBlue/DEF
2 4. Turn starting switch to ON position.
tank sensor
If this failure code is cleared, any internal parts in the original AdBlue/DEF tank
sensor is defective. (In case of an internal defect, troubleshooting is impossible as
an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

40-354 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1677]

FAILURE CODE [CA1677] (ALL-K-AFG0-410-20-B)

Action level Failure code AdBlue/DEF Temperature Sensor Low Error

Failure
L01 CA1677 (Engine controller system)
Detail of fail- Failure of AdBlue/DEF temperature sensor (Short circuit of thermistor for temperature measure-
ure ment)
Action of
Advances to Inducement strategy. (EU Specification)
controller
Phenomenon • Failure to measure AdBlue/DEF level.
on machine • Engine power deration according to inducement strategy. (EU Specification)
• The AdBlue/DEF temperature sensor is one of the AdBlue/DEF tank sensors integrated
with the AdBlue/DEF level sensor and AdBlue/DEF quality sensor performs CAN commu-
nication with the engine controller.
Related
• If the thermistor for temperature measurement shorts, this failure code is sent to the en-
information gine controller via CAN communication and displayed.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Check the sensor connector for contamination and damage.
2. Turn starting switch to OFF position.
3. Replace the AdBlue/DEF tank sensor.
Defective AdBlue/DEF
2 4. Turn starting switch to ON position.
tank sensor
If this failure code is cleared, any internal parts in the original AdBlue/DEF tank
sensor is defective. (In case of an internal defect, troubleshooting is impossible as
an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-355
FAILURE CODE [CA1678] 40 TROUBLESHOOTING

FAILURE CODE [CA1678] (ALL-K-AFG0-410-30-B)

Action level Failure code AdBlue/DEF Temperature Sensor High Error

Failure
L01 CA1678 (Engine controller system)
Detail of fail- Failure of AdBlue/DEF temperature sensor (Open circuit of thermistor for temperature measure-
ure ment)
Action of
Advances to Inducement strategy. (EU Specification)
controller
Phenomenon • Failure to measure AdBlue/DEF level.
on machine • Engine power deration according to inducement strategy. (EU Specification)
• The AdBlue/DEF temperature sensor is one of the AdBlue/DEF tank sensors integrated
with the AdBlue/DEF level sensor and AdBlue/DEF quality sensor performs CAN commu-
nication with the engine controller.
Related
• If the thermistor for temperature measurement is open, this failure code is sent to the en-
information gine controller via CAN communication and displayed.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Check the sensor connector for contamination and damage.
2. Turn starting switch to OFF position.
3. Replace the AdBlue/DEF tank sensor.
Defective AdBlue/DEF
2 4. Turn starting switch to ON position.
tank sensor
If this failure code is cleared, any internal parts in the original AdBlue/DEF tank
sensor is defective. (In case of an internal defect, troubleshooting is impossible as
an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

40-356 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1682]

FAILURE CODE [CA1682] (ALL-K-AFH1-410-70-B)

Action level Failure code AdBlue/DEF pump boosting error

Failure
L01 CA1682 (Engine controller system)
Detail of fail- Pump priming for preparation of injection cannot be performed due to the breakage of AdBlue/DEF
ure pump or clogging of hose.
Action of • Stops driving AdBlue/DEF pump.
controller • Inducement strategy is activated.
Phenomenon • NOx emission increases because AdBlue/DEF injection is disabled.
on machine • Engine output is reduced based on Inducement strategy.
• Engine controller does not display this failure code while AdBlue/DEF supply system is un-
der thawing control. (It cannot judge because AdBlue/DEF injection is disabled.)
• Start the engine, wait for 3 minutes, and then check that the number showing 4 conditions
below is other than 1 (Thawing). (You cannot troubleshoot this failure until thawing is com-
pleted.)
• The state of each heater is 1: Thawing control, 2: Warming, 3 or 0: OFF.
On the monitoring code screen, input following number directly to check the value.
19305 AdBlue/DEF Tank Heating State
19306 AdBlue/DEF Suction Return Line Heater State
19307 AdBlue/DEF Pressure Line Heater State
19309 AdBlue/DEF Pump Heater State
• If “AdBlue/DEF pump pressure” rises to around 900 kPa on “Pre-defined Monitoring”
screen of the AdBlue/DEF pump, this failure code is not displayed.
Related
• Related value can be checked on the following screens. (Also, you can check the value by
information
inputting the number directly.)
• Pre-defined Monitoring (18/28) AdBlue/DEF pump
1. 19120 AdBlue/DEF Injection Quantity
2. 19108 AdBlue/DEF Pump Pressure
3. 19109 AdBlue/DEF Pump Pressure Sensor Voltage
4. 19304 AdBlue/DEF Pump State
5. 19136 AdBlue/DEF Pump Temperature
6. 19114 AdBlue/DEF Reverting Valve Cmd
NOTICE
This failure code requires“ Loaded Diagnostics Operation To Clear Failure Code”. After in-
vestigating the cause of the problem and completing the repair, perform “Loaded Diagnos-
tics Operation To Clear Failure Code” to make sure the failure code is cleared. (This failure
code is not cleared by simply turning the starting switch to ON position.)

No. Cause Procedure, measuring location, criteria and remarks

Defective AdBlue/DEF If failure code [CA3558] or [CA3559] or [CA3571] or [CA3572] is displayed on the
1
pump system abnormality record screen, perform troubleshooting these first.
Open circuit or short cir- If failure code [CA3713] or [CA5115] is displayed on the abnormality record screen,
2 cuit in AdBlue/DEF line perform troubleshooting these first.
heater 1
Defective AdBlue/DEF If failure code [CA2976] is also displayed, perform checks on causes 2 and after in
3 pump temperature sen- troubleshooting for this failure code.
sor system
Defective AdBlue/DEF If failure code [CA1669] or [CA3868] or [CA4732] or [CA4739] or [CA4769] is dis-
4
level sensor system played, perform troubleshooting these first.

HB365LC-3 40-357
FAILURE CODE [CA1682] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If failure code [CA1673] or [CA3497] or [CA3498] or [CA3547] is displayed, trouble-
shoot for those codes first.
5 Low AdBlue/DEF level
If the level is low, replenish AdBlue/DEF until it can be seen in the sight gauge, and
then “Loaded Diagnostics Operation To Clear Failure Code”.
Defective AdBlue/DEF Perform troubleshooting for failure code [CA3713] (excluding replacement of en-
6
line heater circuit gine controller).
If crystallized AdBlue/DEF is adhered to the surrounding of hose, tank, pump, or
engine compartment, it shows AdBlue/DEF may be leaking. Refer to “TESTING
Damaged AdBlue/DEF AND ADJUSTING”, “SETTING AND OPERATION OF MACHINE MONITOR”,
7 hose, AdBlue/DEF leak- “METHOD FOR SETTING WITH TESTING MENU (SCR SERVICE TEST)” to per-
age at connection form AdBlue/DEF Pump Pressure Up Test and find the location of the AdBlue/DEF
leak.
Replace parts as necessary.
Check the AdBlue/DEF suction hose for entry of foreign material or clogging due to
Clogged AdBlue/DEF
8 frozen AdBlue/DEF. Blow air or send AdBlue/DEF through each AdBlue/DEF hose,
suction hose
and repair or replace the hose if clogged.
Check the AdBlue/DEF tank for entry of foreign material. Check the AdBlue/DEF
Clogged AdBlue/DEF
9 tank strainer for clogging. Repair or replace the part if any abnormality is found.
tank strainer
Use AdBlue/DEF for cleaning.
1. Remove the flange from the AdBlue/DEF tank.
2. Check if a suction tube in the AdBlue/DEF tank is torn apart.
Suction tube clogged or 3. see “TESTING AND ADJUSTING”, “SETTING AND OPERATION OF MA-
10 torn apart in the CHINE MONITOR”, “SERVICE MODE”, “METHOD FOR SETTING WITH
AdBlue/DEF tank TESTING MENU (SCR SERVICE TEST)” to perform “AdBlue/DEF Pump
Pressure Up Test” to check if AdBlue/DEF is not leaking from the suction tube
in the AdBlue/DEF tank visually.
If the interval specified in the Operation and Maintenance Manual has elapsed
since the last time the AdBlue/DEF pump filter was replaced, or foreign material
Clogged AdBlue/DEF
11 was found in the check for AdBlue/DEF tank strainer, replace the AdBlue/DEF
pump filter
pump filter. (Refer to “METHOD FOR REPLACING AdBlue/DEF FILTER” in the Op-
eration and Maintenance Manual)
Defective AdBlue/DEF If the cause is not determined by above checks, replace the AdBlue/DEF pump.
12
pump
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
13
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation to Clear Failure Code

Check if the repair has been completed with the following procedure:
(Make sure this failure code is cleared after this procedure.)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start the engine.
3. Run the engine at low idle speed.
4. Check if monitoring code 19108 “AdBlue/DEF Pump Pressure” rises up 900 ± 100 kPa within 5 minutes.
5. After ensuring the above 4., and after 3 minutes, check if this failure code is cleared after 3 minutes.
REMARK
• If this failure code is cleared, repair is completed.
• In case it is not cleared, return to troubleshooting.

40-358 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1683]

FAILURE CODE [CA1683] (ALL-K-AFK1-410-00-B)

Action level Failure code AdBlue/DEF Tank Heating Valve Voltage High Error
Failure
L01 CA1683 (Engine controller system)
Detail of fail-
High voltage error is detected in signal circuit of AdBlue/DEF tank heating valve.
ure
Action of
Advances to Inducement strategy.
controller
Phenomenon • Failure to thaw AdBlue/DEF.
on machine • Engine power deration according to inducement strategy.
• This failure code is displayed when AdBlue/DEF tank heating valve connector is discon-
nected.
• AdBlue/DEF tank heating valve is driven when AdBlue/DEF is thawed and engine starts
Related with the temperature of engine coolant 45 °C or below.
information • AdBlue/DEF tank heating value can also be driven at “AdBlue/DEF tank heater valve test”.
• This failure code is detected only when AdBlue/DEF tank heating value stops.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
Defective AdBlue/DEF 2.
2 Disconnect connector V41, and connect T-adapter to male side.
tank heating valve
Resistance Between V41 (male) (1) and (2) 15 to 30 Ω
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J2, and connect T-adapter to female side.
Open or short circuit in Between ECM J2 (female) (82) and (57)
3
wiring harness
Resistance REMARK 15 to 30 Ω
The resistance value is the same as the value for an
AdBlue/DEF tank heating valve
1. If failure code is still displayed after above checks on cause 3, this check is not
required.
Open circuit in wiring har- 2. Turn starting switch to OFF position.
ness (wire breakage or 3. Disconnect connectors ECM J2 and V41 and connect T-adapters to each
4
defective contact of con- female side.
nector)
Between ECM J2 (female) (82) and V41 (female) (1) Max. 10 Ω
Resistance
Between ECM J2 (female) (57) and V41 (female) (2) Max. 10 Ω

HB365LC-3 40-359
FAILURE CODE [CA1683] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J2 and V41, and connect T-adapter to female
Short circuit in wiring har- side of ECM J2.
5
ness
No continui-
Between ECM J2 (female) (82) and each pin other
Continuity ty (no
than pin (82)
sound)
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector V41, and connect T-adapter to female side.
6
harness 3. Turn starting switch to ON position (with the valve disconnected).
Voltage Between V41 (female) (1) and (2) Max. 4.5 V
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to AdBlue/DEF tank heating valve

40-360 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1684]

FAILURE CODE [CA1684] (ALL-K-AFK1-410-01-B)

Action level Failure code AdBlue/DEF Tank Heating Valve Voltage Low Error
Failure
L01 CA1684 (Engine controller system)
Detail of fail-
Low voltage error is detected in signal circuit of AdBlue/DEF tank heating valve.
ure
Action of
Advances to Inducement strategy.
controller
Phenomenon • Failure to thaw AdBlue/DEF.
on machine • Engine power deration according to inducement strategy.
• The AdBlue/DEF tank heating valve operates when thawing the AdBlue/DEF and when
starting the engine while the temperature of the engine coolant is 45 °C or below.
• The AdBlue/DEF tank heating valve also operates when an “AdBlue/DEF Tank Heater
Valve Test” is implemented.
Related
• This failure code is detected only when the AdBlue/DEF tank heating valve is driven.
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine (Engine coolant temperature: 45 °C or below), “Service mode”
and “Testing menu (SCR service test) - Operate” of “Setting and operating machine moni-
tor” to perform “AdBlue/DEF tank heater valve test”.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness
FORMATION ON TROUBLESHOOTING”, and check it.
1 2.
connector Start engine (engine coolant temperature: Max. 45 °C) or perform
“AdBlue/DEF tank heater valve test”.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
Defective AdBlue/DEF 2.
2 Disconnect connector V41, and connect T-adapter to male side.
tank heating valve
Resistance Between V41 (male) (1) and (2) 15 to 30 Ω
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J2, and connect T-adapter to female side.
Open or short circuit in Between ECM J2 (female) (82) and (57)
3
wiring harness
Resistance REMARK 15 to 30 Ω
The resistance value is the same as the value for an
AdBlue/DEF tank heating valve
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors ECM J2 and V41, and connect T-adapter to either
4 harness (contact with female side.
ground circuit)
Between ECM J2 (female) (82) or V41 (female) (1) and
Resistance Min. 100 kΩ
ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J2 and V41, and connect T-adapter to female
Short circuit in wiring har- side of ECM J2.
5
ness
No continui-
Between ECM J2 (female) (82) and each pin other
Continuity ty (no
than pin (82)
sound)

HB365LC-3 40-361
FAILURE CODE [CA1684] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to AdBlue/DEF tank heating valve

40-362 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1686]

FAILURE CODE [CA1686] (ALL-K-AFG0-410-40-B)

Action level Failure code AdBlue/DEF Quality Sensor Voltage High Error
Failure
L01 CA1686 (Engine controller system)
Detail of fail-
Failure of AdBlue/DEF quality sensor (Piezoelectric element for quality measurement is open)
ure
Action of
Advances to Inducement strategy. (EU Specification)
controller
Phenomenon • The AdBlue/DEF quality cannot be measured.
on machine • Engine power deration according to inducement strategy. (EU Specification)
• The AdBlue/DEF quality sensor is one of the AdBlue/DEF tank sensors integrated with the
AdBlue/DEF level sensor and AdBlue/DEF temperature sensor performs CAN communi-
cation with the engine controller.
Related
• If the engine controller receives open-circuit information of Piezoelectric element for quali-
information ty measurement, this failure code is displayed.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Check the sensor connector for contamination and damage.
2. Turn starting switch to OFF position.
3. Replace the AdBlue/DEF tank sensor.
Defective AdBlue/DEF
2 4. Turn starting switch to ON position.
tank sensor
If this failure code is cleared, any internal parts in the original AdBlue/DEF tank
sensor is defective. (In case of an internal defect, troubleshooting is impossible as
an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-363
FAILURE CODE [CA1691] 40 TROUBLESHOOTING

FAILURE CODE [CA1691] (ALL-K-A9H0-410-00-B)

Action level Failure code Defective Regeneration

Failure
L03 CA1691 (Engine controller systems)

Details of KDOC efficiency (catalyzer function) is lowered. (Because KDOC outlet temperature does not rise
compared with KDOC inlet temperature: 250 to 400 °C as normal, KDOC outlet temperature: 450 to
failure 600 °C as normal during regeneration.)
• EGR valve closed.
Action of
• Engine power deration
controller
• Fuel dosing stops.
Phenomenon
Engine power deration
on machine

40-364 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1691]

k KDPF and KDOC become hot (Min. 500 °C). Be careful not to get burned.
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
(Code: 47300 (°C))
• Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when at
low idle speed (KDPF regeneration is not executed) are 100 to 250 °C, and difference be-
tween these temperatures is approximately 10 °C. (KDOC inlet temperature > KDOC out-
let temperature > KDPF outlet temperature)
• During manual stationary regeneration (normal), KDOC inlet temperature is 250 to 400 °C,
and both KDOC outlet temperature and KDPF outlet temperature are 450 to 600 °C.
• When dosing fuel does not blow out (KDOC drying) during manual stationary regenera-
tion, all of KDOC inlet temperature, KDOC outlet temperature and KDPF outlet tempera-
ture are 250 to 400 °C.
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.
Related
• Test exhaust gas color. For details, see “TESTING AND ADJUSTING”, “TEST EXHAUST
information
GAS COLOR”.
• Failure code [CA2637] may be also displayed. However, perform troubleshooting for this
failure code.
• When soot accumulation is at level 3 or lower, manual stationary regeneration can be per-
formed only from active regeneration for service.
• Procedure of performing the manual stationary regeneration from the "active regeneration
for service".
1. Start engine.
2. Make sure that machine is in safe condition.
3. Display Testing screen from Service Menu screen of machine monitor, open Active
Regeneration for Service, and perform Manual Stationary Regeneration (manual sta-
tionary regeneration finishes in approximately 40 minutes).
• Confirmation method of repair completion: For checking repair completion, start engine
and perform manual stationary regeneration if KDOC is not replaced. (See cause 5.)
NOTICE
• Confirmation of repair completion is not necessary if KDOC is replacecd.
• When KDOC in KDPF is changed, perform reset procedure for KDOC change and
then finish repair.

No. Cause Procedure, measuring location, criteria and remarks

When KDPF cooled down sufficiently or there are significant differences between
Defective KDOC outlet
1 the KDOC outlet temperature and the KDOC inlet temperature or KDPF outlet tem-
temperature sensor
perature at idle (non-regeneration), change the KDPF temperature sensor.
Set the working mode to “B”, suddenly accelerate the engine from low idle to high
idle two times, and then keep the engine running at high idle for 5 seconds.
NOTICE
Defective exhaust gas
2 • If an excess black smoke is seen at high idle during acceleration, per-
color
form “KDPF GETS CLOGGED IN A SHORT TIME”.
• Black smoke powder which comes out during acceleration but disap-
pears at high idle is normal.

HB365LC-3 40-365
FAILURE CODE [CA1691] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

k Perform after KDPF and KDOC cooled down sufficiently.

1. Remove KDPF.
2. Remove KDOC.
Defective KDOC (stain, 3. Blow air from KDOC outlet and remove stains on ceramic surface inside
3 crack, damage on KDOC KDOC.
surface) 4. Check if the ceramic inside KDOC has cracks.
KDOC is defective if any cracks are found in KDOC (change KDOC).
NOTICE
Perform the following whether or not KDOC is changed:
1. Attach KDOC and KDPF.
2. Turn starting switch to ON position.
3. On the Service screen of the machine monitor, display “Diagnostic Tests”
screen, open 03 “KDPF Memory Reset”, and perform 03 “KDOC Change”
(Reset after KDOC change).

NOTICE
Reset after KDOC
4 • Failure codes [CA1691] and [CA2637] are cleared when reset after
change
KDOC change is performed. At this point, a corrective action which is
effective when the failure code is displayed and is taken for dozing
fuel which is not injected is reset.
• Check that reset after KDOC change is complete successfully (by re-
set count). If not, perform troubleshooting again.
• If KDOC is changed, troubleshooting is complete without performing
manual stationary regeneration.

NOTICE
Perform if KDOC is not changed:
1. Turn starting switch to ON position.
2. Take notes on the temperature in initial state and during manual stationary
regeneration from the KDOC inlet temperature sensor and the KDPF outlet
temperature sensor to check if the KDOC outlet temperature sensor is nor-
mal (see Related information).
3. Perform manual stationary regeneration (see Related information).
Defective KDOC (de- 4. Turn starting switch to OFF position.
5 graded catalyst action of
KDOC) 5. Start the engine and perform manual stationary regeneration (to check if
failure code [CA2637] is displayed).

NOTICE
• Troubleshooting is complete after making sure that the failure code is
cleared.
• If failure code [CA2637] is displayed after manual stationary regenera-
tion is complete, KDOC is defective (catalyst action of KDOC is de-
graded. Change KDOC).
• Perform cause 4 again when KDOC is changed.

40-366 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1694]

FAILURE CODE [CA1694] (ALL-K-AFA0-410-10-B)

Action level Failure code SCR Outlet NOx Sensor In Range Error
Failure
L01 CA1694 (Engine controller system)
Detail of fail- The value of the NOx sensor of the SCR outlet is abnormal compared with the turbocharger outlet
ure NOx emission value
Action of
None in particular
controller
Phenomenon NOx emission may increase or ammonia may be exhausted because AdBlue/DEF injection works
on machine inappropriately.

k SCR assembly, sensor fitting piping, and sensor probe become hot (Min. 400 °C). Be
careful not to get burned.
k Be careful not to get burned by the sensor probe as it is heated by itself even if the
ambient temperature is not high.
• If the SCR outlet NOx sensor probe is disconnected from the exhaust pipe or loosened,
this failure code may appear.
• The SCR outlet NOx sensor and turbocharger outlet NOx sensor are not serviceable,
Related therefore, replace the sensor if it is defective.
information NOTICE
• For this failure code, after investigating the cause of the problem and completing the
repair, perform “Loaded Diagnostics Operation To Confirm Failure Correction” to
make sure repair is completed. (This failure code is not cleared by only turning ON
the starting switch.)
• If the failure code of active regeneration prohibition or that of AdBlue/DEF injection
prohibition is displayed, the failure cannot be cleared. Clear the corresponding fail-
ure codes first.

No. Cause Procedure, measuring location, criteria and remarks

Defective turbocharger If failure code [CA1885], [CA3232], [CA3649], [CA3682], [CA3718], [CA3725], or
outlet NOx sensor sys- [CA3748] is displayed, perform troubleshooting for these failure codes failure codes
tem first.
1
(Open circuit, internal de-
fect, defective sensor
heater)
Defective SCR outlet If failure code [CA1887], [CA2771], [CA3545], [CA3583], [CA3681], or [CA3717] is
NOx sensor system displayed, perform troubleshooting for these failure codes first.
2 (Open circuit, internal de-
fect, defective sensor
heater)
Defective connection be- Check if the SCR outlet NOx sensor probe is installed securely.
tween the SCR outlet
3
NOx sensor probe and
an exhaust pipe
1. Check if urea deposits are accumulated in the AdBlue/DEF mixing tube and
the AdBlue/DEF injector mount.
Accumulation of urea de- 2.
If deposits are accumulated, remove the AdBlue/DEF mixing tube to remove
4 posits in AdBlue/DEF
deposits and clean the tube.
mixing tube
3. Check if urea deposits are accumulated in the SCR inlet case. If accumulated,
perform the next item.

HB365LC-3 40-367
FAILURE CODE [CA1694] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. If urea deposit is accumulated inside the SCR inlet case, remove the urea
Accumulated urea de- deposit as much as possible.
5
posit in SCR assembly
2. Repair AdBlue/DEF mixing tube back to normal.
1. Refer to “TESTING AND ADJUSTING”, “SETTING AND OPERATION OF
MACHINE MONITOR”, “SERVICE MODE”, “METHOD FOR SETTING
WITH TESTING MENU (SCR SERVICE TEST)” to perform an
“AdBlue/DEF INJECTOR INJECTION AMOUNT TEST” to judge the injec-
tor.
2. If the AdBlue/DEF injection amount test results are within the values speci-
Abnormal injection from fied in “TESTING AND ADJUSTING”, it is OK. Proceed to step 4.
6
AdBlue/DEF injector
3. If the AdBlue/DEF injection amount is out of the range specified in “Testing
and adjusting”, replace the AdBlue/DEF injector.
4. When the repair is completed, repeat “Loaded Diagnostics Operation To
Clear Failure Code” the system two times (repeat the operation two times
to ensure AdBlue/DEF to be sublimed, in case it has flown into the catalyst
(Required time: approximately 2 hours)).
If no failure is found by preceding checks, the turbocharger outlet NOx sensor may
Defective turbocharger
7 be defective. (Abnormality in the turbocharger outlet NOx sensor due to adverse ef-
outlet NOx sensor
fects of sulfur content)

Urea deposit is accumu- 1. Perform “Loaded Diagnostics Operation To Clear Failure Code” to sublime
lated in the AdBlue/DEF urea deposit.
8 mixing tube but it is re- 2. Repair is completed if the failure code is cleared after performing “Loaded
movable by application of Diagnostics Operation To Clear Failure Code” (urea deposit has been re-
the thermal load. moved by sublimation).
Defective SCR outlet If no failure is found by the above checks, the SCR outlet NOx sensor is defective
9
NOx sensor (NOx sensor measurement probe is clogged with urea deposit)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
10
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Clear Failure Code

Check if the repair has been completed with the following procedure.
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Disconnect the connector P55 (for automatic regeneration).
3. Start the engine.
REMARK
Ignore other failure codes displayed.
4. Secure a safety condition and run the engine at low idle until the aftertreatment devices regeneration pilot
lamp lights up (for approximately 10 minutes).
5. Stop the engine
6. Connect the connector P55.
7. Start the engine.
8. After starting the engine, “Turn the key to OFF position.” is displayed on the machine monitor. Then, turn
the starting switch to OFF position once and start the engine again.
9. Check that the aftertreatment devices regeneration pilot lamp is lit (automatic regeneration), and perform
the following operation.
Set the swing lock to ON position, working mode to B, and run the engine with one-side track idle off the
ground (set the fuel dial to FULL and travel to Hi) until the failure code is cleared (for approximately 20 mi-
nutes).

40-368 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1694]

10. Check that the failure code is cleared, and perform the following operation.
Run the engine at low idle until the aftertreatment devices regeneration pilot lamp goes out. Then repair
work is completed.
REMARK
If this failure code is not cleared at this stage, return to the troubleshooting.

HB365LC-3 40-369
FAILURE CODE [CA1695] 40 TROUBLESHOOTING

FAILURE CODE [CA1695] (ALL-K-A9HY-410-00-B)

Action level Failure code Sensor 5 Supply Voltage High Error

Failure
L03 CA1695 (Engine controller system)
Details of High voltage error is detected in 5 V power supply of the KDPF differential pressure sensor, KDPF
failure outlet pressure sensor and, AdBlue/DEF pump pressure sensor.

• Operates at estimated value of KDPF outlet pressure sensor. (Operation may be per-
formed at 0 kPa {0 kg/cm2} .)
• Operates at estimated value of KDPF differential pressure sensor. (Operation may be per-
Action of formed at 0 kPa.)
controller • Operates at fixed value (1300 kPa) of AdBlue/DEF pump pressure.
• EGR valve closed.
• Engine power deration
• Regeneration control stops.
Phenomenon
Engine power deration
on machine
• KDPF differential pressure sensor and KDPF outlet pressure sensor are provided as a
unit.
Related • After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.
• Engine power deration is canceled when the failure code is cleared and the starting switch
is turned OFF (not canceled only by deactivation of the failure code).

No. Cause Procedure, measuring location, criteria and remarks

Defective sensor 5 power Perform troubleshooting for failure code [CA1696].
1
supply system

40-370 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1696]

FAILURE CODE [CA1696] (ALL-K-A9HY-410-10-B)

Action level Failure code Sensor 5 Supply Voltage Low Error

Failure
L03 CA1696 (Engine controller system)
Detail of fail- Low voltage error is detected in 5 V power supply of the KDPF differential pressure sensor, KDPF
ure outlet pressure sensor and, AdBlue/DEF pump pressure sensor.
• Operates at estimated value of KDPF outlet pressure sensor. (Operation may be per-
formed at 0 kPa {0 kg/cm2} .)
• Operates at estimated value of KDPF differential pressure sensor. (Operation may be per-
Action of formed at 0 kPa {0 kg/cm2} .)
controller • Operates at fixed value (-100 kPa) of AdBlue/DEF pump pressure.
• Closes EGR valve.
• Controls engine output for operation.
• Stops regeneration control.
Phenomenon
Engine power deration
on machine
• KDPF differential pressure sensor and KDPF outlet pressure sensor are provided as a
unit.

Related • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
information
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note the engine power deration is not canceled right after the failure
code is cleared).

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Starting switch: OFF
2. Disconnect following connectors one by one and turn starting switch to ON
position each time.
3. Each time troubleshooting is finished, return to step 1.
If this failure code goes out, disconnected sensor is defective.
Defective sensor or wir-
2
ing harness REMARK
Other failure codes are also displayed. This is because the connector is dis-
connected. Ignore all failure codes except for [CA1695].
KDPF differential pressure (outlet pressure) sensor E25
Connector
AdBlue/DEF pump pressure sensor MB02
1. Starting switch: OFF
Ground fault in wiring 2. Disconnect connectors ECM J2, E25, and MB02, and connect T-adapter to
3 harness (contact with either female side.
ground circuit)
Between ECM J2 (female) (8) and ground, or between
Resistance Min. 100 kΩ
E25 (female) (4) and ground

HB365LC-3 40-371
FAILURE CODE [CA1696] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Starting switch: OFF
2. Disconnect connectors ECM J2, E25, and MB02, and connect T-adapter to
Short circuit in wiring har-
4 female side of ECM J2.
ness
Between ECM J2 (female) (8) and each pin other than
Resistance Min. 100 kΩ
pin (8)

REMARK
If the fuse is not blown out, this check is not required.
1. Turn the starting switch to OFF position.
2. Disconnect connector E25.
3. Insert T-adapter into connector ECM J2, or connect T-adapter to female
side of connector E25.
Defective engine control-
5 4. Turn the starting switch to ON position.
ler
5. If no failure is found by this check, repeat from procedures of cause 1
again.
Between ECM J2 (8) and (32), or between E25 (fe- 4.75 to
Voltage
male) (4) and (1) 5.25 V
If no failure is found by above checks, engine controller is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to KDPF differential pressure and KDPF outlet pressure
sensor

40-372 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1712]

FAILURE CODE [CA1712] (ALL-K-AFK0-410-00-B)

Action level Failure code AdBlue/DEF tank thawing error

Failure
L01 CA1712 (Engine controller system)
Detail of fail- AdBlue/DEF tank thawing cannot be completed due to the failure of AdBlue/DEF tank heating valve
ure and engine coolant circuit, etc.
Action of
None in particular
controller
Phenomenon
NOx emission increases because AdBlue/DEF injection is disabled.
on machine
• Engine controller judges if this failure code is displayed only during thawing control of the
AdBlue/DEF tank (The value of 19305 AdBlue/DEF Tank Heating State is “1”).
• 19305 AdBlue/DEF Tank Heating State, 1: Thawing, 2: Warming, 3 or 0: OFF
• On “Pre-defined Monitoring” screen, AdBlue/DEF tank thawing control diagnosis is used.
(The numbers below denote monitoring codes).
• Pre-defined Monitoring (21/28) AdBlue/DEF tank thawing control
1. 19305 AdBlue/DEF Tank Heating State
Related 2. 19102 AdBlue/DEF Tank HtrValve Command
3. 19115 AdBlue/DEF Temperature in Tank
information
4. 04107 Engine Coolant Temperature
5. 19400 Ambient Temperature
6. 19133 Engine Room Temperature
NOTICE
For this failure code, after investigating the cause of the problem and completing the repair,
perform “Loaded Diagnostics Operation to Confirm Failure Correction” to make sure the fail-
ure code is cleared. (Completion of repair cannot be judged simply by turning the starting
switch to ON position.)

No. Cause Procedure, measuring location, criteria and remarks

Defective AdBlue/DEF If failure code [CA1683] or [CA1684] is displayed on the abnormality record screen,
1 tank heating valve sys- perform troubleshooting these first.
tem
Defective AdBlue/DEF If failure code [CA1677] or [CA1678] is displayed on the abnormality record screen,
2 tank temperature sensor perform troubleshooting these first.
system

HB365LC-3 40-373
FAILURE CODE [CA1712] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

See “TESTING AND ADJUSTING”, “SERVICE MODE” of “SETTING AND OPERA-
TION MACHINE MONITOR”, “METHOD FOR SETTING WITH TESTING MENU
(SCR SERVICE TEST)” to perform an “AdBlue/DEF TANK HEATER RELAY TEST”
and check if the AdBlue/DEF tank heater valve is driven normally.
Confirm that the AdBlue/DEF tank heating valve operates in response to 19102
“AdBlue/DEF Tank HtrValve Command” (switches between 0 and 1).
1. Remove the coolant hose from the outlet side of the AdBlue/DEF tank heating
valve, and plug the removed hose.
2. Start the engine.
3. Perform an “AdBlue/DEF TANK HEATER RELAY TEST” to drive the
AdBlue/DEF tank heating valve.
Mechanical failure of
4. Make sure that coolant flows out in response to valve open and close com-
3 AdBlue/DEF tank heating
valve mands.
REMARK
If coolant flows out in response to valve operation, the AdBlue/DEF tank
heating valve is normal.
If coolant does not flow out:
Increase the temperature of the inlet side coolant hose to make sure that the cool-
ant flows out.
1. If coolant flows out from the inlet side coolant hose, replace the AdBlue/DEF
tank heating valve.
2. If coolant does not flow out from the inlet side coolant hose, clogging of the
coolant circuit is suspected.
Check if the engine coolant circuit in the engine or AdBlue/DEF tank is leaking or
Clogged engine coolant clogged. In addition check if the engine coolant level is appropriate. If there are
4
circuit and trapped air some problems, repair the relevant portions. Bleed air from the engine coolant
again.
Perform “Loaded Diagnostics Operation To Confirm Failure Correction”. If the AdBl-
Defective AdBlue/DEF
5 ue/DEF tank temperature does not rise correctly, replace the AdBlue/DEF tank sen-
tank temperature sensor
sor.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation to Confirm Failure Correction

Check if the repair has been completed with the following procedure:
(Make sure this failure code is not displayed after this procedure.)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start the engine.
3. Check monitoring code 19115 “AdBlue/DEF Temperature in Tank” on the “Pre-defined Monitoring” screen.
1) In case, monitoring code 19115 “AdBlue/DEF Temperature in Tank” is less than 1 °C.
1] Check if monitoring code 19102 “AdBlue/DEF Tank HtrValve Command” is issued (from 0 to
1) ,and perform warm-up operation.
When monitoring code 04107 “Coolant Temperature” becomes 0 °C or more during warm-up oper-
ation, monitoring code 19102 “AdBlue/DEF Tank HtrValve Command” is issued (from 0 to 1).
2] Keep warm-up operation and that monitoring code 04107 “Coolant Temperature” is 20 °C or more.
3] Confirmation will be completed if the AdBlue/DEF tank temperature becomes 4 °C or more within
an hour after the “AdBlue/DEF Tank HtrValve Command” is issued. If it becomes 4 °C or less, re-
turn to troubleshooting.
2) In case, monitoring code 19115 “AdBlue/DEF Temperature in Tank” is 1 °C or more.

40-374 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1712]

1] Perform warm-up operation, and raise the monitoring code 04107 “Coolant Temperature” to the
degree over 20 °C added to the ambient temperature.
2] See “TESTING AND ADJUSTING”, “SERVICE MODE” and “METHOD FOR OPERATING TEST-
ING MENU (SCR SERVICE TEST)” in “SETTING AND OPERATION OF MACHINE MONITOR” to
perform “AdBlue/DEF Tank Heater Valve Test”.
3] When monitoring code 04107 “Coolant Temperature” is less than the ambient temperature added
to 20 °C during “AdBlue/DEF tank heater relay test”, perform warm-up operation together with
“AdBlue/DEF Tank Heater Valve Test” again.
4] Confirmation will be completed if the AdBlue/DEF temperature in Tank becomes 5 °C or above
within an hour after starting the “AdBlue/DEF Tank Heater Valve Test”. If it becomes 5 °C or less,
return to troubleshooting.
4. After the repair is completed, see “PROCEDURE FOR TESTING AND TROUBLESHOOTING” to clear the
failure code and make sure that the failure code has been cleared from the Abnormality Record screen.

HB365LC-3 40-375
FAILURE CODE [CA1713] 40 TROUBLESHOOTING

FAILURE CODE [CA1713] (ALL-K-AFK1-410-10-B)

Action level Failure code AdBlue/DEF tank heating valve open stuck error
Failure
L01 CA1713 (Engine controller system)
Detail of fail-
AdBlue/DEF tank heating valve is always open.
ure
Action of
None in particular
controller
Phenomenon
AdBlue/DEF in AdBlue/DEF tank may be deteriorated prematurely by heat.
on machine
• Engine controller does not display this failure code during AdBlue/DEF tank thawing con-
trol. (Engine controller masks this failure code.)
• 19305 AdBlue/DEF Tank Heating State, 1: Thawing, 2: Warming, 3 or 0: OFF
• On “Pre-defined Monitoring” screen, AdBlue/DEF tank thawing control diagnosis is used.
(The numbers below denote monitoring codes).
• Pre-defined Monitoring (21/28) AdBlue/DEF tank thawing control
1. 19305 AdBlue/DEF Tank Heating State
Related 2. 19102 AdBlue/DEF Tank HtrValve Command
3. 19115 AdBlue/DEF Temperature in Tank
information
4. 04107 Engine Coolant Temperature
5. 19400 Ambient Temperature
6. 19133 Engine Room Temperature
NOTICE
For this failure code, after investigating the cause of the problem and completing the repair,
perform “Loaded Diagnostics Operation to Confirm Failure Correction” to make sure the re-
pair is completed. (Completion of repair cannot be judged simply by turning the starting
switch to ON position.)

No. Cause Procedure, measuring location, criteria and remarks

Defective AdBlue/DEF If failure code [CA1683] or [CA1684] is displayed on the abnormality record screen,
1 tank heating valve sys- perform troubleshooting these first.
tem
Defective AdBlue/DEF If failure code [CA1677] or [CA1678] is displayed on the abnormality record screen,
2 tank temperature sensor perform troubleshooting these first.
system

40-376 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1713]

No. Cause Procedure, measuring location, criteria and remarks

See Testing and adjusting, “service modes” of “setting and operating machine mon-
itor”, “operating method of testing menu (SCR service test)” to perform an
“AdBlue/DEF tank heater relay test” and check if the AdBlue/DEF tank heater valve
is driven normally.
Confirm that the AdBlue/DEF tank heating valve operates in response to 19102
“AdBlue/DEF Tank HtrValve Command” (switches between 0 and 1).
1. Remove the coolant hose from the outlet side of the AdBlue/DEF tank heating
valve, and plug the removed hose.
Mechanical failure of 2. Start the engine.
3 AdBlue/DEF tank heating 3.
Perform an “AdBlue/DEF tank heater relay test” to drive the AdBlue/DEF tank
valve
heating valve.
4. Make sure that coolant flows out in response to valve open and close com-
mands.
If coolant flows out regardless of valve open and close commands, replace the
AdBlue/DEF tank heating valve.
REMARK
If coolant flows out in response to valve operation, the AdBlue/DEF tank
heating valve is normal.
Perform “Loaded Diagnostics Operation To Confirm Failure Correction”. If the AdBl-
Defective AdBlue/DEF
4 ue/DEF tank temperature does not rise correctly, replace the AdBlue/DEF tank sen-
tank temperature sensor
sor.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation to Confirm Failure Correction

Check if the repair has been completed with the following procedure:
(Make sure this failure code is not displayed after this procedure.)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position.
3. Check if monitoring code 19102 “AdBlue/DEF Tank HtrValve Command” is not issued (0) on “Pre-defined
Monitoring” screen.
4. Start the engine and check the monitoring code 19115 “AdBlue/DEF Temperature in Tank”.
5. Raise monitoring code 04107 “Coolant Temperature” to the degree 10 °C or more than AdBlue/DEF tank
temperature.
6. Check again if the monitoring code 19102 “AdBlue/DEF Tank HtrValve Command” is not issued (0) on the
“Pre-defined Monitoring” screen.
7. Check if monitoring code 19115 “AdBlue/DEF Temperature in Tank” is 1 °C or less after a lapse of 5 mi-
nutes after starting the engine.
8. After the repair is completed, see “CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING” to
clear the failure code and make sure that the failure code has been cleared from the Abnormality Record
screen.
REMARK
If the monitoring code 19115 “AdBlue/DEF Temperature in Tank” is 2 °C or more, return to troubleshooting.

HB365LC-3 40-377
FAILURE CODE [CA1714] 40 TROUBLESHOOTING

FAILURE CODE [CA1714] (ALL-K-AFG0-410-50-B)

Action level Failure code AdBlue/DEF Quality Sensor Out of Calibration Error
Failure
L01 CA1714 (Engine controller system)
Detail of fail-
AdBlue/DEF quality sensor transmission data is abnormal
ure
Action of
Advances to Inducement strategy. (EU Specification)
controller
Phenomenon • The AdBlue/DEF quality data cannot be measured.
on machine • Engine power deration according to inducement strategy. (EU Specification)
• The AdBlue/DEF quality sensor is one of the AdBlue/DEF tank sensors integrated with the
AdBlue/DEF level sensor and AdBlue/DEF temperature sensor performs CAN communi-
cation with the engine controller.
Related
• If the AdBlue/DEF tank sensor is changed without installing genuine spare parts, this fail-
information ure code is displayed.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Check the sensor connector for contamination and damage.
2. Turn starting switch to OFF position.
3. Replace the AdBlue/DEF tank sensor.
Defective AdBlue/DEF
2 4. Turn starting switch to ON position.
tank sensor
If this failure code is cleared, any internal parts in the original AdBlue/DEF tank
sensor is defective. (In case of an internal defect, troubleshooting is impossible as
an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

40-378 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1715]

FAILURE CODE [CA1715] (ALL-K-AFG0-410-60-B)

Action level Failure code AdBlue/DEF Quality Sensor Internal Circuit Error
Failure
L01 CA1715 (Engine controller system)
Detail of fail-
Failure of AdBlue/DEF quality sensor (Abnormality in the circuit for quality measurement)
ure
Action of
Advances to Inducement strategy. (EU Specification)
controller
Phenomenon • The AdBlue/DEF quality data cannot be measured.
on machine • Engine power deration according to inducement strategy. (EU Specification)
• The AdBlue/DEF quality sensor is one of the AdBlue/DEF tank sensors integrated with the
AdBlue/DEF level sensor and AdBlue/DEF temperature sensor performs CAN communi-
cation with the engine controller.
Related
• If the engine controller receives information that the circuit for quality measurement is ab-
information normal, this failure code is displayed.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Check the sensor connector for contamination and damage.
2. Turn starting switch to OFF position.
3. Replace the AdBlue/DEF tank sensor.
Defective AdBlue/DEF
2 4. Turn starting switch to ON position.
tank sensor
If this failure code is cleared, any internal parts in the original AdBlue/DEF tank
sensor is defective. (In case of an internal defect, troubleshooting is impossible as
an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-379
FAILURE CODE [CA1776] 40 TROUBLESHOOTING

FAILURE CODE [CA1776] (ALL-K-AFA3-410-00-B)

Action level Failure code Sensor Supply Relay Voltage High Error
Failure
L01 CA1776 (Engine controller system)
Detail of fail-
A high voltage error occurs in sensor power supply relay circuit.
ure
Action of
None in particular
controller
• Inoperative KDPF temperature sensor, turbocharger outlet NOx sensor, SCR outlet NOx
Phenomenon
sensor, ammonia sensor, SCR temperature sensor and AdBlue/DEF tank sensor.
on machine
• NOx emission increases because AdBlue/DEF injection is disabled.
• This failure code is displayed if the connector is removed when the sensor power supply
relay is turned OFF.
• Note that sensor power supply relay connector is energized even if starting switch is
turned to OFF position.
• This failure code is detected until the sensor power supply relay is turned OFF, during
which the engine controller shuts down since starting switch is turned to OFF position.
• This failure code is not detected when starting switch is at ON position and not displayed
Related on the monitor standard screen. Check the detection on "Abnormality Record" screen.
information • Troubleshooting of this failure code covers circuits from engine controller through sensor
power supply relay to ground.
NOTICE
• If the failure code is displayed, perform investigation of the cause, perform repair,
clear “Electrical Sys Abnormality Record”, turn starting switch off, and shut down
the engine controller. (See “PROCEDURE FOR TROUBLESHOOTING” in this chap-
ter.) Turn starting switch to ON position again and check "Abnormality Record"
screen. If this failure code is not logged, the repair is completed.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
FORMATION ON TROUBLESHOOTING”, and check it.
2. Turn starting switch to ON position.
3. Perform deletion of “Electrical Sys Abnormality Record” in “SERVICE
Defective wiring harness MODE” of machine monitor.
1
connector
4. Turn the starting switch to OFF position, and shut down the engine control-
ler.
5. Turn starting switch to ON position.
If this failure code is not logged on Abnormality Record screen, wiring harness con-
nector is defective.
1. Starting switch: OFF
2. Check that system operating lamp does not light up, and then turn battery
Open circuit in wiring har- disconnect switch to OFF position.
ness (wire breakage or 3. Disconnect connectors ECM J1 and R52 and connect T-adapters to each
2
defective contact of con- female side.
nector)
Between ECM J1 (female) (9) and R52 (female) (5) Max. 10 Ω
Resistance
Between R52 (female) (4) and ground Max. 10 Ω

40-380 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1776]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn the bat-
tery disconnect switch OFF.
Defective sensor power 3. Disconnect connector R52, and replace sensor power supply relay.
3
supply relay
4. Turn the battery disconnect switch ON.
5. Turn starting switch to ON position.
If this failure code is cleared, the original sensor power supply relay is defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-381
FAILURE CODE [CA1776] 40 TROUBLESHOOTING

Circuit diagram related to sensor power supply relay circuit

40-382 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1777]

FAILURE CODE [CA1777] (ALL-K-AFA3-410-01-B)

Action level Failure code Sensor Supply Relay Voltage Low Error
Failure
L01 CA1777 (Engine controller system)
Detail of fail-
Low voltage error occurs in sensor power supply relay circuit.
ure
Action of
None in particular
controller
• Inoperative KDPF temperature sensor, turbocharger outlet NOx sensor, SCR outlet NOx
Phenomenon
sensor, ammonia sensor, SCR temperature sensor and AdBlue/DEF tank sensor.
on machine
• NOx emission increases because AdBlue/DEF injection is disabled.
• Be careful that voltage is applied to the connector of the sensor power supply relay even if
the starting switch is OFF.
Related • Troubleshooting of this failure code covers circuits from engine controller through sensor
information power supply relay to ground.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Check if fuses No. 1 and 2 in fuse box F02 are blown.
Defective fuses No. 1
1 REMARK
and 2 in fuse box F02
If blown, perform troubleshooting for ground fault in wiring harness.
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn the bat-
tery disconnect switch OFF.
Defective sensor power 3. Disconnect connector SSR, and replace sensor power supply relay.
2
supply relay
4. Turn the battery disconnect switch ON.
5. Turn starting switch to ON position.
If this failure code is cleared, the original sensor power supply relay is defective.
If no failure is found by above checks, this check is not required.
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors J1 and R52, and connect the T-adapter to each
Open circuit in wiring har- female side.
ness (wire breakage or 4.
3 Remove the fuses No. 1 and 2 in fuse box F02.
defective contact of con-
nector) Between J1 (female) (9) and R52 (female) (5) Max. 10 Ω
Between R52 (female) (4) and ground Max. 10 Ω
Resistance Between fuse box F02-2 and R52 (female) (1) Max. 10 Ω
Between fuse box F02-1 and R52 (female) (2) Max. 10 Ω
Between fuse box F02-1 and R52 (female) (3) Max. 10 Ω

HB365LC-3 40-383
FAILURE CODE [CA1777] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
Ground fault in wiring connect switch to OFF position.
4 harness (contact with 3. Disconnect the connectors J1 and R52, and connect the T-adapter to each
GND circuit) female side.
Between ground and J1 (female) (9) or R52 (female)
Resistance Max. 10 Ω
(5)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)

40-384 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1777]

Circuit diagram related to sensor power supply relay circuit

HB365LC-3 40-385
FAILURE CODE [CA1843] 40 TROUBLESHOOTING

FAILURE CODE [CA1843] (ALL-K-A18B-410-00-B)

Action level Failure code

Failure Crankcase Pressure Sensor High Error (Engine controller system)
L01 CA1843
Details of
High voltage error is detected in signal circuit of crankcase pressure sensor.
failure
Action of
Sets crankcase pressure to fixed value. (approximately 0 kPa)
controller
Phenomenon
None in particular
on machine
• Signal voltage from crankcase pressure sensor can be checked by monitoring function.
(Code: 48401 (V))
Related • Pressure in crankcase pressure sensor can be checked by monitoring function. (Code:
information 48400 (MPa))
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
If failure code [CA352] or [CA386] is also displayed, perform troubleshooting these
first.
1. Turn starting switch to OFF position.
Defective sensor power 2.
2 Disconnect connector P57 and connect T-adapter to female side.
supply system
3. Turn starting switch to ON position.
Between P57 (female) (1) 4.75 to
Voltage Power supply
and (2) 5.25 V
1. Turn starting switch to OFF position.
Defective crankcase 2. Disconnect connector P57.
3 pressure sensor (internal 3. Turn starting switch to ON position.
defect)
If failure code changes from [CA1843] to [CA1844], crankcase pressure sensor is
defective.
1. Starting switch: OFF
2. Disconnect connectors ECM J1 and P57, and connect T-adapters to each
Open circuit in wiring har-
female side.
ness (ground line break-
4
age or defective contact NOTICE
of connector)
Open circuit in GND line
Resistance Between ECM J1 (female) (54) and P57 (female) (2) Max. 10 Ω
1. Starting switch: OFF
2. Disconnect connectors ECM J1 and P57, and connect T-adapter to either
Short circuit in wiring har-
5 female side.
ness
Between ECM J1 (female) (63) and (78), or between
Resistance Min. 100 kΩ
P57 (female) (1) and (3)

40-386 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1843]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector P57 and connect T-adapter to female side.
6
harness 3. Turn starting switch to ON position.
Voltage Between P57 (female) (3) and (2) Max. 1 V
If no failure is found by above checks, engine controller is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)
Reference
Defective engine control- 1. Turn starting switch to OFF position.
7
ler 2. Insert T-adapter into connector ECM J1.
3. Turn starting switch to ON position.
Between ECM J1 (63) and
Voltage Sensor output 0.3 to 4.7 V
(54)

Circuit diagram related to crankcase pressure sensor

HB365LC-3 40-387
FAILURE CODE [CA1844] 40 TROUBLESHOOTING

FAILURE CODE [CA1844] (ALL-K-A18B-410-10-B)

Action level Failure code Crankcase pressure sensor low error

Failure
L01 CA1844 (Engine controller system)
Detail of fail-
Low voltage error is detected in signal circuit of crankcase pressure sensor.
ure
Action of
Sets crankcase pressure to fixed value (approximately 0 kPa) for operation.
controller
Phenomenon
None in particular
on machine
• Signal voltage from crankcase pressure sensor can be checked with monitoring function.
(Code: 48401 (V))
Related • Pressure by crankcase pressure sensor can be checked with monitoring function. (Code:
information 48400 (MPa))
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective wiring harness
1
connector
Defective sensor power
2 Disconnect connector P57 and connect T-adapter to female side.
supply system
Open circuit in wiring har-
ness (wire breakage or
3
defective contact of con-
nector)
1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
FORMATION ON TROUBLESHOOTING”, and check it.
2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
If failure code [CA352] or [CA386] is also displayed, perform troubleshooting these
first.
1. Turn starting switch to OFF position.
2.
3. Turn starting switch to ON position.
Between P57 (female) (1) 4.75 to
Voltage Power supply
and (2) 5.25 V
1. Starting switch: OFF
2. Disconnect connectors ECM J1 and P57, and connect T-adapters to each
female side.
NOTICE
If there is any abnormality in wiring harness, disconnect connector OEM
CONNECTION and check similarly to see if abnormality is in engine harness
or in chassis harness.
REMARK
If failure code is still displayed after above checks on Max. 10 Ω
cause 2, this check is not required.
Between ECM J1 (female) (78) and P57 (female) (1)
Resistance REMARK
If failure code is still displayed after above checks on Max. 10 Ω
cause 2, this check is not required.
Between ECM J1 (female) (54) and P57 (female) (2)
Between ECM J1 (female) (63) and P57 (female) (3) Max. 10 Ω

40-388 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1844]

No. Cause Procedure, measuring location, criteria and remarks

1. Starting switch: OFF
2. Disconnect connectors ECM J1 and P57, and connect T-adapters to each
female side.
Ground fault in wiring NOTICE
4 harness (contact with
If there is any abnormality in wiring harness, disconnect connector OEM
ground circuit)
CONNECTION and check similarly to see if abnormality is in engine harness
or in chassis harness.
Between ground and ECM J1 (female) (63) or P57 (fe-
Resistance Min. 100 kΩ
male) (3)
1. Starting switch: OFF
2. Disconnect connectors ECM J1 and P57, and connect T-adapter to either
Short circuit in wiring har-
5 female side.
ness
Between ECM J1 (female) (63) and (54), or between
Resistance Min. 100 kΩ
P57 (female) (2) and (3)
1. Turn starting switch to OFF position.
Defective crankcase 2. Insert T-adapter to connector P57.
6 pressure sensor (internal 3. Turn starting switch to ON position.
defect)
Between P57 (female) (3)
Voltage Sensor output 0.3 to 4.7 V
and (2)
If no failure is found by above checks, engine controller is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)
Reference
Defective engine control- 1. Turn starting switch to OFF position.
7
ler 2. Insert T-adapter into connector ECM J1.
3. Turn starting switch to ON position.
Between ECM J1 (63) and
Voltage Sensor output 0.3 to 4.7 V
(54)

Circuit diagram related to crankcase pressure sensor

HB365LC-3 40-389
FAILURE CODE [CA1879] 40 TROUBLESHOOTING

FAILURE CODE [CA1879] (ALL-K-A9HW-410-00-B)

Action level Failure code KDPF Differential Pressure Sensor High Error (Engine controller sys-
Failure
L03 CA1879 tem)

Details of
High voltage error is detected in signal circuit of KDPF differential pressure sensor.
failure
• Operates at estimated value of KDPF differential pressure sensor. (If other failure code al-
so is displayed, operation may be performed at 0 kPa.)
Action of
• EGR valve closes and VGT opens fully.
controller
• Engine power deration
• Regeneration control stops.
Phenomenon
Engine power deration
on machine

k KDPF becomes hot (Min. 500 °C). Be careful not to get burned.
• KDPF differential pressure sensor and KDPF outlet pressure sensor are provided as a
unit.
• If failure code [CA3133] is displayed instead of failure code [CA1695], wire breakage (de-
fective contact of connector) of GND line is highly possible.
Related • Signal voltage from KDPF differential pressure sensor can be checked by monitoring func-
tion. (Code: 47101 (V))
information
• Differential pressure in KDPF differential pressure sensor can be checked by monitoring
function. (Code: 47100 (kPa))
• Engine power deration is canceled when the failure code is cleared and the starting switch
is turned OFF (not canceled only by deactivation of the failure code).
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
If failure code [CA1695] or [CA1696] is displayed, perform troubleshooting for
[CA1695] or [CA1696] first.
1. Turn starting switch to OFF position.
Defective sensor power 2.
2 Disconnect connector E25, and connect T-adapter to female side.
supply system
3. Turn starting switch to ON position.
4.75 to
Voltage Between E25 (female) (4) and (1)
5.25 V

40-390 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1879]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector E25.
3. Turn starting switch to ON position.
If this failure code is changed to [CA1881], the KDPF differential pressure sensor is
Defective KDPF differen-
3 defective.
tial pressure sensor
NOTICE
• If this failure code is displayed, the wiring harness or engine control-
ler is defective.
• Ignore other failure codes displayed.
If failure code is still displayed after above checks on cause 2, this check is not re-
quired.
Open circuit in wiring har- 1.
Starting switch: OFF
ness (wire breakage of
4 2. Disconnect connectors ECM J2 and E25, and connect T-adapters to each
GND line or defective
contact of connector) female side.
Resistance Between ECM J2 (female) (32) and E25 (female) (1) Max. 10 Ω
1. Starting switch: OFF
2. Disconnect connectors ECM J2 and E25, and connect T-adapter to female
Short circuit in wiring har- side of ECM J2.
5
ness
No continui-
Between ECM J2 (female) (41) and each pin other
Continuity ty (no sound
than pin (41)
is heard)
1. Starting switch: OFF
2. Disconnect connector E25.
3. Connect T-adapter to female side of connector E25, or insert T-adapter to
Hot short circuit in wiring
6 connector ECM J2.
harness
4. Turn starting switch to ON position (with connector E25 disconnected).
Between ECM J2 (female) (41) and (32), or between
Voltage Max. 1 V
E25 (female) (2) and (1)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-391
FAILURE CODE [CA1879] 40 TROUBLESHOOTING

Circuit diagram related to KDPF differential pressure sensor

40-392 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1881]

FAILURE CODE [CA1881] (ALL-K-A9HW-410-10-B)

Action level Failure code KDPF Differential Pressure Sensor Low Error
Failure
L03 CA1881 (Engine controller system)
Details of
Low voltage error is detected in signal circuit of KDPF differential pressure sensor.
failure
• Operates at estimated value of KDPF differential pressure sensor. (If other failure code al-
so is displayed, operation may be performed at 0 kPa.)
Action of
• EGR valve closes and VGT opens fully.
controller
• Engine power deration
• Regeneration control stops.
Phenomenon
Engine power deration
on machine

k KDPF becomes hot (Min. 500 °C). Be careful not to get burned.
• KDPF differential pressure sensor and KDPF outlet pressure sensor are provided as a
unit.
• If failure code [CA3134] is also displayed instead of failure code [CA1696], it is highly pos-
sible that sensor connector is removed or wire breakage (defective contact of connector)
occurs in 5 V line.
• This failure code is displayed if sensor connector is disconnected.
Related
• Signal voltage from KDPF differential pressure sensor can be checked by monitoring func-
information
tion. (Code: 47101 (V))
• Differential pressure in KDPF differential pressure sensor can be checked by monitoring
function. (Code: 47100 (kPa))
• Engine power deration is canceled when the failure code is cleared and the starting switch
is turned OFF (not canceled only by deactivation of the failure code).
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
If failure code [CA1695] or [CA1696] is displayed, perform troubleshooting for
[CA1695] or [CA1696] first.
1. Turn starting switch to OFF position.
Defective sensor power 2.
2 Disconnect connector E25, and connect T-adapter to female side.
supply system
3. Turn starting switch to ON position.
4.75 to
Voltage Between E25 (female) (4) and (1)
5.25 V

HB365LC-3 40-393
FAILURE CODE [CA1881] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Starting switch: OFF
2. Disconnect connectors ECM J2 and E25, and connect T-adapters to each
female side.

Open circuit in wiring har- If failure code is still displayed after above checks on
ness (wire breakage or cause 2, this check is not required. Max. 10 Ω
3
defective contact of con- Between ECM J2 (female) (32) and E25 (female) (1)
nector)
Resistance If failure code is still displayed after above checks on
cause 2, this check is not required. Max. 10 Ω
Between ECM J2 (female) (8) and E25 (female) (4)
Between ECM J2 (female) (41) and E25 (female) (2) Max. 10 Ω
1. Starting switch: OFF
Ground fault in wiring 2. Disconnect connectors ECM J2 and E25, and connect T-adapter to either
4 harness (contact with female side.
ground circuit)
Between ECM J2 (female) (41) and ground, or be-
Resistance Min. 100 kΩ
tween E25 (female) (2) and ground
1. Starting switch: OFF
2. Disconnect connectors ECM J2 and E25, and connect T-adapter to female
Short circuit in wiring har- side of ECM J2.
5
ness
No continui-
Between ECM J2 (female) (41) and each pin other
Continuity ty (no sound
than pin (41)
is heard)
1. Turn starting switch to OFF position.
Defective KDPF differen- 2. Insert T-adapter into connector E25.
6
tial pressure sensor 3. Turn starting switch to ON position.
Voltage Between E25 (2) and (1) 0.5 to 4.5 V
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to KDPF differential pressure sensor

40-394 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1883]

FAILURE CODE [CA1883] (ALL-K-A9HW-410-20-B)

Action level Failure code KDPF Differential Pressure Sensor In Range Error
Failure
L03 CA1883 (Engine controller system)
Details of Signal voltage from KDPF differential pressure sensor does not show correct value. (Signal voltage
failure is within use range.)

• Operates at estimated value of KDPF differential pressure sensor. (If other failure code al-
so is displayed, operation may be performed at 0 kPa.)
Action of • EGR valve closes.
controller • Engine power deration
• Regeneration control stops.
• Fuel dosing stops.
Phenomenon
Engine power deration
on machine

k KDPF becomes hot (Min. 500 °C). Be careful not to get burned.
• KDPF differential pressure sensor and KDPF outlet pressure sensor are integrated.
• Signal voltage from KDPF differential pressure sensor can be checked by monitoring func-
tion. (Code: 47101 (V))
• Differential pressure in KDPF differential pressure sensor can be checked by monitoring
function. (Code: 47100 (kPa))
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
(Code: 47300 (°C))
• Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
Use “Short socket adapter: 799T-601-4611”.
• For details of access to KDPF differential pressure sensor, wiring harness and tube, see
Related “Chapter 50 DISASSEMBLY AND ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEM-
information BLY” and “DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY”.
• After turning starting switch to OFF position, engine controller performs AdBlue/DEF purg-
ing (for Max. 6 minutes) and then stops. To restart engine, wait until system operating
lamp goes off after turning starting switch to OFF position, and then turn starting switch to
ON position.
• “Loaded Diagnostics Operation To Clear Failure Code”.
NOTICE
• This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. Af-
ter investigating the cause of the problem and completing the repair, perform “Load-
ed Diagnostics Operation To Clear Failure Code” to make sure the failure code is
cleared. (This failure code is not cleared by only turning ON the starting switch
again.)
• This failure code is cleared by performing operations indicated in TESTING AND AD-
JUSTING, “SETTING AND OPERATION OF MACHINE MONITOR”, “SERVICE MODE”,
“METHOD FOR SETTING WITH TESTING MENU (ENGINE CONTROLLER ACTIVE
FAULT CLEAR)”.

HB365LC-3 40-395
FAILURE CODE [CA1883] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Remove KDPF differential pressure sensor tube.
2. Clean and unclog the KDPF differential pressure sensor tube.
3. Check the KDPF differential pressure sensor tube for cracks or damages.
4. Securely connect both ends of the tube and install the KDPF differential
pressure sensor tube.
Defective KDPF differen-
1 Reference
tial pressure sensor tube
How to check clogged KDPF differential pressure sensor tube
1. Turn starting switch to ON position.
2. Monitor the differential pressure by using KDPF differential pressure sen-
sor on Self-define Monitoring screen of the machine monitor.
Code 47100(kPa) 0 ± 3( kPa)
See “REMOVE AND INSTALL KDPF ASSEMBLY”, and “DISASSEMBLE AND AS-
Improper installation of
2 SEMBLE OF KDPF ASSEMBLY” in Chapter 50 DISASSEMBLY AND ASSEMBLY
KDPF
for repair.
If failure code [CA1695] or [CA1696] is displayed, perform troubleshooting for
[CA1695] or [CA1696] first.
1. Turn starting switch to OFF position.
Defective sensor power 2.
3 Disconnect connector E25, and connect T-adapter to female side.
supply system
3. Turn starting switch to ON position.
4.75 to
Voltage Between E25 (female) (4) and (1)
5.25 V
1. See descriptions of wiring harness and connectors in “Electrical equip-
Defective wiring harness ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
4
connector FORMATION ON TROUBLESHOOTING”, and check and repair defects, if
any.
1. Turn starting switch to OFF position.
2. Disconnect connector E25.
3. Turn starting switch to ON position.
If failure code [CA1881] is cleared, the wiring harness or engine controller is defec-
tive.
Check cause 4 again.
Ignore other failure codes displayed.
1. Turn starting switch to OFF position.
Defective wiring harness
5 2. Disconnect connector E25 and connect short socket adapter to female
or engine controller
side.
REMARK
Connect 5 V to the signal line. (Short-circuit pins (4) and (3) of connector E25.)
3. Turn starting switch to ON position.
If failure code [CA1879] is cleared, the wiring harness or engine controller is defec-
tive.
Check cause 4 again.
Ignore other failure codes displayed.
Defective KDPF differen- If failure codes [CA1881] and [CA1879] are displayed after checks on cause 5, the
6
tial pressure sensor KDPF differential pressure sensor is defective.

40-396 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1883]

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks, any internal parts in the engine
Defective engine control-
7 controller is defective. (In case of an internal defect, troubleshooting is impossible
ler
as an assembly. Replace whole assembly.)

Loaded Diagnostics Operation To Clear Failure Code

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is cleared after this procedure.)
k Place the machine on a level ground.
1. Turn the starting switch to ON position and leave it for 1 minute.
REMARK
The engine controller has to recognize the dispersion of sensor when the starting switch is turned to ON
position.
2. Turn the starting switch from OFF position to ON position.
3. Start the engine and run it at low idle for approximately 1 minute.
4. After finishing the warm-up operation, set the swing lock switch to ON position, working mode to B, and fuel
control dial to MAX position.
5. Perform arm IN relief for 40 seconds.
NOTICE
Take care not to overheat the oil of work equipment.
6. If the failure code is cleared after steps 1 to 5 are performed, repair work is completed.
7. If this failure code is not cleared, repeat the above step 5 for 3 times.
8. If the failure code is cleared, repair work is completed.
Circuit diagram related to KDPF differential pressure sensor

HB365LC-3 40-397
FAILURE CODE [CA1885] 40 TROUBLESHOOTING

FAILURE CODE [CA1885] (ALL-K-AFM0-410-10-B)

Action level Failure code Turbo outlet NOx sensor circuit error
Failure
L01 CA1885 (Engine controller system)
Detail of fail- Turbo outlet NOx sensor does not display the value due to internal circuit error of turbo outlet NOx
ure sensor.
Action of • Operates using the NOx value in the memory.
controller • Inducement strategy is activated (EU specifications).
• AdBlue/DEF injection becomes inappropriate and the NOx emission may increase, or am-
Phenomenon
monia may be discharged.
on machine
• Engine output is reduced based on Inducement strategy (EU specifications).
k The turbocharger outlet, KDPF, sensor fitting piping, and sensor probe become hot
as 500 °C or higher. Be careful not to get burn injury.
k As for the sensor probe, be careful not to get burn injury even if the surroundings
are not hot, because sensor itself is heated.
• Turbo outlet NOx sensor communicates with engine controller through CAN communica-
tion.
• Turbo outlet NOx sensor operates when KDOC inlet temperature is 150 °C or higher
(19203 Turbo Outlet NOx Sensor State is “1”).
• The turbocharger outlet NOx sensor does not operate when KDOC inlet temperature is
150 °C or lower, and correct value is not displayed (the sensor does not operate by simply
turning the starting switch to ON even when it is normal).
• On Pre-defined Monitoring screen, engine operation state diagnosis, SCR catalyst, NOx
sensor, ammonia sensor diagnosis are used.
• Pre-defined Monitoring (16/28) Engine operation state
Related 1. 01002 Engine Speed
information 2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
• Pre-defined Monitoring (19/28) SCR catalyst/NOX sensor/NH3 sensor
1. 19120 AdBlue/DEF Injection Quantity
2. 19205 SCR NH3 Concentration Corrected
3. 19202 Turbo Outlet NOx Corrected
4. 19209 SCR Outlet NOx Corrected
5. 19203 Turbo Outlet NOx Sensor State
6. 19210 SCR Outlet NOx Sensor State
NOTICE
For this failure code, after investigating the cause of the problem and completing the re-
pair, perform “Loaded Diagnostics Operation To Confirm Failure Correction” to make
sure the failure code is cleared.

No. Cause Procedure, measuring location, criteria and remarks

CAN communication sys- If failure code [CA3232] is displayed, perform troubleshooting for [CA3232] first.
1
tem error
Defective sensor power If failure code [CA1776] or [CA1777] is displayed, perform troubleshooting for
2
supply system [CA1776] or [CA1777] first.

40-398 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1885]

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks, the turbocharger outlet NOx
sensor may be defective.
1. Turn starting switch to OFF position.
Defective turbocharger 2. NOx sensor fails, therefore, replace the turbocharger outlet NOx sensor.
3
outlet NOx sensor
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is cleared, the original sensor is defective. (In case of an internal
defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

Perform the following procedure to check that the repair is completed.
Clear this failure code by “Engine Controller Inducement Fault Clear” before step 1. (EU specification)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start the engine.
3. Set the working mode to B.
4. Run the engine at high idle speed with safe condition in order to raise the exhaust gas temperature. (Keep
the engine speed so that the monitoring code 47300 “KDOC 1 Inlet Temperature” becomes 150 °C or high-
er. Check that the monitoring code 19203 “Turbo Outlet NOx Sensor State” changes from 0 to 1.)
5. Repair is completed if failure code is not displayed after 3 minutes have passed.
REMARK
If the turbocharger outlet NOx sensor cannot be activated (that is, monitoring code 19203 “Turbo Outlet NOx
Sensor State” remains as 0), return to troubleshooting.

HB365LC-3 40-399
FAILURE CODE [CA1887] 40 TROUBLESHOOTING

FAILURE CODE [CA1887] (ALL-K-AFA0-410-30-B)

Action level Failure code SCR outlet NOx sensor circuit error
Failure
L01 CA1887 (Engine controller system)
Detail of fail- The engine controller does not receive SCR outlet NOx sensor data due to a communication error
ure with the SCR outlet NOx sensor.
Action of • Operates at default NOx value (0 ppm).
controller • Inducement strategy is activated (EU specifications).
• AdBlue/DEF injection becomes inappropriate and the NOx emission may increase, or am-
Phenomenon
monia may be discharged.
on machine
• Engine output is reduced based on Inducement strategy (EU specifications).
k SCR assembly, sensor fitting piping, and sensor probe are heated to 400 °C or high-
er. Be careful not to get burn injury.
k As for the sensor probe, be careful not to get burn injury even if the surroundings
are not hot, because sensor itself is heated.
• SCR outlet NOx sensor is smart sensor which communicates with engine controller with
other sensors through CAN communication.
• SCR outlet NOx sensor operates when SCR Outlet Temperature is 150 °C or higher
(19210 SCR Outlet NOx Sensor State is “1”).
• SCR outlet NOx sensor does not operate when SCR outlet temperature is 150 °C or lower,
and correct value is not displayed (the sensor does not operate by simply turning the start-
ing switch to ON position even when it is normal).
• On “Pre-defined Monitoring” screen, engine operation state diagnosis, SCR catalyst, NOx
sensor, ammonia sensor diagnosis are used.
• Pre-defined Monitoring (16/28) Engine operation state
Related 1. 01002 Engine Speed
information 2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
• Pre-defined Monitoring (19/28) SCR catalyst/NOX sensor/NH3 sensor
1. 19120 AdBlue/DEF Injection Quantity
2. 19205 SCR NH3 Concentration Corrected
3. 19202 Turbo Outlet NOx Corrected
4. 19209 SCR Outlet NOx Corrected
5. 19203 Turbo Outlet NOx Sensor State
6. 19210 SCR Outlet NOx Sensor State
NOTICE
For this failure code, after investigating the cause of the problem and completing the repair,
perform “Loaded Diagnostics Operation To Confirm Failure Correction” to make sure the
failure code is cleared.

No. Cause Procedure, measuring location, criteria and remarks

Defective CAN communi- If failure code [CA2771] is displayed, perform troubleshooting for [CA2771] first.
1
cation system
Defective sensor power If failure code [CA1776] or [CA1777] is displayed, perform troubleshooting for
2
supply system [CA1776] or [CA1777] first.

40-400 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1887]

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by preceding checks, the SCR outlet NOx sensor is defective.
1. Turn starting switch to OFF position.
2. Replace the SCR outlet NOx sensor.
Defective SCR outlet
3 3. Turn starting switch to ON position.
NOx sensor
4. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is cleared, the original sensor is defective. (In case of an internal
defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

Perform the following procedure to check that the repair is completed.
Clear this failure code by “Engine Controller Inducement Fault Clear” before step 1. (EU specification)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start the engine.
3. Set the working mode to B.
4. Run the engine at high idle speed with safe condition in order to raise the exhaust gas temperature. (Keep
the engine speed so that the monitoring code 19302 “SCR Outlet Temperature” becomes 150 °C or higher.
Check that the monitoring code 19210 “SCR Outlet NOx Sensor State” changes from 0 to 1.)
5. Repair is completed if failure code is not displayed after 3 minutes have passed.
REMARK
If the SCR outlet NOx sensor cannot be activated (that is, 19210 “SCR Outlet NOx Sensor State” remains as 0),
return to troubleshooting.

HB365LC-3 40-401
FAILURE CODE [CA1921] 40 TROUBLESHOOTING

FAILURE CODE [CA1921] (ALL-K-A9H0-410-20-B)

Action level Failure code KDPF Soot Accumulation High Error 1

Failure
L03 CA1921 (Engine controller system)

Details of This failure code requests users to perform “Manual stationary regeneration” immediately, because
KDPF soot accumulation level is 6 or 7 and it means a large amount of soot is accumulated in
failure KCSF (If soot accumulation level is 8, KDPF must be replaced.)
• EGR valve closes and fully opens VGT.
Action of
• Controls output for operation.
controller
• Disables automatic regeneration but enables manual stationary regeneration.
Phenomenon
Engine power deration
on machine

k Since KDOC and KDPF are heated to 500 °C or above, be careful not to get burned.
• Temperature detected by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• Temperature detected by KDOC outlet temperature sensor can be checked with monitor-
ing function. (Code: 47400 (°C))
• Temperature detected by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• Signal voltage from KDPF differential pressure sensor can be checked by monitoring func-
tion. (Code: 47101 (V))
• Differential pressure in KDPF differential pressure sensor can be checked by monitoring
function. (Code: 47100 (kPa))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when at
low idle speed (KDPF regeneration is not executed) are approximately 100 to 250 °C, and
difference between these temperatures is approximately 10 °C. (KDOC inlet temperature >
KDOC outlet temperature > KDPF outlet temperature)
• When manual stationary regeneration is in progress, KDOC inlet temperature is approxi-
mately 250 to 400 °C, and KDOC outlet temperature and KDPF outlet temperature are ap-
proximately 450 to 550 °C.
Related • The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
information outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.
• Test exhaust gas color. For details, see “TESTING AND ADJUSTING”, “TEST EXHAUST
GAS COLOR”.
• Soot accumulation amount in KDPF is classified into 8 levels. Current soot accumulation
level can be checked in 02 Active Regeneration for Service screen of machine monitor.
• Manual stationary regeneration downs soot accumulation level 7 from level 8 by removing
soot.
• If soot accumulation level is 8, failure code [CA1922] is displayed. At this time, KDPF is
completely clogged with soot and inspection, cleaning or replacement is required.
• If another failure code is displayed (including when manual stationary regeneration is in
progress), perform troubleshooting for these failure codes first.
• If failure code [CA1922] is originally displayed, failure code changes from [CA1922] to
[CA1921] in troubleshooting process. In this case, see failure code [CA1922].
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note the engine power deration is not canceled right after the failure
code is cleared).

40-402 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1921]

Time required for the manual stationary regeneration depends on the accumulated soot in KCSF,
however, it is estimated as follows.
• If soot accumulation is level 4: Approximately 40 minutes to 1 hour
Related
• If soot accumulation is level 5: Approximately 1 to 2 hours
information
• If soot accumulation is level 6 or 7: Approximately 2 to 3 hours
• If soot accumulation is level 8: Manual stationary regeneration cannot be performed.
Cause for excessive soot accumulation
1. Engine runs in light load area where exhaust gas temperature is high enough to burn soot
in KDPF.
• Low gas temperature at entering into KDPF cause a large amount of soot to be accu-
mulated.
• To protect KDPF from soot accumulation, it is necessary to run the engine under high
load.
2. There is an engine failure generating excessive black smoke.
Related
3. The function of disable regeneration is set from monitor.
information
• Regeneration is set not to perform automatically even if soot is accumulated. It is re-
quired to cancel regeneration disable and perform regeneration at safe place.
Method of canceling regeneration disable
• Select Cancel of Regeneration Disable from Aftertreatment Devices Regeneration screen
of user menu, and perform it. (For details, see “PROCEDURE FOR CANCEL OF AFTER-
TREATMENT DEVICES REGENERATION DISABLE SETTING” of “HANDLE Komatsu
Diesel Particulate Filter (KDPF)” of “Handling” in Operation and Maintenance Manual.)

No. Cause Procedure, measuring location, criteria and remarks

1. Check that regeneration disable is not set on machine monitor. (Cancel the
regeneration disable if it is set.)
2. Start the engine.
3. Secure the safety of the machine.
4. Perform “manual stationary regeneration” in user mode.
Defective accumulation When the manual stationary regeneration is completed successfully, the repair
1 is completed.
of soot in KDPF (KCSF)
If the regeneration is not completed after 3 hours, perform troubleshooting for
[CA2639].
5. Check that the failure code is cleared after manual stationary regeneration
is complete.
6. If failure code [CA1921] or [CA2639] is displayed after manual stationary
regeneration is complete, perform check on cause 2.

HB365LC-3 40-403
FAILURE CODE [CA1921] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

• If failure code [CA1921], or [CA2639] is displayed after manual stationary
regeneration is completed, perform the following:
• For details of checking the exhaust gas color, see TESTING AND AD-
JUSTING, “TEST EXHAUST GAS COLOR”.
• Perform regeneration disable on the machine monitor to check the exhaust
gas color.
Defective exhaust gas 1. Set the working mode to “B”, suddenly accelerate the engine from low idle to
2 high idle two times, and then keep the engine running at high idle for 5 sec-
color
onds.
If an excess black smoke is seen at high idle during acceleration, perform S
MODE, “KDPF GETS CLOGGED IN A SHORT TIME”.
Black smoke powder which comes out during acceleration but disappears at
high idle is normal.
2. To finish the exhaust gas color check, cancel the regeneration disable.
3. Make sure that the failure code is not displayed.

40-404 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1922]

FAILURE CODE [CA1922] (ALL-K-A9H0-410-30-B)

Action level Failure code KDPF Soot Accumulation High Error 2

Failure
L04 CA1922 (Engine controller system)

Details of • If soot accumulation is level 8 : Manual stationary regeneration cannot be performed.

failure • Engine must be stopped immediately and perform diagnostic test and maintenance.
• EGR valve closes and fully opens VGT.
Action of
• Controls output for operation.
controller
• Disables automatic regeneration and manual stationary regeneration.
Phenomenon
Engine power deration
on machine

k Since KDOC and KDPF are heated to 500 °C or above, be careful not to get burned.
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
(Code: 47300 (°C))
• Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
• Signal voltage from KDPF differential pressure sensor can be checked by monitoring func-
tion. (Code: 47101 (V))
• Differential pressure in KDPF differential pressure sensor can be checked by monitoring
function. (Code: 47100 (kPa))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when at
low idle speed (KDPF regeneration is not executed) are approximately 100 to 250 °C, and
difference between these temperatures is approximately 10 °C. (KDOC inlet temperature >
KDOC outlet temperature > KDPF outlet temperature)
Related • When manual stationary regeneration is in progress, KDOC inlet temperature is approxi-
information mately 250 to 400 °C, and KDOC outlet temperature and KDPF outlet temperature are ap-
proximately 450 to 550 °C.
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.
• Test exhaust gas color. For details, see “TESTING AND ADJUSTING”, “TEST EXHAUST
GAS COLOR”.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note the engine power deration is not canceled right after the failure
code is cleared).
• Soot accumulation amount in KDPF is classified into 8 levels. Current soot accumulation
level can be checked in 02 Active Regeneration for Service screen of machine monitor.
• Manual stationary regeneration downs soot accumulation level 7 from level 8 by removing
soot.
• If soot accumulation level is 8, failure code [CA1922] is displayed. At this time, KDPF is
completely clogged with soot and inspection, cleaning or replacement is required.

HB365LC-3 40-405
FAILURE CODE [CA1922] 40 TROUBLESHOOTING

Time required for the manual stationary regeneration depends on the accumulated soot in KCSF,
however, it is estimated as follows.
• If soot accumulation is level 4: Approximately 40 minutes to 1 hour
• If soot accumulation is level 5: Approximately 1 to 2 hours
• If soot accumulation is level 6 or 7: Approximately 2 to 3 hours
• If soot accumulation is level 8: Manual stationary regeneration cannot be performed.
Cause for excessive soot accumulation
1. Engine runs in light load area where exhaust gas temperature is high enough to burn soot
in KDPF.
• Low gas temperature at entering into KDPF cause a large amount of soot to be accu-
mulated.
• To protect KDPF from soot accumulation, it is necessary to run the engine under high
load.
2. There is an engine failure generating excessive black smoke.
3. The function of disable regeneration is set from monitor.
• Regeneration is set not to perform automatically even if soot is accumulated. Cancel
regeneration disable at safe place.
Method of canceling regeneration disable
Select Cancel of Regeneration Disable from Aftertreatment devices regeneration screen of user
Related menu, and perform it. (For details, see “PROCEDURE FOR CANCEL OF AFTERTREATMENT DE-
information VICES REGENERATION DISABLE SETTING” of “HANDLE Komatsu Diesel Particulate Filter
(KDPF)” of “Handling” in Operation and Maintenance Manual.)
Method of performing active regeneration for service
When soot accumulation is at level 3 or lower, manual stationary regeneration can be performed on-
ly from Active Regeneration for Service.
1. Start engine.
2. Make sure that machine is in a safe condition.
3. From service menu of machine monitor, display Diagnostic Tests screen, open Active Re-
generation for Service, and then perform Manual Stationary Regeneration.
Method of resetting KDPF cleaning
Display Testing screen from service menu of machine monitor, open KDPF Memory Reset, and per-
form KDPF cleaning (resetting KDPF cleaning).
Method of resetting KDPF change
Display Testing screen from service menu of machine monitor, open KDPF Memory Reset, and per-
form KDPF change (resetting KDPF change).
Removing humidity in KCSF
When KCSF of KDPF has been replaced, be sure to perform Manual Stationary Regeneration from
Active Regeneration for Service and remove humidity, etc. in KCSF after resetting KDPF cleaning
and KDPF change.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Check that “Regeneration Disable” is chosen on the screen of the machine
Increased accumulation monitor. (See operation manual) Cancel the “Regeneration Disable” if it is
1 of soot due to regenera- chosen.
tion disable
2. Cancel regeneration disable and perform cause 2 and subsequent causes.

40-406 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1922]

No. Cause Procedure, measuring location, criteria and remarks

Check records for appeared failure codes.
1. Turn starting switch to ON position.
2. ON the Abnormality Record screen of the machine monitor, check records
for appeared failure codes CA2639, CA1921, and CA1922.
Period between CA2639 and CA1921 ≧ 360sec. (KOMTRAX Record) or ≧ 0.1h
(Monitor Record screen) and period between CA1921 and CA1922 ≧ 360sec.
(KOMTRAX Record) or ≧ 0.1h (Monitor Record screen)
[When the above condition is met]
REMARK
Because accumulated soot amount is high, KDPF regeneration cannot be per-
formed.
1. Change KCSF or KDPF.
2. Turn the starting switch to ON and perform “KDPF Cleaning” reset (see “PRE-
CAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE”).
Make sure that failure code [CA1922] changed to [CA1921].
If failure code [CA1922] persists, check the operation procedure for “KDPF
Defective KDPF (KCSF)
2 Memory Reset”, then perform “KDPF Cleaning” Reset again.
(change KCSF)
3. Perform Reset after “KDPF Change” (see “PRECAUTIONS FOR KDPF
(KCSF, KDOC) CLEANING AND CHANGE”).
4. Perform checks on causes 4 to 7.
5. Start the engine.
6. Secure the safety of the machine.
7. Perform “Active Regeneration for Service” to remove humidity, etc. in KCSF.
When the manual stationary regeneration is finished correctly, the repair is
completed.
If the regeneration is not completed after 3 hours, perform troubleshooting for
[CA2639].
Check that the failure code is cleared after manual stationary regeneration is
complete.
If failure code [CA1922], [CA1921] or [CA2639] is displayed after manual sta-
tionary regeneration is complete, perform checks on cause 8.
[When the above condition is NOT met]
Actual accumulation of soot is less than the indicated value. Perform checks on
cause 3.

HB365LC-3 40-407
FAILURE CODE [CA1922] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If the actual accumulation of soot is less than the the indicated value on the ma-
chine monitor:
1. Perform checks on causes 4 to 7.
2. Turn the starting switch to ON and perform “KDPF Cleaning” reset (see “PRE-
CAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE”).
Make sure that failure code [CA1922] changed to [CA1921].
If failure code [CA1922] persists, check the operation procedure for “KDPF
Memory Reset” Reset, then perform “KDPF Cleaning” Reset again.(see “PRE-
CAUTIONS FOR KDPF (KCSF, KDOC) CLEANING AND CHANGE”)
NOTICE
Do not perform “KDOC Change”(resetting KDOC Change) if KCSF or
Defective KDPF (KCSF) KDOC is not changed.
3 (abnormal accumulation
of soot) 3. Start the engine.
4. Secure the safety of the machine.
5. Perform “manual stationary regeneration” in user mode.
When the manual stationary regeneration is finished correctly, the repair is
completed.
If failure code [CA1922] is displayed again within 1 hour after starting the man-
ual stationary regeneration, perform steps 2 and 3 again.
If the regeneration is not completed after 3 hours, perform troubleshooting for
[CA2639].
Check that the failure code is cleared after manual stationary regeneration is
complete.
If failure code [CA1922], [CA1921] or [CA2639] is displayed after manual sta-
tionary regeneration is complete, perform checks on cause 8.
Defective KDOC inlet If failure code [CA3313], [CA3314] or [CA3315] is displayed, perform troubleshoot-
4
temperature sensor ing for [CA3313], [CA3314] or [CA3315].
Defective KDOC outlet If failure code [CA3316], [CA3317] or [CA3318] is displayed, perform troubleshoot-
5
temperature sensor ing for [CA3316], [CA3317] or [CA3318].
Defective KDPF outlet If failure code [CA3319], [CA3321] or [CA3322] is displayed, perform troubleshoot-
6
temperature sensor ing for [CA3319], [CA3321] or [CA3322].
1. Turn starting switch to ON position.
2. Monitor the differential pressure by using KDPF differential pressure sensor on
Self-define Monitoring screen of the machine monitor.
Code 47100 ( kPa) 0±3 kPa

NOTICE
Defective KDPF differen-
Perform the following when differential pressure is not within the above
7 tial pressure sensor (in-
range:
cluding the sensor tube)
1. Remove KDPF differential pressure sensor tube.
2. Clean and unclog the KDPF differential pressure sensor tube.
Perform this when the KDPF differential pressure sensor tube is not clogged.
3. Check “Short circuit in wiring harness” for failure code [CA1881] or
[CA1879] (change the KDPF differential pressure sensor if no short circuit
is found).

40-408 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1922]

No. Cause Procedure, measuring location, criteria and remarks

• If failure code [CA1921], or [CA2639] is displayed after manual stationary
regeneration is completed, perform the following:
• For details of checking the exhaust gas color, see TESTING AND AD-
JUSTING, “TEST EXHAUST GAS COLOR”.
• Perform regeneration disable on the machine monitor to check the exhaust
gas color.
Defective exhaust gas 1. Set the working mode to “B”, suddenly accelerate the engine from low idle to
8 high idle two times, and then keep the engine running at high idle for 5 sec-
color
onds.
If an excess black smoke is seen at high idle during acceleration, perform S
MODE, “KDPF GETS CLOGGED IN A SHORT TIME”.
Black smoke powder which comes out during acceleration but disappears at
high idle is normal.
2. To finish the exhaust gas color check, cancel the regeneration disable.
3. Make sure that the failure code is not displayed.

HB365LC-3 40-409
FAILURE CODE [CA1942] 40 TROUBLESHOOTING

FAILURE CODE [CA1942] (ALL-K-A18B-410-20-B)

Action level Failure code Crankcase Pressure Sensor In Range Error

Failure
L01 CA1942 (Engine controller system)
Details of
For output from crankcase pressure sensor, value out of normal range is displayed.
failure
Action of
None in particular
controller
Phenomenon
on machine
• Signal voltage from crankcase pressure sensor can be checked by monitoring function.
(Code: 48401 (V))
• Pressure in crankcase pressure sensor can be checked by monitoring function. (Code:
Related 48400 (MPa))
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• This code is displayed if sensor value is not abnormal when turning starting switch to ON
position.

No. Cause Procedure, measuring location, criteria and remarks

Defective crankcase Crankcase pressure sensor system may be defective. Perform troubleshooting for
1
pressure sensor failure codes [CA1843] and [CA1844].
2 Clogged KCCV filter Replace the KCCV filter.
If an error persists after replacement of the KCCV filter and emulsions are detected
Blocked KCCV gas pip-
3 inside KCCV, blocked emulsions may be suspected in KCCV blow by gas piping.
ing
Check that there is no coolant leakage.
The error does not disappear after replacing KCCV filter, and “Crankcase Pressure
High Error 1” or “Crankcase Pressure High Error 2” is also displayed, piston ring
4 Increase of blowby gas may be worn or broken, or oil from VGT may be leaked, valve guide and stem seal
may be worn or damaged. Perform troubleshooting “TROUBLESHOOTING OF EN-
GINE (S MODE)”, “Engine oil consumption is excessive”.

40-410 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1993]

FAILURE CODE [CA1993] (ALL-K-A9H0-410-10-B)

Action level Failure code KDPF Differential Pressure Low Error

Failure
L03 CA1993 (Engine controller system)
Details of
Sensor voltage from KDPF differential pressure sensor is lower than threshold value.
failure
• EGR valve closes.
Action of • Engine power deration
controller • Regeneration control stops.
• Fuel dosing stops.
Phenomenon
Engine power deration
on machine

k KDPF becomes hot (Min. 500 °C). Be careful not to get burned.
• KDPF differential pressure sensor and KDPF outlet pressure sensor are integrated.
• Signal voltage from KDPF differential pressure sensor can be checked by monitoring func-
tion. (Code: 47101 (V))
• Differential pressure in KDPF differential pressure sensor can be checked by monitoring
function. (Code: 47100 (kPa))
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
(Code: 47300 (°C))
• Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
• For details of access to KDPF differential pressure sensor, wiring harness and tube, see
“Chapter 50 DISASSEMBLY AND ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEM-
Related BLY” and “DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY”.
information • After turning starting switch to OFF position, engine controller performs AdBlue/DEF purg-
ing (for Max. 6 minutes) and then stops. To restart engine, wait until system operating
lamp goes off after turning starting switch to OFF position, and then turn starting switch to
ON position.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note the engine power deration is not canceled right after the failure
code is cleared).
NOTICE
• This failure code requires “ Loaded Diagnostics Operation To Confirm Failure Cor-
rection”. After investigating the cause of the problem and completing the repair, per-
form “ Loaded Diagnostics Operation To Confirm Failure Correction” to make sure
the failure code is cleared.
• This failure code is cleared by performing operations indicated in “TESTING AND
ADJUSTING”, “SETTING AND OPERATION OF MACHINE MONITOR”, “SERVICE
MODE”, “METHOD FOR SETTING WITH TESTING MENU (ENGINE CONTROLLER AC-
TIVE FAULT CLEAR)”.

No. Cause Procedure, measuring location, criteria and remarks

Defective KDPF differen- If failure code [CA1879], [CA1881] or [CA1883] is displayed, perform troubleshoot-
1 tial pressure sensor sys- ing for [CA1879], [CA1881] or [CA1883].
tem

HB365LC-3 40-411
FAILURE CODE [CA1993] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

2 KCSF failure 1
Defective KDPF differen-
3 3.
tial pressure sensor tube
4 KCSF failure 2
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler
1. Turn the starting switch to OFF position temporarily, and then turn it to ON
position again.
2. Check if a failure code other than [CA1993] appears.
3. Start the engine, set the working mode to “B”, accelerate the engine sud-
denly from low idle to high idle 2 times, and then keep the engine running
at high idle for 5 seconds. At this time, check the exhaust gas color at the
exhaust pipe during this sudden acceleration and high idle.
4. Perform step 3. If black smoke is exhausted from the exhaust pipe, KCSF
is defective. Check the existence of KCSF, check for a damage and mixed
foreign material to perform repair.
NOTICE
If black smoke emission is not found, perform procedures of cause 3 and af-
ter.
Check if:
1. the KDPF differential pressure sensor tube is present,
2. the KDPF differential pressure sensor tube is not connected improperly,
the removed KDPF differential pressure sensor tube for clogging, cracks,
or damages, or
4. the both ends of the KDPF differential pressure sensor tube is not loose.
5. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
1. If this failure code is displayed again after preceding procedures are imple-
mented, remove KDPF, then remove KCSF, and check filters for existence,
damages or contamination by foreign materials. Repair it if necessary.
2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
3. Perform repair again from cause 1 if this failure code is displayed again af-
ter “Loaded Diagnostics Operation To Confirm Failure Correction” has
been performed.
an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is not displayed after this procedure.)
k Place the machine on a level ground.
1. Turn the starting switch to ON position.
2. Perform “Engine Controller Active Fault Clear” from “service mode” of the machine monitor and clear this
failure code.
3. Turn the starting switch from OFF position to ON position.
4. Start the engine and run it at low idle for approximately 1 minute.
5. After finishing the warm-up operation, set the swing lock switch to ON position, working mode to B, and fuel
control dial to MAX position.
6. Perform arm IN relief for 1 minute.
NOTICE
Take care not to overheat the oil of work equipment.
7. If the failure code is not displayed again after steps 1 to 6 are performed, repair work is completed.

40-412 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA1993]

Circuit diagram related to KDPF differential pressure sensor

HB365LC-3 40-413
FAILURE CODE [CA2185] 40 TROUBLESHOOTING

FAILURE CODE [CA2185] (ALL-K-AF4P-410-00-B)

Action level Failure code Throttle Sensor Supply Voltage High Error
Failure
L03 CA2185 (Engine controller system)
Detail of fail-
A high voltage occurs in throttle sensor power supply (5 V) circuit.
ure
• If this failure code is displayed when starting switch is in ON position, set value to that be-
Action of fore detecting abnormality and fix it for operation.
controller • If turning starting switch to ON in abnormal condition, operation is performed at 100% val-
ue.
Phenomenon
Engine speed cannot be controlled by fuel dial.
on machine
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector P20, and turn starting switch to ON position.
Defective fuel dial (throt-
2 If this failure code is cleared, throttle sensor is defective.
tle sensor)
Other failure codes are displayed as well. This is because connector is disconnect-
ed. Ignore failure codes other than this failure code.
1. Starting switch: OFF
2. Disconnect connector P20, and connect T-adapter to female side of ECM
Short circuit in wiring har-
3 J2.
ness
Between ECM J2 (female) (9) and each pin other than No continui-
Continuity
ECM J2 (female) (9) pin ty
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to throttle sensor

40-414 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2186]

FAILURE CODE [CA2186] (ALL-K-AF4P-410-10-B)

Action level Failure code Throttle Sensor Supply Voltage Low Error
Failure
L03 CA2186 (Engine controller system)
Detail of fail-
A low voltage occurs in throttle sensor power supply (5 V) circuit.
ure
• If this failure code is displayed when starting switch is in ON position, set value to that be-
Action of fore detecting abnormality and fix it for operation.
controller • If turning starting switch to ON in abnormal condition, operation is performed at 100% val-
ue.
Phenomenon
Engine speed cannot be controlled by fuel dial.
on machine
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective wiring harness
1
connector
Defective fuel dial (throt-
2 If this failure code is cleared, throttle sensor is defective.
tle sensor)
Ground fault in wiring
3 harness (contact with
ground circuit)
Defective engine control- 2.
4
ler
1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
FORMATION ON TROUBLESHOOTING”, and check it.
2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector P20, and turn starting switch to ON position.
Other failure codes are displayed as well. This is because connector is disconnect-
ed. Ignore failure codes other than this failure code.
1. Starting switch: OFF
2. Disconnect connectors ECM J2 and P20, and connect T-adapter to either
female side.
Between ground and ECM J2 (female) (9) or P20 (fe-
Resistance Min. 100 kΩ
male) (1)
If no failure is found by above checks, engine controller is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)
1. Starting switch: OFF
Insert T-adapter to connector ECM J2 or disconnect connector P20, and
connect T-adapter to female side.
3. Starting switch: ON
Between ECM J2 (9) and (33), or between P20 (fe- 4.75 to
Voltage
male) (1) and (3) 5.25 V

HB365LC-3 40-415
FAILURE CODE [CA2186] 40 TROUBLESHOOTING

Circuit diagram related to throttle sensor

40-416 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2249]

FAILURE CODE [CA2249] (ALL-K-AD00-410-10-B)

Action level Failure code

Failure Common Rail Pressure Low Error 2 (Engine controller system)
L03 CA2249
Details of No-pressure error is detected in supply pump. (Pressure lower than specified pressure continues for
failure a long time: Level 2.)

Action of • Restricts engine output for operation.

controller • Restricts common rail pressure.
Phenomenon
Engine power deration
on machine
• Signal voltage from common rail pressure sensor can be checked by monitoring function.
(Code: 36401 (V))
Related • Common rail pressure in common rail pressure sensor can be checked by monitoring
information function. (Code: 36400 (MPa))
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

Supply pump pressure Perform troubleshooting for failure code [CA559].
1
low error

HB365LC-3 40-417
FAILURE CODE [CA2265] 40 TROUBLESHOOTING

FAILURE CODE [CA2265] (ALL-K-A9JG-410-00-B)

Action level Failure code

Failure Fuel Feed Pump Open Circuit Error (Engine controller system)
L01 CA2265
Details of
Fuel feed pump drive signal circuit is open.
failure
Action of
None in particular
controller
Phenomenon
Engine startability becomes poor.
on machine
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “c: Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check them.
1
connector 2. Start the engine.
If this failure code is not displayed, the wiring harness connector is defective.
1. Turn starting switch to OFF position.
2 Defective feed pump 2. Disconnect connector FUEL LIFT PUMP.
Resistance Between FUEL LIFT PUMP (male) (1) and (2) Max. 20 Ω
1. Turn starting switch to OFF position.
Open or short circuit in 2.
3 Disconnect connector ECM J1 and connect T-adapter to female side.
wiring harness
Resistance Between ECM J1 (female) (14) and (38) Max. 20 Ω
If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors ECM J1 and FUEL LIFT PUMP, and connect T-
ness (wire breakage or adapters to each female side.
4
defective contact of con-
nector) Between ECM J1 (female) (14) and FUEL LIFT PUMP
Max. 10 Ω
(female) (1)
Resistance
Between ECM J1 (female) (38) and FUEL LIFT PUMP
Max. 10 Ω
(female) (2)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and FUEL LIFT PUMP, and connect T-
Short circuit in wiring har-
5 adapter to female side of ECM J1.
ness
Between ECM J1 (female) (14) and each pin other No continui-
Continuity
than pins (14) and (15) ty

40-418 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2265]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector FUEL LIFT PUMP.
3. Insert T-adapter into connector ECM J1, or connect T-adapter to female
side of FUEL LIFT PUMP.
Hot short circuit in wiring 4. Turn starting switch to ON position (with connector FUEL LIFT PUMP dis-
6 connected), and measure after 1 minute.
harness
REMARK
Average voltage is displayed because of PWM.
Between ECM J1 (14) and (38), or between FUEL
Voltage Max. 6 V
LIFT PUMP (female) (1) and (2)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)

CIRCUIT DIAGRAM (ELECTRIC FUEL FEED PUMP SWITCH)

HB365LC-3 40-419
FAILURE CODE [CA2266] 40 TROUBLESHOOTING

FAILURE CODE [CA2266] (ALL-K-A9JG-410-10-B)

Action level Failure code Fuel Feed Pump Short Circuit Error
Failure
L01 CA2266 (Engine controller system)
Details of
Fuel feed pump drive signal circuit shorts.
failure
Action of
None in particular
controller
Phenomenon
Engine power deration
on machine
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “c: Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Start engine.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector FUEL LIFT PUMP.
3. Turn starting switch to ON position.
2 Defective feed pump
If this failure code [CA2266] disappears, the fuel feed pump is defective.
REMARK
Since connector is disconnected, ignore all the other failure codes except this one.
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1 and connect T-adapter to female side.
Open or short circuit in
3
wiring harness Between ECM J1 (female) (14) and (38) Max. 20 kΩ
Resistance
Between ECM J1 (female) (14) and ground Min. 100 kΩ
If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.
Ground fault in wiring
4 harness (contact with 2. Disconnect connectors ECM J1 and FUEL LIFT PUMP, and connect T-
GND circuit) adapter to either female side.
Between ground and ECM J1 (female) (14) or FUEL
Resistance Min. 100 kΩ
LIFT PUMP (female) (1)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1, FUEL LIFT PUMP, and EFP, and connect
Short circuit in wiring har-
5 T-adapter to either female side.
ness
Between ECM J1 (female) (14) and (38), or between
Resistance Min. 100 kΩ
FUEL LIFT PUMP (female) (1) and (2)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

40-420 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2266]

CIRCUIT DIAGRAM (ELECTRIC FUEL FEED PUMP SWITCH)

HB365LC-3 40-421
FAILURE CODE [CA2271] 40 TROUBLESHOOTING

FAILURE CODE [CA2271] (ALL-K-A9S7-410-00-B)

Action level Failure code EGR Valve Position Sensor High Error
Failure
L03 CA2271 (Engine controller system)
Detail of fail-
High voltage occurs in signal circuit of EGR valve position sensor.
ure
• Engine power deration.
Action of • EGR valve closed.
controller • Regeneration control stops.
• Advances to Inducement strategy. (EU Specification)
Phenomenon • Engine power deration
on machine • Engine power deration according to inducement strategy. (EU Specification).
• Signal voltage from EGR valve position sensor can be checked with monitoring function.
(Code: 18101 (V))
• EGR valve position (mm) sensed by EGR valve position sensor can be checked with mon-
Related itoring function. (Code: 18100 (mm))
information • Engine power deration is canceled when the failure code is cleared and the starting switch
is turned OFF (not canceled only by deactivation of the failure code).
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
Defective sensor power If failure code [CA187] or [CA227] is displayed, perform troubleshooting for those
2
supply system codes first.
1. Turn starting switch to OFF position.
Defective EGR valve lift 2. Disconnect connector SEGR.
3
sensor (internal defect) 3. Turn starting switch ON (with connector SEGR disconnected).
If failure code [CA2271] changes to [CA2272], the sensor is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector INTER-CONNECT.
Defective connector box 3. Turn starting switch to ON position.
4
(internal short circuit) If failure code [CA2271] changes to [CA2272], the connector box is defective.
REMARK
Ignore other failure codes displayed.
1. Turn starting switch to OFF position.
Open circuit of connector 2.
Disconnect connectors INTER-CONNECT and SEGR, and connect T-adapter
box (wire breakage of
5 to male side of INTER-CONNECT or female side of SEGR.
ground line or defective
contact of connector) Between INTER-CONNECT (male) (4) and SEGR (fe-
Resistance Max. 10 Ω
male) (B)

40-422 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2271]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors INTER-CONNECT and SEGR, and connect T-adapter
Short circuit of connector
6 to male side of INTER-CONNECT or female side of SEGR.
box (internal short circuit)
Between INTER-CONNECT (male) (3) and (5), or be-
Resistance Min. 100 kΩ
tween SEGR (female) (A) and (C)
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors ECM J1 and INTER-CONNECT, and connect T-
ness (wire breakage of
7 adapters to each female side.
GND line or defective
contact of connector) Between ECM J1 (female) (57) and INTER-CONNECT
Resistance Max. 10 Ω
(female) (4)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and INTER-CONNECT, and connect T-
Short circuit in wiring har-
8 adapter to either female side.
ness
Between ECM J1 (female) (81) and (88), or between
Resistance Min. 100 kΩ
INTER-CONNECT (female) (3) and (5)
1. Turn starting switch to OFF position.
2. Disconnect connector INTER-CONNECT, and connect T-adapter to female
Hot short circuit in wiring side.
9
harness
3. Turn starting switch to ON position.
Voltage Between INTER-CONNECT (female) (5) and ground Max. 1 V
If no failure is found by above checks, engine controller is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)
Reference
Defective engine control- 1. Turn starting switch to OFF position.
10
ler
2. Insert T-adapter into connector ECM J1.
3. Turn starting switch to ON position.
Voltage Between ECM J1 (88) and (57) 1.0 to 4.0 V

CIRCUIT DIAGRAM (EGR VALVE LIFT SENSOR)

HB365LC-3 40-423
FAILURE CODE [CA2272] 40 TROUBLESHOOTING

FAILURE CODE [CA2272] (ALL-K-A9S7-410-10-B)

Action level Failure code EGR Valve Position Sensor Low Error
Failure
L03 CA2272 (Engine controller system)
Detail of fail-
Low voltage occurs in signal circuit of EGR valve position sensor.
ure
• Engine power deration.
Action of • EGR valve closed.
controller • Regeneration control stops.
• Advances to Inducement strategy. (EU Specification)
Phenomenon • Engine power deration
on machine • Engine power deration according to inducement strategy. (EU Specification).
• Signal voltage from EGR valve position sensor can be checked with monitoring function.
(Code: 18101 (V))
• EGR valve position (mm) sensed by EGR valve position sensor can be checked with mon-
itoring function. (Code: 18100 (mm))
Related
• This failure code is displayed if sensor connector is disconnected.
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• Engine power deration is canceled when the failure code is cleared and the starting switch
is turned OFF (not canceled only by deactivation of the failure code).

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
If failure code [CA187] or [CA227] is displayed, perform troubleshooting for those
codes first.
1. Turn starting switch to OFF position.
Defective sensor power 2.
2 Disconnect connector SEGR and connect T-adapter to female side.
supply system
3. Turn starting switch to ON position.
Between SEGR (female) 4.75 to
Voltage Power supply
(A) and (B) 5.25 V

40-424 HB365LC-3
40 TROUBLESHOOTING
No. Cause
Open circuit of connector
box (wire breakage or
3 male) (A)
defective contact of con-
nector)
Ground fault of connector
4 box (contact with ground
circuit)
Short circuit of connector
5 to male side of INTER-CONNECT or female side of SEGR.
box (internal short circuit)
Open circuit in wiring har-
ness (wire breakage or
6 (female) (3)
defective contact of con-
nector)
Ground fault in wiring
7 harness (contact with
ground circuit)
HB365LC-3
FAILURE CODE [CA2272]
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors INTER-CONNECT and SEGR, and connect T-
adapter to male side of INTER-CONNECT and female side of SEGR.
If power supply voltage in check on cause 2 is normal,
this check is not required.
Max. 10 Ω
Between INTER-CONNECT (male) (3) and SEGR (fe-
If power supply voltage in check on cause 2 is normal,
Resistance
this check is not required.
Max. 10 Ω
Between INTER-CONNECT (male) (4) and SEGR (fe-
male) (B)
Between INTER-CONNECT (male) (5) and SEGR (fe-
Max. 10 Ω
male) (C)
1. Turn starting switch to OFF position.
2. Disconnect connectors INTER-CONNECT and SEGR, and connect T-
adapter to male side of INTER-CONNECT and female side of SEGR.
Between ground and INTER-CONNECT (male) (5) or
Min. 100 kΩ
SEGR (female) (C)
Resistance
Between ground and INTER-CONNECT (male) (3) or
Min. 100 kΩ
SEGR (female) (A)
1. Turn starting switch to OFF position.
2. Disconnect connectors INTER-CONNECT and SEGR, and connect T-adapter
Between INTER-CONNECT (male) (4) and (5), or be-
Resistance Min. 100 kΩ
tween SEGR (female) (B) and (C)
1. Turn starting switch to OFF position.
2. Disconnect connectors INTER-CONNECT and ECM J1, and connect T-
adapters to each female side.
If power supply voltage in check on cause 2 is normal,
this check is not required.
Max. 10 Ω
Between ECM J1 (female) (81) and INTER-CONNECT
If power supply voltage in check on cause 2 is normal,
Resistance
this check is not required.
Max. 10 Ω
Between ECM J1 (female) (57) and INTER-CONNECT
(female) (4)
Between ECM J1 (female) (88) and INTER-CONNECT
Max. 10 Ω
(female) (5) (sensor output)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and INTER-CONNECT, and connect T-
adapter to either female side.
Between ECM J1 (female) (88) and ground, or be-
Resistance Min. 100 kΩ
tween INTER-CONNECT (female) (5) and ground
40-425
FAILURE CODE [CA2272] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and INTER-CONNECT, and connect T-
Short circuit in wiring har-
8 adapter to either female side.
ness
Between ECM J1 (female) (88) and (57), or between
Resistance Min. 100 kΩ
INTER-CONNECT (female) (5) and (4)
If no failure is found in causes 1 through 8 but found in cause 9, the sensor is de-
fective.
1. Turn starting switch to OFF position.
Defective EGR valve lift 2.
9 Insert T-adapter into connector ECM J1 or SEGR.
sensor
3. Turn starting switch to ON position.
Between ECM J1 (88) and (57), or between SEGR (C)
Voltage 1.0 to 4.0 V
and (B)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
10
ler an internal defect, troubleshooting cannot be performed.)

CIRCUIT DIAGRAM (EGR VALVE LIFT SENSOR)

40-426 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2288]

FAILURE CODE [CA2288] (ALL-K-AA09-410-02-B)

Action level Failure code

Failure Turbocharger Speed High Error 1 (Engine controller system)
L01 CA2288
Details of
Turbocharger runs at abnormally high speed.
failure
Action of
Runs turbocharger speed at fixed value of 125000 rpm.
controller
Phenomenon
Engine output decreases.
on machine
• Speed sensed by turbocharger speed sensor can be checked with monitoring function.
Related (Code: 48100 (rpm))
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

Increased turbocharger Turbocharger speed may increase abnormally high. Check it.
1
speed
2 Defective turbocharger Turbocharger may be defective. Check it.
Defective turbocharger If failure code is still displayed after above checks on cause 1, turbocharger speed
3
speed sensor sensor system may be defective. Perform troubleshooting for failure code [CA687].

HB365LC-3 40-427
FAILURE CODE [CA2311] 40 TROUBLESHOOTING

FAILURE CODE [CA2311] (ALL-K-AD81-410-01-B)

Action level Failure code lMV Solenoid Error

Failure
L03 CA2311 (Engine controller system)
Details of Resistance value of supply pump actuator circuit is unusually high or low. Or common rail pressure
failure error.

Action of
None in particular
controller
Phenomenon
Engine power deration
on machine
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

1 Defective IMV solenoid Perform troubleshooting for failure codes [CA271] and [CA272].
2 Rail pressure error Perform troubleshooting for failure code [CA449].

40-428 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2349]

FAILURE CODE [CA2349] (ALL-K-A9S0-410-00-B)

Action level Failure code

Failure EGR Valve Solenoid Open Circuit Error (Engine controller system)
L03 CA2349
Detail of fail-
Open circuit occurs in EGR valve solenoid drive circuit.
ure
• Engine power deration.
Action of • EGR valve closed.
controller • Regeneration control stops.
• Advances to Inducement strategy. (EU Specification)
Phenomenon • Engine power deration
on machine • Engine output is reduced based on inducement strategy. (EU Specification).
• Signal current to EGR valve solenoid can be checked with monitoring function. (Code:
48600 (mA))
Related • Engine power deration is canceled when the failure code is cleared and the starting switch
information is turned OFF (not canceled only by deactivation of the failure code).
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “c: Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
Defective EGR valve sol-
2 enoid (internal open cir- 2. Disconnect connector EGR-SOL, and connect T-adapter to male side.
cuit)
Resistance Between EGR-SOL (male) (1) and (2) 5 to 10 Ω
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J1 and connect T-adapter to female side.
Open or short circuit in REMARK
3
wiring harness system
If resistance is 100 kΩ or higher, wiring harness has open circuit. If resistance is
10 Ω or below, wiring harness has short circuit.
Resistance Between ECM J1 (female) (13) and (76) 5 to 10 Ω
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and EGR-SOL, and connect T-adapter to
Ground fault in wiring either female side.
4 harness system (contact Between ground and ECM J1 (female) (13) or EGR-
with ground circuit) Min. 100 kΩ
SOL (female) (1)
Resistance
Between ground and ECM J1 (female) (76) or EGR-
Min. 100 kΩ
SOL (female) (2)

HB365LC-3 40-429
FAILURE CODE [CA2349] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.
Open circuit of connector 2. Disconnect connectors EGR-SOL and INTER-CONNECT, and connect T-
box (wire breakage or adapter to female side of EGR-SOL or male side of INTER-CONNECT.
5
defective contact of con-
nector) Between INTER-CONNECT (male) (1) and EGR-SOL
Max. 10 Ω
(female) (1)
Resistance
Between INTER-CONNECT (male) (2) and EGR-SOL
Max. 10 Ω
(female) (2)
If failure code is still displayed after above checks on cause 4, this check is not re-
quired.
1. Turn starting switch to OFF position.
Ground fault of connector 2. Disconnect connectors EGR-SOL and INTER-CONNECT, and connect T-
6 box (contact with ground adapter to female side of EGR-SOL or male side of INTER-CONNECT.
circuit) Between ground and INTER-CONNECT (male) (1) or
Min. 100 kΩ
EGR-SOL (female) (1)
Resistance
Between ground and INTER-CONNECT (male) (2) or
Min. 100 kΩ
EGR-SOL (female) (2)
If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors ECM J1 and INTER-CONNECT, and connect T-
ness (wire breakage or adapters to each female side.
7
defective contact of con-
nector) Between ECM J1 (female) (13) and INTER-CONNECT
Max. 10 Ω
(female) (1)
Resistance
Between ECM J1 (female) (76) and INTER-CONNECT
Max. 10 Ω
(female) (2)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and INTER-CONNECT, and connect T-
Short circuit in wiring har-
8 adapter to female side of ECM J1.
ness
Between ECM J1 (female) (13) and each pin other No continui-
Continuity
than pin (13) ty
If failure code is still displayed after above checks on cause 4, this check is not re-
quired.
1. Turn starting switch to OFF position.

Ground fault in wiring 2. Disconnect connectors ECM J1 and INTER-CONNECT, and connect T-
9 harness (contact with adapter to either female side.
ground circuit) Between ground and ECM J1 (female) (13) or INTER-
Min. 100 kΩ
CONNECT (female) (1)
Resistance
Between ground and ECM J1 (female) (76) or INTER-
Min. 100 kΩ
CONNECT (female) (2)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
10
ler an internal defect, troubleshooting cannot be performed.)

40-430 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2349]

CIRCUIT DIAGRAM (EGR VALVE SOLENOID)

HB365LC-3 40-431
FAILURE CODE [CA2353] 40 TROUBLESHOOTING

FAILURE CODE [CA2353] (ALL-K-A9S0-410-10-B)

Action level Failure code

Failure EGR Valve Solenoid Short Circuit Error (Engine controller system)
L03 CA2353
Detail of fail-
Short circuit occurs in EGR valve solenoid drive circuit.
ure
• Engine power deration.
Action of • EGR valve closed.
controller • Regeneration control stops.
• Advances to Inducement strategy. (EU Specification)
Phenomenon • Engine power deration
on machine • Engine output is reduced based on inducement strategy. (EU Specification).
• Signal current to EGR valve solenoid can be checked with monitoring function. (Code:
48600 (mA))
Related • Engine power deration is canceled when the failure code is cleared and the starting switch
information is turned OFF (not canceled only by deactivation of the failure code).
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “c: Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector EGR-SOL, and connect T-adapter to male side.
Defective EGR valve sol-
2 enoid (internal open cir- Between EGR-SOL (male) (1) and (2) 5 to 10 Ω
cuit)
Resistance Min.
Between EGR-SOL (male) (1) and ground
100 MΩ
1. Turn starting switch to OFF position.
2. Disconnect connectors INTER-CONNECT and EGR-SOL, and connect T-
Short circuit of connector
3 adapters to male side of INTER-CONNECT.
box
Between INTER-CONNECT (male) (1) and each pin No continui-
Continuity
other than pin (1) ty
1. Turn starting switch to OFF position.
2. Disconnect connector INTER-CONNECT, and connect T-adapter to female
side.
3. Turn starting switch to ON position (with connector INTER-CONNECT dis-
Hot short circuit in wiring
4 connected).
harness
REMARK
hot short circuit in negative line
Voltage BetweenINTER-CONNECT (female) (2) and ground Max. 3 V
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)

40-432 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2353]

CIRCUIT DIAGRAM (EGR VALVE SOLENOID)

HB365LC-3 40-433
FAILURE CODE [CA2357] 40 TROUBLESHOOTING

FAILURE CODE [CA2357] (ALL-K-A9J0-410-00-B)

Action level Failure code EGR Valve Servo Error

Failure
L03 CA2357 (Engine controller system)
Details of EGR valve malfunctions. (Responsing value from EGR position sensor is different from the value of
failure EGR valve opening command.)

• Engine power deration.

Action of • EGR valve closed.
controller • Advances to Inducement strategy. (EU Specification)
• Regeneration control stops.
Phenomenon • Engine output is reduced based on inducement strategy (EU Specification).
on machine • Engine power deration
• Position of EGR valve can be checked with monitoring function. (Code: 18100 EGR Valve
Position (mm))
Related • Engine power deration is canceled when the failure code is cleared and the starting switch
information is turned OFF (not canceled only by deactivation of the failure code).
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective relevant sys- If other failure codes are also displayed, perform troubleshooting for them.
1
tem
For testing of EGR valve drive pressure, see “TESTING AND ADJUSTING”, “TEST
Defective EGR valve EGR VALVE AND VGT DRIVING OIL PRESSURE”.
2
driving oil pressure
If EGR valve drive pressure is abnormal, perform checks on causes 3 and 4.
• For check of engine oil pressure, see “TESTING AND ADJUSTING”,
Defective engine oil pres- “TEST ENGINE OIL PRESSURE”.
3 sure system (main cir-
cuit) • If engine oil pressure is not normal, perform troubleshooting (S mode).
(Engine oil pressure drops)
Defective EGR valve oil Oil pump and relief valve for EGR valve circuit may be defective. Check them.
4
pump
Defective hydraulic pip- Hydraulic piping for EGR valve circuit may be defective. Check it.
5
ing for EGR valve
Defective hydraulic return Hydraulic return piping for EGR valve circuit may be defective. Check it.
6
piping for EGR valve
• EGR valve may have mechanical trouble. Check it.
7 Defective EGR valve • Check especially that there is no foreign material in oil inlet and outlet of
EGR valve.
Defective EGR valve lift Perform troubleshooting for failure codes [CA2271] and [CA2272].
8
sensor
If failure code is still displayed after above checks on causes 1 to 8, engine control-
Defective engine control-
9 ler is defective. (In case of an internal defect, troubleshooting is impossible as an
ler
assembly. Replace whole assembly.)

40-434 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2381]

FAILURE CODE [CA2381] (ALL-K-AAQ8-410-00-B)

Action level Failure code VGT Position Sensor High Error

Failure
L03 CA2381 (Engine controller system)
Details of
High voltage is generated in VGT position sensor signal circuit.
failure
• Engine power deration.
Action of
• EGR valve closes and fully opens VGT.
controller
• Regeneration control stops.
Phenomenon
Engine power deration
on machine
• Signal voltage from VGT position sensor can be checked with monitoring function. (Code:
48701 (V))
• Position (mm) detected by VGT position sensor can be checked with monitoring function.
Related (Code: 48700 (mm))
information • Engine power deration is canceled when the failure code is cleared and the starting switch
is turned OFF (not canceled only by deactivation of the failure code).
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equipment” in
“CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
Defective wiring harness TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
Defective sensor power If failure code [CA187] or [CA227] is also displayed, perform troubleshooting these
2
supply system first.
1. Turn starting switch to OFF position.
Defective VGT position 2. Disconnect connector SVGT.
3
sensor (internal defect) 3. Turn starting switch ON (with connector SVGT disconnected).
If failure code [CA2381] changes to [CA2382], the sensor is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector INTER-CONNECT.
Defective connector box 3. Turn starting switch to ON position.
4
(internal short circuit) If failure code [CA2381] changes to [CA2382], the connector box is defective.
REMARK
Ignore other failure codes displayed.
1. Turn starting switch to OFF position.
Open circuit of connector 2.
Disconnect connectors INTER-CONNECT and SVGT, and connect T-adapter
box (wire breakage of
5 to male side of INTER-CONNECT or female side of SVGT.
ground line or defective
contact of connector) Between INTER-CONNECT (male) (9) and SVGT (fe-
Resistance Max. 10 Ω
male) (B)

HB365LC-3 40-435
FAILURE CODE [CA2381] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors ECM J1 and INTER-CONNECT, and connect T-
ness (wire breakage or
6 adapters to each female side.
defective contact of con-
nector) Between ECM J1 (female) (57) and INTER-CONNECT
Resistance Max. 10 Ω
(female) (9)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and INTER-CONNECT, and connect T-
Short circuit in wiring har-
7 adapter to either female side.
ness
Between ECM J1 (female) (67) and (81), or between
Resistance Min. 100 kΩ
INTER-CONNECT (female) (10) and (8)
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector SVGT and connect T-adapter to female side.
8
harness 3. Turn starting switch ON (with connector SVGT disconnected).
Voltage Between SVGT (female) (C) and (B) Max. 1 V
If no failure is found by above checks, engine controller is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)
Reference
Defective engine control- 1. Turn starting switch to OFF position.
9
ler
2. Insert T-adapter into connector ECM J1.
3. Turn starting switch to ON position.
Voltage Between ECM J1 (67) and (57) 1.0 to 4.0 V

CIRCUIT DIAGRAM (VGT POSITION SENSOR)

40-436 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2382]

FAILURE CODE [CA2382] (ALL-K-AAQ8-410-10-B)

Action level Failure code VGT Position Sensor Low Error

Failure
L03 CA2382 (Engine controller system)
Detail of fail-
Low voltage is generated in VGT position sensor signal circuit.
ure
• Engine power deration.
Action of
• EGR valve closes and fully opens VGT.
controller
• Regeneration control stops.
Phenomenon
Engine power deration
on machine
• Signal voltage from VGT position sensor can be checked with monitoring function. (Code:
48701 (V))
• Position (mm) detected by VGT position sensor can be checked with monitoring function.
(Code: 48700 (mm))
Related • Engine power deration is canceled by turning starting switch to OFF position after this fail-
information ure code is cleared (note that the engine power deration is not canceled right after the fail-
ure code is cleared).
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• This failure code is displayed if sensor connector is disconnected.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equipment” in
“CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
Defective wiring harness TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
If failure code [CA187] or [CA227] is also displayed, perform troubleshooting these
first.
1. Turn starting switch to OFF position.
Defective sensor power 2.
2 Disconnect connector SVGT and connect T-adapter to female side.
supply system
3. Turn starting switch to ON position.
Between SVGT (female) 4.75 to
Voltage Power supply
(A) and (B) 5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connectors INTER-CONNECT and SVGT, and connect T-
adapter to male side of INTER-CONNECT or female side of SVGT.
If failure code is still displayed after above checks on
cause 2, this check is not required.
Open circuit of connector Max. 10 Ω
Between INTER-CONNECT (male) (8) and SVGT (fe-
box (wire breakage or
3 male) (A)
defective contact of con-
nector) If failure code is still displayed after above checks on
Resistance
cause 2, this check is not required.
Max. 10 Ω
Between INTER-CONNECT (male) (9) and SVGT (fe-
male) (B)
Between INTER-CONNECT (male) (10) and SVGT (fe-
Max. 10 Ω
male) (C)

HB365LC-3 40-437
FAILURE CODE [CA2382]
No. Cause
Ground fault of connector
4 box (contact with ground
circuit)
Short circuit of connector
5 Between INTER-CONNECT (male) (9) and (10), or be-
box (internal short circuit)
Open circuit in wiring har-
ness (wire breakage of
6 (female) (8)
GND line or defective
contact of connector)
Ground fault in wiring
7 harness (contact with
ground circuit)
Short circuit in wiring har-
8 adapter to either female side.
ness
Defective VGT position
9
sensor
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
10
ler an internal defect, troubleshooting cannot be performed.)
40-438
40 TROUBLESHOOTING
Procedure, measuring location, criteria and remarks
1. Turn starting switch to OFF position.
2. Disconnect connectors INTER-CONNECT and SVGT, and connect T-
adapter to male side of INTER-CONNECT or female side of SVGT.
Between ground and INTER-CONNECT (male) (10) or
Min. 100 kΩ
SVGT (female) (C)
Resistance
Between ground and INTER-CONNECT (male) (8) or
Min. 100 kΩ
SVGT (female) (A)
1. Turn starting switch to OFF position.
2. Disconnect connectors INTER-CONNECT and SVGT, and connect T-
adapter to male side of INTER-CONNECT or female side of SVGT.
Min. 100 kΩ
tween SVGT (female) (B) and (C)
Resistance
Between INTER-CONNECT (male) (8) and (9), or be-
Min. 100 kΩ
tween SVGT (female) (A) and (B)
1. Turn starting switch to OFF position.
2. Disconnect connectors INTER-CONNECT and ECM J1, and connect T-
adapters to each female side.
If power supply voltage in check on cause 2 is normal,
this check is not required.
Max. 10 Ω
Between ECM J1 (female) (81) and INTER-CONNECT
If power supply voltage in check on cause 2 is normal,
Resistance
this check is not required.
Max. 10 Ω
Between ECM J1 (female) (57) and INTER-CONNECT
(female) (9)
Between ECM J1 (female) (67) and INTER-CONNECT
Max. 10 Ω
(female) (10) (sensor output)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and SVGT, and connect T-adapter to ei-
ther female side.
Between ECM J1 (female) (67) and ground, or be-
Resistance Min. 100 kΩ
tween INTER-CONNECT (female) (10) and ground
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J1 and INTER-CONNECT, and connect T-
Between ECM J1 (female) (67) and (57), or between
Resistance Min. 100 kΩ
INTER-CONNECT (female) (10) and (9)
If no failure is found in causes 1 through 8 but found in cause 9, the sensor is de-
fective.
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector ECM J1 or SVGT.
3. Turn starting switch to ON position.
Between ECM J1 (67) and (57), or between SVGT (C)
Voltage 1.0 to 4.0 V
and (B)
HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2382]

CIRCUIT DIAGRAM (VGT POSITION SENSOR)

HB365LC-3 40-439
FAILURE CODE [CA2383] 40 TROUBLESHOOTING

FAILURE CODE [CA2383] (ALL-K-AAQB-410-00-B)

Action level Failure code VGT Solenoid Open Circuit Error

Failure
L03 CA2383 (Engine controller system)
Detail of fail-
Open circuit occurs in VGT solenoid drive circuit.
ure
• Engine power deration.
Action of
• EGR valve closes and fully opens VGT.
controller
• Regeneration control stops.
Phenomenon
Engine power deration
on machine
• Signal current to VGT solenoid can be checked with monitoring function. (Code: 48600
(mA))
Related • Engine power deration is canceled when the failure code is cleared and the starting switch
information is turned OFF (not canceled only by deactivation of the failure code).
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
Defective VGT solenoid 2.
2 Disconnect connector VGT-SOL, and connect T-adapter to male side.
(internal open circuit)
Resistance Between VGT-SOL (male) (1) and (2) 5 to 10 Ω
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J2, and connect T-adapter to female side.
Open or short circuit in REMARK
3
wiring harness
If resistance is 100 kΩ or higher, wiring harness has open circuit. If resistance is
10 Ω or below, wiring harness has short circuit.
Resistance Between ECM J2 (female) (80) and (2) 5 to 10 Ω
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-adapters to
Ground fault in wiring each female side.
4 harness system (contact Between ground and ECM J2 (female) (80) or VGT-
with ground circuit) Min. 100 kΩ
SOL (female) (1)
Resistance
Between ground and ECM J2 (female) (2) or VGT-SOL
Min. 100 kΩ
(female) (2)

40-440 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2383]

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.
Open circuit of connector 2. Disconnect connectors VGT-SOL and INTER-CONNECT, and connect T-
box (wire breakage or adapter to female side of VGT-SOL or male side of INTER-CONNECT.
5
defective contact of con-
nector) Between INTER-CONNECT (male) (6) and VGT-SOL
Max. 10 Ω
(female) (1)
Resistance
Between INTER-CONNECT (male) (7) and VGT-SOL
Max. 10 Ω
(female) (2)
If failure code is still displayed after above checks on cause 4, this check is not re-
quired.
1. Turn starting switch to OFF position.
Ground fault of connector 2. Disconnect connectors VGT-SOL and INTER-CONNECT, and connect T-
6 box (contact with ground adapter to female side of VGT-SOL or male side of INTER-CONNECT.
circuit) Between ground and INTER-CONNECT (male) (6) or
Min. 100 kΩ
VGT-SOL (female) (1)
Resistance
Between ground and INTER-CONNECT (male) (7) or
Min. 100 kΩ
VGT-SOL (female) (2)
If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-adapters to
ness (wire breakage or each female side.
7
defective contact of con-
nector) Between ECM J2 (female) (80) and INTER-CONNECT
Max. 10 Ω
(female) (6)
Resistance
Between ECM J2 (female) (2) and INTER-CONNECT
Max. 10 Ω
(female) (7)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J2 and INTER-CONNECT, and connect T-
Ground fault in wiring adapters to each female side.
8 harness (contact with Between ground and ECM J2 (female) (80) or INTER-
ground circuit) Min. 100 kΩ
CONNECT (female) (6)
Resistance
Between ground and ECM J2 (female) (2) or INTER-
Min. 100 kΩ
CONNECT (female) (7)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J2 and VGT-SOL, and connect T-adapter to
Short circuit in wiring har-
9 female side of ECM J2.
ness
Between ECM J2 (female) (80) and each pin other No continui-
Continuity
than pin (80) ty
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
10
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-441
FAILURE CODE [CA2383] 40 TROUBLESHOOTING

CIRCUIT DIAGRAM (VGT VALVE SOLENOID)

40-442 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2386]

FAILURE CODE [CA2386] (ALL-K-AAQB-410-10-B)

Action level Failure code

Failure VGT Solenoid Short Circuit Error (Engine controller system)
L03 CA2386
Detail of fail-
Short circuit occurs in VGT solenoid drive circuit.
ure
• Engine power deration.
Action of
• EGR valve closes and fully opens VGT.
controller
• Regeneration control stops.
Phenomenon
Engine power deration
on machine
• Signal current to VGT solenoid can be checked with monitoring function. (Code: 48600
(mA))
Related • Engine power deration is canceled when the failure code is cleared and the starting switch
information is turned OFF (not canceled only by deactivation of the failure code).
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector VGT-SOL, and connect T-adapter to male side.
Defective VGT solenoid
2
(internal short circuit) Between VGT-SOL (male) (1) and (2) 5 to 10 Ω
Resistance
Between VGT-SOL (male) (1) and ground Min. 100 kΩ
1. Turn starting switch to OFF position.
2. Disconnect connectors INTER-CONNECT and VGT-SOL, and connect T-
Short circuit of connector adapters to male side of INTER-CONNECT.
3
box
No continui-
Between INTER-CONNECT (male) (6) and each pin
Continuity ty (no sound
other than pin (6)
is heard)
1. Turn starting switch to OFF position.
2. Disconnect connector INTER-CONNECT, and connect T-adapter to female
side.
3. Turn starting switch to ON position (with connector INTER-CONNECT dis-
Hot short circuit in wiring
4 connected).
harness
REMARK
hot short circuit in negative line
Voltage Between INTER-CONNECT (female) (7) and ground Max. 3 V
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-443
FAILURE CODE [CA2386] 40 TROUBLESHOOTING

CIRCUIT DIAGRAM (VGT VALVE SOLENOID)

40-444 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2387]

FAILURE CODE [CA2387] (ALL-K-AA09-410-20-B)

Action level Failure code VGT Servo Error

Failure
L03 CA2387 (Engine controller system)
Detail of fail- VGT servo error occurs. (Response from VGT position sensor differs from VGT opening command
ure value.)
• EGR valve closes and fully opens VGT.
Action of
• Engine power deration.
controller
• Regeneration control stops.
Phenomenon
Engine power deration
on machine
• Engine power deration is canceled when the failure code is cleared and the starting switch
Related is turned OFF (not canceled only by deactivation of the failure code).
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective relevant sys- If other failure codes are also displayed, perform troubleshooting for them.
1
tem
For testing of VGT drive pressure, see “TESTING AND ADJUSTING”, “TEST EGR
Insufficient VGT drive VALVE AND VGT DRIVING OIL PRESSURE”.
2
pressure
If VGT drive pressure is abnormal, perform checks on causes 3, 4 and 5.
• For check of engine oil pressure, see “TESTING AND ADJUSTING”,
Defective engine oil pres- “TEST ENGINE OIL PRESSURE”.
3 sure system (main cir-
cuit) • If engine oil pressure is not normal, perform troubleshooting (S mode).
(Engine oil pressure drops)
4 Defective VGT oil pump Oil pump and relief valve for VGT valve circuit may be defective. Check them.
Defective hydraulic pip- Hydraulic piping for VGT circuit may be defective. Check it.
5
ing for VGT
Defective hydraulic return Hydraulic return piping for VGT circuit may be defective. Check it.
6
piping for VGT
VGT may have a mechanical failure. Check it.
Also check that there is no foreign material in oil inlet of VGT servo.
Defective VGT (Mechani- If KDOC inlet temperature: approximately 250 °C or below and VGT solenoid cur-
7
cal failure) rent: approximately 1000 mA are kept after active regeneration for service, VGT is
defective (See failure code CA2639 because approximate manual stationary regen-
eration time depends on the soot level estimation).
Defective VGT position Perform troubleshooting for failure codes [CA2381] and [CA2382].
8
sensor
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
9
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-445
FAILURE CODE [CA2555] 40 TROUBLESHOOTING

FAILURE CODE [CA2555] (ALL-K-AM71-410-00-B)

Action level Failure code Intake Air Heater Relay Open Circuit Error
Failure
L01 CA2555 (Engine controller system)
Detail of fail-
Open circuit is detected in preheat relay drive circuit (primary circuit).
ure
Action of
None in particular
controller
Phenomenon Intake air heater does not work in auto preheating mode (resulting in degraded startability and emis-
on machine sion of white smoke at low temperatures).

• Temperature sensed by charge temperature sensor (boost temperature sensor) can be

checked with monitoring function. (Code: 18500 (°C))
• Troubleshooting of this failure code covers circuits from engine controller to primary (coil)
circuit of pre-heater relay.
Related
• This failure code is detected only when the relay is OFF. Troubleshoot with charge temper-
information ature at -2 °C and above.
• For troubleshooting of secondary circuit of heater relay and pre-heater relay, see E-mode.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position (charge (boost) temperature: Min. -2 °C

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “c. METHOD FOR
CHECKING ELECTRIC EQUIPMENT” in “CHECKS BEFORE TROUBLE-
SHOOTING” of “RELATED INFORMATION ON TROUBLESHOOTING”,
Defective wiring harness and check it.
1
connector 2. Turn starting switch to ON position. (charge (boost) temperature: Min.
-2 °C)
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect relay R18, and connect T-adapter to male side.
200 to
Resistance Between R18 (male) (1) and (2)
400 Ω
Defective preheating re-
2
lay PHR 1. Turn starting switch to OFF position.
2. Replace relay R18 with another one.
3. Turn starting switch to ON position.
If this failure code is cleared, original preheat relay R18 is defective.
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connector J2, and connect T-adapter to female side.
3
wiring harness Between J2 (female) (75) and (61) 200 to
Resistance
Coil resistance of relay R18 400 Ω

40-446 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2555]

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connector J2 and relay R18, and connect T-adapter to each fe-
4
ness male side.
Between J2 (female) (75) and R18 (female) (1) Max. 1 Ω
Resistance
Between J2 (female) (61) and R18 (female) (2) Max. 1 Ω
Perform under conditions under which no preheating takes place (engine coolant:
-2 °C or above).
1. Turn starting switch to OFF position.
Hot short circuit in wiring
5 2. Insert T-adapter into connector J2.
harness
3. Turn starting switch to ON position.
Voltage Between J2 (75) and (61) Max. 1 V
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-447
FAILURE CODE [CA2555] 40 TROUBLESHOOTING

CIRCUIT DIAGRAM (INTAKE AIR HEATER RELAY)

40-448 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2556]

FAILURE CODE [CA2556] (ALL-K-AM71-410-10-B)

Action level Failure code Intake Air Heater Relay Short Circuit Error
Failure
L01 CA2556 (Engine controller system)
Detail of fail-
Short circuit is detected in intake air heater relay drive circuit (primary circuit).
ure
Action of
None in particular
controller
Phenomenon Intake air heater does not work in auto preheating mode (resulting in degraded startability and emis-
on machine sion of white smoke at low temperatures).

• Temperature sensed by charge temperature sensor (boost temperature sensor) can be

checked with monitoring function. (Code: 18500 (°C))
• Troubleshooting of this failure code covers circuits from engine controller to primary (coil)
circuit of pre-heater relay.
Related
• This failure code is detected only when the relay is ON. Troubleshoot with charge temper-
information ature at -3 °C and below.
• For troubleshooting of secondary circuit of heater relay and pre-heater relay, see E-mode.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position (charge (boost) temperature: Max. -3 °C

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “c. METHOD FOR
CHECKING ELECTRIC EQUIPMENT” in “CHECKS BEFORE TROUBLE-
SHOOTING” of “RELATED INFORMATION ON TROUBLESHOOTING”,
Defective wiring harness and check it.
1
connector 2. Turn starting switch to ON position. (charge (boost) temperature: Min.
-2 °C)
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect relay R18, and connect T-adapter to male side.
200 to
Resistance Between R18 (male) (1) and (2)
400 Ω
Defective preheating re-
2
lay 1. Turn starting switch to OFF position.
2. Replace relay R18 with another one.
3. Turn starting switch to ON position.
If this failure code is cleared, original preheat relay R18 is defective.
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connector J2 and relay R18, and connect T-adapter to either
3 harness (contact with female side.
ground circuit)
Between J2 (female) (75) or R18 (female) (1) and
Resistance Min. 1 MΩ
ground
1. Turn starting switch to OFF position.
2. Disconnect connector J2 and relay R18, and connect T-adapter to female
Short circuit in wiring har-
4 side of J2.
ness
Between J2 (female) (75) and each pin other than pin No continui-
Continuity
(75) ty

HB365LC-3 40-449
FAILURE CODE [CA2556] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)

40-450 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2556]

CIRCUIT DIAGRAM (INTAKE AIR HEATER RELAY)

HB365LC-3 40-451
FAILURE CODE [CA2637] 40 TROUBLESHOOTING

FAILURE CODE [CA2637] (ALL-K-A900-410-00-B)

Action level Failure code KDOC Face Plugging

Failure
L01 CA2637 (Engine controller system)
KDOC face is plugged.
1. The KDOC surface is contaminated due to the operating conditions, and the catalytic effi-
Details of
ciency has dropped (clean the DOC).
failure
2. Deteriorated KDOC due to high temperature, dropped efficiency due to deposit, or drop-
ped efficiency due to damage (Replace KDOC with a new or used one.)
Action of
Fuel dosing stops.
controller
Phenomenon
None
on machine

k Since temperature of the turbocharger exhaust connector, KDOC and KDPF exceeds
500°C, be careful not to get burned.
When KDOC in KDPF is changed, perform reset procedure for KDOC change and then finish repair.
Procedure of performing the manual stationary regeneration from the "active regeneration for serv-
ice".
When soot accumulation is at level 3 or lower, manual stationary regeneration can be performed on-
ly from Active Regeneration for Service.
1. Start engine.
2. Make sure that machine is in safe condition.
3. From service menu of machine monitor, display Diagnostic Tests screen, open Active Re-
Related generation for Service, and then perform “Manual Stationary Regeneration”.
information When operation efficiency of KDOC is decreasing, failure code [AQ10N3] may appear after failure
code [CA2637] is displayed repeatedly. If operation efficiency of KDOC is low, failure code [CA1691]
of regeneration ineffective may appear.
For check of the exhaust gas color, see “30 TESTING AND ADJUSTING”, “TEST EXHAUST GAS
COLOR”.
[Method of clearing failure code]
Start the engine, perform warm-up operation, and operate the machine in normal work for approxi-
mately 3 hours. (The time required for clearing codes will be reduced by high exhaust temperature
conditions.)
NOTICE
Operate the machine approximately 3 hours and check that this failure code is cleared.

No. Cause Procedure, measuring location, criteria and remarks

1 Defective VGT If failure code [CA238*] is displayed, perform troubleshooting for the code first.
If failure code [CA227*] or [CA23**] is displayed, perform troubleshooting for those
2 Defective EGR valve
codes first.
1. Remove turbocharger exhaust connector
2. Check inside of turbocharger exhaust connector for adhesion of oil and
Defective turbocharger
3 fuel.
exhaust connector
If there is any, perform troubleshooting for failure codes [CA227*], [CA23**], etc.
which are related to EGR valve and VGT.
Defective exhaust con- Check the exhaust system between the turbocharger and KDPF for damages in
4
nector or duct to KDPF connectors or ducts or loose connections.

40-452 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2637]

No. Cause Procedure, measuring location, criteria and remarks

1. Set the working mode to “B”, suddenly accelerate the engine from low idle
to high idle two times, and then keep the engine running at high idle for 5
seconds.
Defective exhaust gas If an excess black smoke is seen at high idle during acceleration, perform “KDPF
5 GETS CLOGGED IN A SHORT TIME”.
color
REMARK
Black smoke powder which comes out during acceleration but disappears at
high idle is normal.
1. Attach KDOC and KDPF.
2. Turn starting switch to ON position.
3. On the Service screen of the machine monitor, display “Diagnostic Tests”
screen, open 03 “KDPF Memory Reset”, and perform 03 “KDOC Change”
Reset after KDOC (Reset after KDOC change).
6
change NOTICE
• Check that reset after KDOC change is complete successfully (by re-
set count). If not, perform troubleshooting again.
• If KDOC is changed, troubleshooting is complete without performing
manual stationary regeneration.
1. Remove KDPF.
2. Remove KDOC.
NOTICE
7 Defective KDOC • Check if KDOC has any cracks (change KDOC if any).
• Check if KDOC inlet surface is clogged with soot 50 % or more (Clean-
ing of KDOC).
• Perform cause 7 when KDOC is changed, and perform causes 7 and 8
when it is cleaned.
1. Perform manual stationary regeneration from active regeneration for serv-
ice.
2. Turn starting switch to OFF position.
3. Perform manual stationary regeneration from active regeneration for serv-
Manual stationary regen- ice again (to confirm the completion of the repair).
8
eration performed
NOTICE
If failure code [CA2637] is displayed after performing active regeneration for
service, KDOC's efficiency is degraded. Change KDOC and perform the reset
after KDOC change (see cause 7).

HB365LC-3 40-453
FAILURE CODE [CA2639] 40 TROUBLESHOOTING

FAILURE CODE [CA2639] (ALL-K-A9H0-410-40-B)

Action level Failure code

Failure Manual Stationary Regeneration Request (Engine controller system)
L01 CA2639
The “Manual Stationary Regeneration Request”prompts operator to forcibly perform “Manual Sta-
Details of tionary Regeneration”, which is more effective to remove soot, because soot accumulation in the
failure KCSF of KDPF has exceeded the level for automatic regeneration.
Soot accumulation reaches level 4 or 5.
Action of
Normal control
controller
Phenomenon
None in particular
on machine

NOTICE
• If this failure code [CA2639] is displayed, perform manual stationary regeneration.
• This failure code is displayed during Manual Stationary Regeneration, but it is nor-
mal.
• If this failure code is still displayed after several hours have passed since the man-
ual stationary regeneration, perform the following troubleshooting procedures.
k Since KDOC and KDPF are heated to 500 °C or above, be careful not to get burned.
• If KDOC inlet temperature is below approximately 280 °C, fuel dosing is disabled, so ac-
tually regeneration does not start when engine controller started manual stationary regen-
eration.
• Temperature detected by KDOC inlet temperature sensor can be checked with monitoring
function. (Code: 47300 (°C))
• VGT solenoid current can be checked with monitoring function. (Code: 48800 (mA))
Related • Temperature detected by KDOC outlet temperature sensor can be checked with monitor-
information ing function. (Code: 47400 (°C))
• Temperature detected by KDPF outlet temperature sensor can be checked with monitoring
function. (Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when at
low idle speed (KDPF regeneration is not executed) are approximately 100 to 250 °C, and
difference between these temperatures is approximately 10 °C. (KDOC inlet temperature >
KDOC outlet temperature > KDPF outlet temperature)
• When manual stationary regeneration is in progress, KDOC inlet temperature is approxi-
mately 250 to 400 °C, and KDOC outlet temperature and KDPF outlet temperature are ap-
proximately 450 to 550 °C.
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.
• For check of the exhaust gas color, see “30 TESTING AND ADJUSTING”, “TEST EX-
HAUST GAS COLOR”.

40-454 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2639]

• How to perform manual stationary regeneration

1. Start engine.
2. Make sure that machine is in a safe condition.
3. From service menu of machine monitor, display Diagnostic Tests screen, open Active Re-
generation for Service, and then perform Manual Stationary Regeneration.
• Switch operation during manual stationary regeneration: By pressing "1", "2", "3" in order
while numeral input switch [4] is pressed, the screen changes to Monitoring.
Time required for the manual stationary regeneration depends on the accumulated soot in KCSF,
Related
however, it is estimated as follows.
information
• If soot accumulation is level 4: Approximately 40 minutes to 1 hour
• If soot accumulation is level 5: Approximately 1 to 2 hours
• If soot accumulation is level 6 or 7: Approximately 2 to 3 hours
• If soot accumulation is level 8: Manual stationary regeneration cannot be performed.
• If another failure code is displayed (including when manual stationary regeneration is in
progress), perform troubleshooting for these first.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Check that “Regeneration Disable” is chosen on the screen of the machine
Increased accumulation monitor. (See operation manual) Cancel the “Regeneration Disable” if it is
1 of soot due to regenera- chosen.
tion disable
2. Cancel regeneration disable and perform cause 2 and subsequent causes.
After temperature is cooled down sufficiently, run engine at low idle speed and
Defective KDOC inlet check if temperature differences between the KDOC inlet temperature and the
2
temperature sensor KDOC outlet temperature, or KDPF outlet temperature is not large. If it is large dif-
ference, try to change KDOC inlet temperature sensor.
VGT may have a mechanical failure. Check it.
Also check that there is no foreign material in oil inlet of VGT servo.
Defective VGT (Mechani- If KDOC inlet temperature: approximately 250 °C or below and VGT solenoid cur-
3
cal failure) rent: approximately 1000 mA are kept after active regeneration for service, VGT is
defective (See failure code CA2639 because approximate manual stationary regen-
eration time depends on the soot level estimation).
Defective KDPF (KDOC, Perform troubleshooting for “S-22 ACTIVE REGENERATION TAKES TIME” of S
4
or KCSF) mode.
• If failure code [CA1921], or [CA2639] is displayed after manual stationary
regeneration is completed, perform the following:
• For details of checking the exhaust gas color, see TESTING AND AD-
JUSTING, “TEST EXHAUST GAS COLOR”.
• Perform regeneration disable on the machine monitor to check the exhaust
gas color.
Defective exhaust gas 1. Set the working mode to “B”, suddenly accelerate the engine from low idle to
5 high idle two times, and then keep the engine running at high idle for 5 sec-
color
onds.
If an excess black smoke is seen at high idle during acceleration, perform S
MODE, “KDPF GETS CLOGGED IN A SHORT TIME”.
Black smoke powder which comes out during acceleration but disappears at
high idle is normal.
2. To finish the exhaust gas color check, cancel the regeneration disable.
3. Make sure that the failure code is not displayed.

HB365LC-3 40-455
FAILURE CODE [CA2639] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

40-456 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2771]

FAILURE CODE [CA2771] (ALL-K-AFA0-410-00-B)

Action level Failure code SCR Outlet NOx Sensor Datalink Timeout Error
Failure
L01 CA2771 (Engine controller system)
Detail of fail- The engine controller does not receive SCR outlet NOx sensor data due to a communication error
ure with the SCR outlet NOx sensor.
Action of • Runs the controller using the default NOx emission value (0 ppm).
controller • Advances to Inducement strategy.
• NOx emission may increase or ammonia may be exhausted because AdBlue/DEF injec-
Phenomenon tion works inappropriately.
on machine • Engine output is reduced based on inducement strategy.
• SCR outlet NOx concentration detection error
k The turbocharger outlet, the sensor installation piping, KDPF, and KDOC become hot
(Min. 500 °C). Be careful not to get burned.
k SCR assembly, the sensor installation piping, and the sensor probe become hot
(Min. 400 °C). Be careful not to get burned.
k Be careful not to get burned by the sensor probe as it is heated by itself even if the
ambient temperature is not high.
• SCR outlet NOx sensor is a smart sensor which communicates with the engine controller
via CAN along with other sensors.
• This failure code is displayed if the sensor connector or a smart sensor (power supply) re-
lay connector is removed.
• CAN communication failure codes related to engine sensors include [CA2771], [CA3232],
[CA3868], [CA3911], [CA4151], and [CA4152]. If all of these failure codes are displayed, a
defect in any of the 6 sensors, a defective smart sensor power supply relay/relay system
or a ground fault or short circuit or hot short circuit in wiring harness (CAN communication
line) can be suspected.
Related
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
information
using multimeter.
• AdBlue/DEF tank sensor consists of the AdBlue/DEF level sensor, AdBlue/DEF tempera-
ture sensor, and AdBlue/DEF quality sensor and is integrated into one sensor controller
which provides CAN communication with the engine controller.
• The KDPF temperature sensor consists of the KDOC inlet temperature sensor, the KDOC
outlet temperature sensor, and the KDPF outlet temperature sensor and is integrated into
one sensor controller which provides CAN communication with the engine controller.
• For replacement of the KDPF temperature sensor, see DISASSEMBLY AND ASSEMBLY,
“DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY”.
• The SCR temperature sensor and the SCR outlet temperature sensor are integrated into
one sensor controller which provides CAN communication with the engine controller.
• For replacement of the SCR temperature sensor, see DISASSEMBLY AND ASSEMBLY,
“Remove and install SCR temperature sensor”.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector
2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.

HB365LC-3 40-457
FAILURE CODE [CA2771] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If failure code [CA1776] or [CA1777] is displayed, perform troubleshooting for
[CA1776] or [CA1777] first.
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
Defective smart sensor disconnect switch to OFF position.
2 power supply relay sys- 3. Disconnect relay connector R52, and connect T-adapter to female side.
tem
4. Turn the battery disconnect switch ON.
5. Turn starting switch to ON position.
6. Perform troubleshooting for failure code [CA1776] if a failure is found.
Voltage Between R52 (female) (5) and (4) Min. 22 V
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
3. Disconnect connectors E26, E31, E32, E34, E36, and P63.
4. Insert T-adapter into connector R52.
5. Turn the battery disconnect switch ON.
Defective sensor power 6. Turn starting switch to ON position.
3
supply relay
Between R52 (6) and (4) Min. 22 V
Between R52 (7) and (4) Min. 22 V
Between R52 (8) and (4) Min. 22 V
Voltage
Between R52 (9) and (4) Min. 22 V
Between R52 (11) and (4) Min. 22 V
Between R52 (12) and (4) Min. 22 V
If all 6 failure codes of [CA2771], [CA3232], [CA3868], [CA3911], [CA4151], and
[CA4152] are displayed
1. Turn starting switch to OFF position.
Defective turbocharger
4 2. Disconnect turbocharger outlet NOx sensor (E31).
outlet NOx sensor
3. Turn starting switch to ON position.
Displaying less than 6 failure codes indicates the disconnected sensor is defective.
If all of 6 failure codes of [CA2771], [CA3232], [CA3868], [CA3911], [CA4151], and
[CA4152] are displayed.
1. Turn starting switch to OFF position.
Defective SCR outlet 2. Disconnect SCR outlet NOx sensor (E36).
5
NOx sensor
3. Turn starting switch to ON position.
If any of these 6 codes disappeared, the sensor which has been disconnected is
defective.
If all 6 failure codes of [CA2771], [CA3232], [CA3868], [CA3911], [CA4151], and
[CA4152] are displayed
1. Turn starting switch to OFF position.
Defective SCR tempera-
6 2. Disconnect SCR temperature sensor (E34).
ture sensor
3. Turn starting switch to ON position.
Displaying less than 6 failure codes indicates the disconnected sensor is defective.

40-458 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2771]

No. Cause Procedure, measuring location, criteria and remarks

If all 6 failure codes of [CA2771], [CA3232], [CA3868], [CA3911], [CA4151], and
[CA4152] are displayed
1. Turn starting switch to OFF position.
Defective ammonia sen-
7 2. Disconnect an ammonia sensor (E32).
sor
3. Turn starting switch to ON position.
Displaying less than 6 failure codes indicates the disconnected sensor is defective.
If all of 6 failure codes of [CA2771], [CA3232], [CA3868], [CA3911], [CA4151], and
[CA4152] are displayed.
1. Turn starting switch to OFF position.
Defective KDPF temper- 2. Disconnect KDPF temperature sensor (E26).
8
ature sensor
3. Turn starting switch to ON position.
If any of these 6 codes disappeared, the sensor which has been disconnected is
defective.
If all 6 failure codes of [CA2771], [CA3232], [CA3868], [CA3911], [CA4151], and
[CA4152] are displayed
1. Turn starting switch to OFF position.
Defective AdBlue/DEF
9 2. Disconnect AdBlue/DEF tank sensor (P63).
tank sensor
3. Turn starting switch to ON position.
Displaying less than 6 failure codes indicates the disconnected sensor is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector K10 and D_RES and connect T-adapter to male
side.
Defective CAN terminat-
10 Approx.
ing resistor Between K10 (male) (A) and (B)
120 Ω
Resistance
Approx.
Between RES (male) (A) and (B)
120 Ω
• Communication line
As CAN terminating resistors of 120 Ω are connected in parallel, therefore, when
circuit resistance is measured at connector of CAN communication, if combined re-
sistance is 60 Ω, there is no open circuit.
1. Turn starting switch to OFF position.
Open circuit and short 2. Check that system operating lamp does not light up, and then turn battery
circuit in wiring harness disconnect switch to OFF position.
11
(broken or short-circuited
3. Disconnect connectors ECM J2 and E36 and connect T-adapters to each
communication line)
female side.
Approxi-
Between E36 (female) (3) and (2)
mately 60 Ω
Resistance
Approxi-
Between ECM J2 (female) (21) and (45)
mately 60 Ω
If no failure is found by above results, this check is not required.
Open circuit in wiring har- 1. Turn starting switch to OFF position.
ness (wire breakage or 2. Disconnect connectors R52 and E36 and connect T-adapters to each fe-
12 defective contact of con- male side.
nector) (broken power
line) Between R52 (female) (12) and E36 (female) (1) Max. 10 Ω
Resistance
Between E36 (female) (4) and ground Max. 10 Ω

HB365LC-3 40-459
FAILURE CODE [CA2771] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Open circuit in wiring har- 3.
ness (wire breakage or
13 defective contact of con-
nector) (broken commu-
nication line)
Ground fault in wiring
14 harness (contact with
ground circuit)
Hot short circuit in wiring
15
harness
Defective SCR outlet
16
NOx sensor
• Communication line
If failure code is still displayed after above checks on cause 11, this check is not
required.
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
Disconnect connectors ECM J2, E36, K10, and K11 and connect T-adapt-
ers to each female side.
Between ECM J2 (female) (21) and E36 (female) (3) Max. 10 Ω
Between ECM J2 (female) (45) and E36 (female) (2) Max. 10 Ω
Between K10 (female) (A) and E36 (female) (3) Max. 10 Ω
Resistance
Between K10 (female) (B) and E36 (female) (2) Max. 10 Ω
Between K11 (female) (A) and E36 (female) (3) Max. 10 Ω
Between K11 (female) (B) and E36 (female) (2) Max. 10 Ω
f failure code (no open circuit) is still displayed after above checks in cause 11,
measure resistance at any one place in Hi line and Lo line.
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
3. Disconnect all related connectors, and connect T-adapter to the female
side of the connector to be measured.
Between one of ECM J2(female)(21),K10(female)
(A),K11(female)(A),E31(female)(3),E32(female)
Min.100 kΩ
(2),E26(female)(3),E34(female)(3),E36(female)
(3),P63(female)(2) and ground
Resistance
Between one of ECM J2(female)(45),K10(female)
(B),K11(female)(B),E31(female)(2),E32(female)
Min.100 kΩ
(3),E26(female)(2),E34(female)(2),E36(female)
(2),P63(female)(1) and ground
f failure code (no open circuit) is still displayed after above checks in cause 11,
measure resistance at any one place in Hi line and Lo line.
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
3. Insert T-adapter into one of the related connectors.
4. Set battery disconnect switch to ON position.
5. Turn starting switch to ON position.
Between one of ECM J2(21), K10(A), K11 (A), E31(3),
1 to 4 V
E32(2), E26(3), E34(3), E36(3), or P63(2) and ground
Voltage
Between one of ECM J2(45), K10(B), K11 (B), E31(2),
1 to 4 V
E32(3), E26(2), E34(2), E36(2), or P63(1) and ground
1. Turn starting switch to OFF position.
2. Replace the SCR outlet NOx sensor (E36).
3. Turn starting switch to ON position.
If this failure code is cleared, the original sensor is defective. (In case of an internal
defect, troubleshooting is impossible as an assembly. Replace whole assembly.)

40-460 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2771]

No. Cause Procedure, measuring location, criteria and remarks

Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
17
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-461
FAILURE CODE [CA2771] 40 TROUBLESHOOTING

Circuit diagram related to SCR system CAN communication

40-462 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2777]

FAILURE CODE [CA2777] (ALL-K-A9H0-410-B0-B)

Action level Failure code Manual Stationary Regeneration Request but KDPF Regeneration
Failure Disable
- CA2777 (Engine controller system)
• The Manual Stationary Regeneration Request prompts operator to forcibly perform "Man-
ual Stationary Regeneration", which is more effective to remove soot, because soot accu-
Detail of fail- mulation in the KCSF of KDPF has exceeded the level for automatic regeneration. Howev-
ure er, the operator is pressing Regeneration Disable, so regeneration is disabled.
• Soot accumulation reaches level 4 or 5.
Action of
None in particular
controller
Phenomenon
None
on machine

HB365LC-3 40-463
FAILURE CODE [CA2777] 40 TROUBLESHOOTING

k If KDOC and KDPF becomes hot (Min. 500 °C). Be careful not to get burned.
REMARK
If manual stationary regeneration is started when KDOC inlet temperature is below approximately
280 °C, fuel dosing is disabled, so actually regeneration does not start.
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
(Code: 47300 (°C))
• VGT solenoid current can be checked by monitoring function. (Code: 48800 (mA))
• Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
• The KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature can
also be confirmed from the troubleshooting screen.
• All of KDOC inlet temperature, KDOC outlet temperature and KDPF outlet temperature
during idle (non-regeneration) are approximately 100 to 250 °C. Each temperature differ-
ence is approximately 10 °C (KDOC inlet temperature > KDOC outlet temperature > KDPF
outlet temperature).
• When manual stationary regeneration is in progress, KDOC inlet temperature is 250 to
400 °C, and KDOC outlet temperature and KDPF outlet temperature are 450 to 600 °C.
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.
Related How to perform manual stationary regeneration
information 1. Start the engine.
2. Secure the safety of the machine.
3. From service menu of machine monitor, display “Diagnostic Tests” screen, open “Active
Regeneration for Service”, clear regeneration disable, and then perform “Manual Station-
ary Regeneration”.
Time required for manual stationary regeneration varies depending on soot accumulation amount in
KCSF. Rough guide is described below.
• Soot accumulation level 4: Approximately 40 minutes to 1 hour
• Soot accumulation level 5: Approximately 1 hour to 2 hours
• If soot accumulation is level 6 or 7: Approximately 2 to 3 hours
• If soot accumulation is level 8: Manual stationary regeneration cannot be performed.
REMARK
• If this failure code is still displayed after several hours have passed since the manual sta-
tionary regeneration, perform the following troubleshooting procedures.
• If other failure code is also displayed (including manual stationary regeneration), perform
troubleshooting for these first.
• This failure code is not a failure but an information to identify the failure.
• If this failure codes frequently is displayed, ask operator to perform “Cancel of Regenera-
tion Disable”and to execute manual stationary regeneration after securing the safety of the
surroundings and check that there is not a person or combustible around the machine.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn the starting switch to ON position.

40-464 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2777]

No. Cause Procedure, measuring location, criteria and remarks

If the failure code is not cleared after Cancel of Regeneration Disable from the ma-
Defective engine control-
1 chine monitor, the engine controller may be defective (In case of an internal defect,
ler
troubleshooting is impossible as an assembly. Replace whole assembly.)

HB365LC-3 40-465
FAILURE CODE [CA2976] 40 TROUBLESHOOTING

FAILURE CODE [CA2976] (ALL-K-AFH1-410-00-B)

Action level Failure code AdBlue/DEF Pump Temperature Sensor Signal Error
Failure
L01 CA2976 (Engine controller system)
Detail of fail-
Power supply, wiring harness, or sensor for AdBlue/DEF pump temperature is defective.
ure
Action of • The last normal value of AdBlue/DEF pump temperature is valid.
controller • Advances to Inducement strategy.
• AdBlue/DEF thawing defective.
Phenomenon
• NOx emission increases in low temperature due to defective AdBlue/DEF pump thawing.
on machine
• Engine output is reduced based on inducement strategy.
• This failure code is displayed when AdBlue/DEF pump connector is disconnected.

Related • Because sensor output is approximately 10 V of pulse waveform, it is not measured by us-
ing multimeter.
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective power supply
system of AdBlue/DEF
1
pump temperature sen-
sor
Defective wiring harness
2
connector
Open circuit in wiring har-
ness (wire breakage or
3 Between ECM J2 (female) (54) and MB02 (female) (8)
defective contact of con-
nector)
Short circuit in wiring har-
4 MB02 (female) (10) and (8)
ness
If failure code [CA3558] or [CA3559] is displayed, perform troubleshooting for
[CA3558] or [CA3559] first.
1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of the failure code
“RELATED INFORMATION ON TROUBLESHOOTING”, and check it.
2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J2 and MB02, and connect T-adapter to ei-
ther female side.
Max. 10 Ω
Between ECM J2 (female) (79) and MB02 (female) (9) Max. 10 Ω
Resistance
Between ECM J2 (female) (06) and MB02 (female)
Max. 10 Ω
(10)
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J2 and MB02, and connect T-adapter to ei-
ther female side.
Between ECM J2 (female) (6) and (54), or between
Min. 100 kΩ
Between ECM J2 (female) (6) and (79), or between
Resistance Min. 100 kΩ
MB02 (female) (10) and (9)
Between ECM J2 (female) (54) and (79), or between
Min. 100 kΩ
MB02 (female) (8) and (9)

40-466 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA2976]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J2 and MB02, and connect T-adapter to ei-
Ground fault in wiring ther female side.
5 harness (contact with Between ECM J2 (female) (6) or MB02 (female) (10)
GND circuit) Min. 100 kΩ
and ground
Resistance
Between ECM J2 (female) (79) or MB02 (female) (9)
Min. 100 kΩ
and ground
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector MB02, and connect T-adapter to female side.
6
harness 3. Turn starting switch to ON position.
Voltage Between MB02 (female) (10) and (8) Max. 4.5 V
Defective AdBlue/DEF If no failure is found by preceding checks, AdBlue/DEF pump temperature sensor
7 pump temperature sen- may be defective. (In case of an internal defect, troubleshooting is impossible as an
sor (internal defect) assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
8
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to AdBlue/DEF pump temperature sensor

HB365LC-3 40-467
FAILURE CODE [CA3133] 40 TROUBLESHOOTING

FAILURE CODE [CA3133] (ALL-K-A9HW-410-30-B)

Action level Failure code KDPF outlet pressure sensor high error
Failure
L03 CA3133 (Engine controller system)
Detail of fail-
High voltage is generated in signal circuit of KDPF outlet pressure sensor.
ure
Action of Drives KDPF outlet pressure sensor at estimated value (gauge pressure). (Operates at 0 kPa
controller (gauge pressure) if other failure code is displayed at the same time).

Phenomenon
None
on machine

k KDPF is heated to 500 °C or higher. Be careful not to get burn injury.

• KDPF differential pressure sensor and KDPF outlet pressure sensor are provided as a
unit.
• If failure code [CA1695] is not displayed but failure code [CA1879] is on screen, ground
line probably has open circuit (defective contact of connector).
Related
• Signal voltage from KDPF outlet pressure sensor can be checked with monitoring function.
information
(Code: 47001 (V))
• Differential pressure detected by KDPF outlet pressure sensor can be checked with moni-
toring function. (Code: 47000 (kPa))
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
If failure code [CA1695] or [CA1696] is displayed, perform troubleshooting for
[CA1695] or [CA1696] first.
1. Turn starting switch to OFF position.
Defective sensor power 2.
2 Disconnect connector E25, and connect T-adapter to female side.
supply system
3. Turn starting switch to ON position.
4.75 to
Voltage Between E25 (female) (4) and (1)
5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connector E25.
3. Turn starting switch to ON position.

Defective KDPF outlet If this failure code is changed to [CA3134], the KDPF outlet pressure sensor is de-
3 fective.
pressure sensor
NOTICE
• If this failure code is displayed, the wiring harness or engine control-
ler is defective.
• Ignore other failure codes displayed.

40-468 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3133]

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks on cause 2, this check is not re-
quired.
Open circuit in wiring har- 1.
Starting switch: OFF
ness (wire breakage of
4 2. Disconnect connectors ECM J2 and E25, and connect T-adapters to each
GND line or defective
contact of connector) female side.
Resistance Between ECM J2 (female) (32) and E25 (female) (1) Max. 10 Ω
1. Starting switch: OFF
2. Disconnect connectors ECM J2 and E25, and connect T-adapter to female
Short circuit in wiring har- side of ECM J2.
5
ness
No continui-
Between ECM J2 (female) (42) and each pin other
Continuity ty (no sound
than pin (42)
is heard)
1. Starting switch: OFF
2. Disconnect connector E25.
Hot short circuit in wiring 3. Connect T-adapter to female side of connector E25, or insert T-adapter to
6 harness (Contact with 24 connector ECM J2.
V circuit) 4. Turn starting switch to ON position (with connector E25 disconnected).
Between ECM J2 (female) (42) and (32), or between
Voltage Max. 1 V
E25 (female) (3) and (1)
Turn starting switch to ON position.
Defective engine control- If this failure code is still displayed and no failure is found by preceding checks, en-
7
ler gine controller is defective. (In case of an internal defect, troubleshooting is impos-
sible as an assembly. Replace whole assembly.)

Circuit diagram related to KDPF outlet pressure sensor

HB365LC-3 40-469
FAILURE CODE [CA3134] 40 TROUBLESHOOTING

FAILURE CODE [CA3134] (ALL-K-A9HW-410-40-B)

Action level Failure code KDPF Outlet Pressure Sensor Low Error
Failure
L03 CA3134 (Engine controller system)
Detail of fail-
Low voltage is generated in signal circuit of KDPF outlet pressure sensor.
ure
Action of Sets KDPF outlet pressure sensor value to an estimated value (gauge pressure) and continues op-
controller eration (operates at 0 kPa (gauge pressure) if other failure codes appear at the same time).

Phenomenon
None
on machine

k Since KDPF is heated to 500 °C or above, be careful not to get burned.

• KDPF differential pressure sensor and KDPF outlet pressure sensor are integrated.
• If failure code [CA1696] is not displayed but failure code [CA1881] is on screen, sensor
connector is probably disconnected or 5 V line probably has open circuit (defective contact
of connector).
Related • This failure code is displayed if sensor connector is disconnected.
information • Signal voltage from KDPF outlet pressure sensor can be checked by monitoring function.
(Code: 47001 (V))
• Differential pressure detected by KDPF outlet pressure sensor can be checked by monitor-
ing function. (Code: 47000 (kPa))
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
If failure code [CA1695] or [CA1696] is displayed, perform troubleshooting for
[CA1695] or [CA1696] first.
1. Turn starting switch to OFF position.
Defective sensor power 2.
2 Disconnect connector E25, and connect T-adapter to female side.
supply system
3. Turn starting switch to ON position.
4.75 to
Voltage Between E25 (female) (4) and (1)
5.25 V
1. Starting switch: OFF
2. Disconnect connectors ECM J2 and E25, and connect T-adapters to each
female side.

Open circuit in wiring har- If failure code is still displayed after above checks on
ness (wire breakage or cause 2, this check is not required. Max. 10 Ω
3
defective contact of con- Between ECM J2 (female) (32) and E25 (female) (1)
nector)
Resistance If failure code is still displayed after above checks on
cause 2, this check is not required. Max. 10 Ω
Between ECM J2 (female) (8) and E25 (female) (4)
Between ECM J2 (female) (42) and E25 (female) (3) Max. 10 Ω

40-470 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3134]

No. Cause Procedure, measuring location, criteria and remarks

1. Starting switch: OFF
Ground fault in wiring 2. Disconnect connectors ECM J2 and E25, and connect T-adapters to each
4 harness (contact with female side.
ground circuit)
Between ECM J2 (female) (42) and ground, or be-
Resistance Min. 100 kΩ
tween E25 (female) (3) and ground
1. Starting switch: OFF
2. Disconnect connectors ECM J2 and E25, and connect T-adapter to female
Short circuit in wiring har- side of ECM J2.
5
ness
No continui-
Between ECM J2 (female) (42) and each pin other
Continuity ty (no sound
than pin (42)
is heard)
1. Turn starting switch to OFF position.
Defective KDPF outlet 2. Insert T-adapter into connector E25.
6
pressure sensor 3. Turn starting switch to ON position.
Voltage Between E25 (3) and (1) 0.5 to 4.5 V
Turn starting switch to ON position.
Defective engine control- If this failure code is still displayed and no failure is found by preceding checks, en-
7
ler gine controller is defective. (In case of an internal defect, troubleshooting is impos-
sible as an assembly. Replace whole assembly.)

Circuit diagram related to KDPF outlet pressure sensor

HB365LC-3 40-471
FAILURE CODE [CA3135] 40 TROUBLESHOOTING

FAILURE CODE [CA3135] (ALL-K-A9HW-410-50-B)

Action level Failure code KDPF Outlet Pressure Sensor In Range Error
Failure
L03 CA3135 (Engine controller system)
Details of Pressure value sensed by KDPF outlet pressure sensor is higher than normal value.
failure (Signal voltage is within operating range.)
Action of Sets KDPF outlet pressure sensor value to an estimated value (gauge pressure) and continues op-
controller eration (operates at 0 kPa (gauge pressure) if other failure codes appear at the same time).

Phenomenon
None
on machine

k The temperature of KDPF and KDOC becomes hot (Min. 500 °C). Be careful not to get
burned.
• KDPF differential pressure sensor and KDPF outlet pressure sensor are integrated.
• KDPF differential pressure sensed by KDPF differential pressure sensor can be checked
by monitoring function. (Code: 47100 (kPa))
• Signal voltage from KDPF outlet pressure sensor can be checked by monitoring function.
(Code: 47001 (V))
• Outlet pressure sensed by KDPF outlet pressure sensor can be checked by monitoring
function. (Code: 47000 (kPa))
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
(Code: 47300 (°C))
• Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
Related REMARK
information
Use “Short-circuit connector: 799T-601-4670”.
• As to procedure for accessing KDPF temperature sensor, see “50 DISASSEMBLY AND
ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND
ASSEMBLE KDPF ASSEMBLY”.
• Engine controller stops after starting switch is turned to OFF position and AdBlue/DEF is
retracted (for up to 6 minutes). So when you restart engine, wait until the system operating
lamp goes out after starting switch is turned OFF, and then turn the starting switch to ON
position.
NOTICE
• This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. Af-
ter investigating the cause of the problem and completing the repair, perform “Load-
ed Diagnostics Operation To Clear Failure Code” to make sure the failure code is
cleared again.
• Before performing “Loaded Diagnostics Operation To Confirm Failure Correction”,
firstly Setting and operating machine monitor, Service mode, Service mode (Engine
Controller Active Fault Clear) to be performed to clearer this failure code.

40-472 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3135]

No. Cause Procedure, measuring location, criteria and remarks

1. Remove KDPF differential pressure sensor tube.
2. Clean and unclog the KDPF differential pressure sensor tube.
3. Check the KDPF differential pressure sensor tube for cracks or damages.
4. Securely connect both ends of the tube and install the KDPF differential
pressure sensor tube.
Defective KDPF differen-
1 Reference
tial pressure sensor tube
How to check clogged KDPF differential pressure sensor tube
1. Turn starting switch to ON position.
2. Monitor the outlet pressure by using KDPF outlet pressure sensor on Self-
define Monitoring screen of the machine monitor.
Code 47000(kPa) 0 ± 3( kPa)
If failure code [CA1695] or [CA1696] is displayed, perform troubleshooting for
[CA1695] or [CA1696] first.
1. Turn starting switch to OFF position.
Defective sensor power 2.
2 Disconnect connector E25, and connect T-adapter to female side.
supply system
3. Turn starting switch to ON position.
4.75 to
Voltage Between E25 (female) (4) and (1)
5.25 V
1. See descriptions of wiring harness and connectors in “Electrical equip-
Defective wiring harness ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
3
connector FORMATION ON TROUBLESHOOTING”, and check and repair defects, if
any.
1. Turn starting switch to OFF position.
2. Disconnect connector E25.
3. Turn starting switch to ON position.
If failure code [CA3134] is cleared, the wiring harness or engine controller is defec-
tive.
Check cause 3 again.
Ignore other failure codes displayed.
1. Turn starting switch to OFF position.
Defective wiring harness
4 2. Disconnect connector E25 and connect short socket adapter to female
or engine controller
side.
REMARK
Connect 5 V to the signal line. (Short-circuit pins (4) and (3) of connector E25.)
3. Turn starting switch to ON position.
If failure code [CA3313] is cleared, the wiring harness or engine controller is defec-
tive.
Check cause 3 again.
Ignore other failure codes displayed.
Defective KDPF outlet If failure codes [CA3134] and [CA3133] are displayed after checks on defective wir-
5
pressure sensor ing harness or engine controller, the KDPF outlet pressure sensor is defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-473
FAILURE CODE [CA3135] 40 TROUBLESHOOTING

Loaded Diagnostics Operation To Clear Failure Code

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is cleared after this procedure.)
k Place the machine on a level ground.
1. Turn the starting switch to OFF position.
2. Turn the starting switch from OFF position to ON position.
3. Start the engine and run it at low idle for approximately 1 minute.
4. Display KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature referring to the
related information.
5. After finishing the warm-up operation, set the swing lock switch to ON position, working mode to B, and fuel
control dial to MAX position.
6. Perform arm IN relief for 40 seconds.
7. If the failure code is cleared after steps 1 to 6 are performed, repair work is completed.
Circuit diagram related to KDPF outlet pressure sensor

40-474 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3142]

FAILURE CODE [CA3142] (ALL-K-AFP0-410-00-B)

Action level Failure code SCR Temperature Sensor High Error

Failure
L01 CA3142 (Engine controller system)
Detail of fail- Open circuit , hot short circuit, or sensor circuit error in SCR temperature sensor measuring section
ure or probe (+)
• Because the SCR temperature is not detected be detected, substitute the SCR outlet tem-
perature for the SCR temperature and run the engine (if the SCR outlet temperature sen-
Action of sor also has an error, use the last normal value).
controller • Advances to Inducement strategy.
• AdBlue/DEF injection stops.
Phenomenon • NOx emission increases because AdBlue/DEF injection is disabled.
on machine • Engine output is reduced based on inducement strategy.
k SCR assembly, the sensor installation piping, and the sensor probe become hot (Min.
400 °C). Be careful not to get burned.
• Open circuit , hot short circuit, or sensor circuit error in SCR temperature sensor measur-
ing section or probe (+) is sent to the engine controller via CAN communication, and this
failure code is displayed.
Related
• The SCR temperature sensor and the SCR outlet temperature sensor are integrated into
information one sensor controller which provides CAN communication with the engine controller.
• For replacement of the SCR temperature sensor, see Disassembly and assembly, “Re-
move and install SCR temperature sensor”.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Replace SCR temperature sensor.
Defective SCR tempera-
1 ture sensor (internal de- 3. Turn starting switch to ON position.
fect) If this failure code is cleared, the original SCR temperature sensor is defective. (In
case of an internal defect, troubleshooting is impossible as an assembly. Replace
whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
2
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-475
FAILURE CODE [CA3143] 40 TROUBLESHOOTING

FAILURE CODE [CA3143] (ALL-K-AFP0-410-10-B)

Action level Failure code SCR Temperature Sensor Low Error

Failure
L01 CA3143 (Engine controller system)
Detail of fail-
Ground fault or sensor circuit error in SCR temperature sensor measuring section or probe (+)
ure
• As the SCR temperature cannot be detected, substitute the SCR outlet temperature for
the SCR temperature and run the engine (if the SCR outlet temperature sensor also has
Action of an error, use the latest normal value).
controller • Advances to Inducement strategy.
• AdBlue/DEF injection stops.
Phenomenon • NOx emission increases because AdBlue/DEF injection is disabled.
on machine • Engine power deration according to inducement strategy.
k SCR assembly, sensor fitting piping, and sensor probe become hot (Min. 400 °C). Be
careful not to get burned.
• The SCR temperature sensor and SCR outlet temperature sensor are integrated into one
sensor controller which provides CAN communication with the engine controller.
Related • Ground fault or sensor circuit error in SCR temperature sensor measuring section or probe
(+) is sent to the engine controller via CAN communication, and this failure code is dis-
information played.
• For the replacement procedure of the SCR temperature sensor, see "Disassembly and as-
sembly," “Remove and install SCR temperature sensor”.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Replace SCR temperature sensor.
Defective SCR tempera-
1 ture sensor (internal de- 3. Turn starting switch to ON position.
fect) If this failure code is cleared, the original SCR temperature sensor is defective. (In
case of an internal defect, troubleshooting is impossible as an assembly. Replace
whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
2
ler an internal defect, troubleshooting cannot be performed.)

40-476 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3144]

FAILURE CODE [CA3144] (ALL-K-AFP0-410-A0-B)

Action level Failure code SCR temperature sensor in range error

Failure
L01 CA3144 (Engine controller system)
Detail of fail- Temperature difference between SCR temperature sensor and SCR outlet temperature sensor is
ure not the same as the expected value.
Action of • Inducement strategy is activated.
controller • Prohibits AdBlue/DEF injection.
Phenomenon • NOx emission increases because AdBlue/DEF injection is disabled.
on machine • Engine output is reduced based on Inducement strategy.
k KDPF, KDOC, and SCR are heated to 500 °C or higher. Be careful not to get burn in-
jury.
• SCR temperature sensor and SCR outlet temperature sensor are integrated into one sen-
sor, and controller of integrated sensor communicates with the engine controller through
CAN communication.
• For SCR temperature sensor replacement, see DISASSEMBLY AND ASSEMBLY, “RE-
MOVE AND INSTALL SCR TEMPERATURE SENSOR”.
• After turning starting switch to OFF position, engine controller performs AdBlue/DEF purge
(for 6 minutes in maximum) and then stops engine. To restart engine, wait until system op-
erating lamp goes out after turning starting switch to OFF position, and then turn the start-
ing switch to ON position.
• Temperature detected by SCR temperature sensor can be checked with “Pre-defined
Monitoring screen”.
• On Pre-defined Monitoring screen, engine operation state diagnosis, AdBlue/DEF level,
and AdBlue/DEF quality sensor diagnosis are used. (The numbers below denote monitor-
ing codes).
• Pre-defined Monitoring (16/28) Engine operation state
Related 1. 01002 Engine Speed
information 2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
• Pre-defined Monitoring (20/28) AdBlue/DEF level, quality sensor
1. 19100 AdBlue/DEF Concentration
2. 19110 AdBlue/DEF Level
3. 19111 AdBlue/DEF Level Corrected
4. 19115 AdBlue/DEF Temperature in Tank
5. 19400 Ambient Temperature
6. 19305 AdBlue/DEF Tank Heating State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correc-
tion”. After investigating the cause of the problem and completing the repair, perform
“Loaded Diagnostics Operation To Confirm Failure Correction” to make sure the failure
code is cleared. (Even if this failure code is not displayed with starting switch in ON po-
sition, completion of repair cannot be determined unless exhaust temperature becomes
high.)

HB365LC-3 40-477
FAILURE CODE [CA3144] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Defective SCR tempera- If failure code [CA3142] or [CA3143] is displayed, perform troubleshooting for
ture sensor (internal [CA3142] or [CA3143].
1
open or short circuit to
ground)
1. If failure code [CA3251] is displayed, perform troubleshooting for
[CA3251].
Defective KDPF system
2. If failure code [CA3253], [CA3254], or [CA3311] is displayed, perform trou-
2 (Abnormal exhaust gas bleshooting for [CA3253], [CA3254], or [CA3311].
temperature to SCR)
3. If failure code [CA3255], [CA3256], or [CA3312] is displayed, perform trou-
bleshooting for [CA3255], [CA3256], or [CA3312].
Defective SCR tempera- See “DISASSEMBLY AND ASSEMBLY”, “REMOVE AND INSTALL SCR ASSEM-
3 ture sensor (installation BLY” and fix installation error, if any.
error)
1. Turn starting switch to ON position.
2. If failure code [CA4277] is displayed or failure code [CA4277] is logged on
the abnormality record screen, perform troubleshooting these first.
3. Check the “AdBlue/DEF concentration” on the troubleshooting assistance
Improper AdBlue/DEF screen (normal value: 29 to 36 %).
4
quality
4. If a failure is found by above checks, it may be contaminated. Replace the
AdBlue/DEF in the tank.
5. Replace the AdBlue/DEF injector.
6. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
1. If the failure code persists after the above checks, replace the SCR tem-
Defective SCR tempera- perature sensor.
5 ture sensor (internal de- 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
fect)
If the failure code is cleared, the SCR temperature sensor may be defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is not displayed after this procedure.)
REMARK
If this failure code is displayed during "Loaded Diagnostics Operation To Confirm Failure Correction", return to
troubleshooting.
1. Clear this failure code by “Engine Controller Inducement Fault Clear”.
2. Turn the starting switch to OFF position, and shut down the engine controller.
3. Start the engine.
4. Run the engine at low idle for approximately 1 minute.
5. After finishing the warm-up operation, set the swing lock switch to ON position, working mode to B, and fuel
control dial to MAX position.
6. Run the engine at high idle for 15 minutes.
7. If this failure code is not displayed, repair work is completed.

40-478 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3146]

FAILURE CODE [CA3146] (ALL-K-AF90-410-10-B)

Action level Failure code SCR Outlet Temperature Sensor High Error
Failure
L01 CA3146 (Engine controller system)
Detail of fail- Open circuit , hot short circuit, or sensor circuit error in SCR outlet temperature sensor measuring
ure section or probe (+)
• As the SCR outlet temperature cannot be detected, substitute the SCR temperature for
the SCR outlet temperature and run the engine (if the SCR temperature sensor also has
Action of an error, use the latest normal value).
controller • Advances to Inducement strategy.
• AdBlue/DEF injection stops
Phenomenon • NOx emission increases because AdBlue/DEF injection is disabled.
on machine • Engine power deration according to inducement strategy.
k The SCR assembly, sensor fitting piping, and sensor probe become hot (Min.
400 °C). Be careful not to get burned.
• The SCR temperature sensor and SCR outlet temperature sensor are integrated into one
sensor controller which provides CAN communication with the engine controller.
Related • Open circuit , hot short circuit, or sensor circuit error in SCR outlet temperature sensor
measuring section or probe (+) is sent to the engine controller via CAN communication,
information and this failure code is displayed.
• For the replacement procedure of the SCR outlet temperature sensor, see "Disassembly
and assembly," “Remove and install SCR temperature sensor”.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Replace SCR temperature sensor.
Defective SCR outlet
1 3. Turn starting switch to ON position.
temperature sensor
If this failure code is cleared, the original sensor is defective. (Troubleshooting of
sensor is impossible.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
2
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-479
FAILURE CODE [CA3147] 40 TROUBLESHOOTING

FAILURE CODE [CA3147] (ALL-K-AF90-410-20-B)

Action level Failure code SCR Outlet Temperature Sensor Low Error
Failure
L01 CA3147 (Engine controller system)
Detail of fail- Ground fault or sensor circuit error in SCR outlet temperature sensor measuring section or probe
ure (+)
• As the SCR outlet temperature cannot be detected, substitute the SCR temperature for
the SCR outlet temperature and run the engine (if the SCR temperature sensor also has
Action of an error, use the latest normal value).
controller • Advances to Inducement strategy.
• AdBlue/DEF injection stops.
Phenomenon • NOx emission increases because AdBlue/DEF injection is disabled.
on machine • Engine power deration according to inducement strategy.
k The SCR assembly, sensor fitting piping, and sensor probe become hot (Min.
400 °C). be careful not to get burned.
• The SCR temperature sensor and SCR outlet temperature sensor are integrated into one
sensor controller which provides CAN communication with the engine controller.
Related • Ground fault or sensor circuit error in SCR outlet temperature sensor measuring section or
probe (+) is sent to the engine controller via CAN communication, and this failure code is
information displayed.
• For the replacement procedure of the SCR outlet temperature sensor, see “Disassembly
and assembly”, “Remove and install SCR temperature sensor”.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Replace SCR temperature sensor.
Defective SCR outlet
1 3. Turn starting switch to ON position.
temperature sensor
If this failure code is cleared, the original sensor is defective. (Troubleshooting of
sensor is impossible.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
2
ler an internal defect, troubleshooting cannot be performed.)

40-480 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3148]

FAILURE CODE [CA3148] (ALL-K-AF90-410-50-B)

Action level Failure code SCR outlet temperature sensor in range error
Failure
L01 CA3148 (Engine controller system)
Detail of fail- Temperature difference between SCR temperature sensor and SCR outlet temperature sensor is
ure not the same as the expected value.
Action of • Inducement strategy is activated.
controller • Prohibits AdBlue/DEF injection.
Phenomenon • NOx emission increases because AdBlue/DEF injection is disabled.
on machine • Engine output is reduced based on Inducement strategy.
k KDPF, KDOC, and SCR are heated to 500 °C or higher. Be careful not to get burn in-
jury.
• SCR temperature sensor and SCR outlet temperature sensor are integrated into one sen-
sor, and controller of integrated sensor communicates with the engine controller through
CAN communication.
• For SCR temperature sensor replacement, see DISASSEMBLY AND ASSEMBLY, “RE-
MOVE AND INSTALL SCR TEMPERATURE SENSOR”.
• After turning starting switch to OFF position, engine controller performs AdBlue/DEF purge
(for 6 minutes in maximum) and then stops engine. To restart engine, wait until system op-
erating lamp goes out after turning starting switch to OFF position, and then turn the start-
ing switch to ON position.
• Temperature detected by SCR temperature sensor can be checked with “Pre-defined
Monitoring screen”.
• On Pre-defined Monitoring screen, engine operation state diagnosis, AdBlue/DEF level,
and AdBlue/DEF quality sensor diagnosis are used. (The numbers below denote monitor-
ing codes).
• Pre-defined Monitoring (16/28) Engine operation state
Related 1. 01002 Engine Speed
information 2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
• Pre-defined Monitoring (20/28) AdBlue/DEF level, quality sensor
1. 19100 AdBlue/DEF Concentration
2. 19110 AdBlue/DEF Level
3. 19111 AdBlue/DEF Level Corrected
4. 19115 AdBlue/DEF Temperature in Tank
5. 19400 Ambient Temperature
6. 19305 AdBlue/DEF Tank Heating State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correc-
tion”. After investigating the cause of the problem and completing the repair, perform
“Loaded Diagnostics Operation To Confirm Failure Correction” to make sure the failure
code is cleared. (Even if this failure code is not displayed with starting switch in ON po-
sition, completion of repair cannot be determined unless exhaust temperature becomes
high.)

No. Cause Procedure, measuring location, criteria and remarks

Defective SCR outlet If failure code [CA3146] or [CA3147] is displayed, perform troubleshooting for
1
temperature sensor [CA3146] or [CA3147].

HB365LC-3 40-481
FAILURE CODE [CA3148] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. If failure code [CA3251] is displayed, perform troubleshooting for
[CA3251].
Defective KDPF system
2. If failure code [CA3253], [CA3254], or [CA3311] is displayed, perform trou-
2 (Abnormal exhaust gas bleshooting for [CA3253], [CA3254], or [CA3311].
temperature to SCR)
3. If failure code [CA3255], [CA3256], or [CA3312] is displayed, perform trou-
bleshooting for [CA3255], [CA3256], or [CA3312].
Defective SCR tempera- See “Disassembly and assembly”, “Removal and installation of SCR temperature
3 ture sensor (installation sensor” and fix installation error, if any.
error or malfunction)
1. Turn starting switch to ON position.
2. If failure code [CA4277] is displayed or failure code [CA4277] is logged on
the abnormality record screen, perform troubleshooting these first.
3. Confirm the “AdBlue/DEF concentration” on the Pre-defined Monitoring
Improper AdBlue/DEF screen (normal value: 29 to 36 %).
4
quality
4. If failure code is still displayed after above checks, it may be contaminated.
Replace the AdBlue/DEF in the tank.
5. Replace the AdBlue/DEF injector.
6. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
1. If the failure code persists after the above checks, replace the SCR tem-
Defective SCR outlet perature sensor.
5 temperature sensor (in- 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
ternal defect)
If the failure code is cleared, the SCR temperature sensor may be defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is not displayed after this procedure.)
REMARK
If this failure code is displayed during "Loaded Diagnostics Operation To Confirm Failure Correction", return to
troubleshooting.
1. Clear this failure code by “Engine Controller Inducement Fault Clear”.
2. Turn the starting switch to OFF position, and shut down the engine controller.
3. Start the engine.
4. Run the engine at low idle for approximately 1 minute.
5. After finishing the warm-up operation, set the swing lock switch to ON position, working mode to B, and fuel
control dial to MAX position.
6. Run the engine at high idle for 15 minutes.
7. If this failure code is not displayed, repair work is completed.

40-482 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3151]

FAILURE CODE [CA3151] (ALL-K-AF00-410-00-B)

Action level Failure code SCR Catalyst Efficiency Low Error 2

Failure
L01 CA3151 (Engine controller system)
Detail of fail-
The SCR catalyst efficiency remains low (20 % or less).
ure
Action of • Stops AdBlue/DEF injection.
controller • Inducement strategy is activated.
Phenomenon • NOx emission increases because AdBlue/DEF injection is disabled.
on machine • Engine output is reduced based on Inducement strategy.
k The turbo outlet part, KDPF, sensor fitting piping, and sensor probe are heated to
500 °C or higher. Be careful not to get burn injury.
k AdBlue/DEF mixing piping, SCR assembly, sensor installation piping, and sensor
probe are heated to 400 °C or higher. Be careful not to get burn injury.
k As for the sensor probe, be careful not to get burn injury even if the surroundings
are not hot, because sensor itself is heated.
k When removing AdBlue/DEF mixing piping or AdBlue/DEF injector, AdBlue/DEF may
leak, so be careful.
• Due to shutdown of engine controller, the engine controller deactivates to stop
AdBlue/DEF injection once. However if another error is detected, the injection stops again.
• This failure code [CA3151] is displayed after the engine controller performs “Active Regen-
eration to clean urea deposit (for approximately 1 hour)” when the failure code [CA3582] is
Related displayed.
information • Make sure that failure code [CA3582] is not displayed when confirming the completion of
repair.
• When the ambient pressure is 80 kPa or less and the ambient temperature is -7 °C or less,
the engine controller does not troubleshoot this failure code. (Failure code is not cleared
even after performing machine operation for clearing the failure code.) Confirm on Pre-de-
fined Monitoring screen.
• Under following condition, failure code is not cleared even after performing machine oper-
ation for clearing the failure code.
1. Active regeneration in progress
2. AdBlue/DEF injection being stopped by other failure code
3. Engine controller has not been shut down normally after this failure code is displayed.
• For the procedure to remove and replace AdBlue/DEF injector, see DISASSEMBLY AND
ASSEMBLY, “REMOVE AND INSTALL AdBlue/DEF INJECTOR”.

HB365LC-3 40-483
FAILURE CODE [CA3151] 40 TROUBLESHOOTING

• On Pre-defined Monitoring screen, following 4 diagnoses are displayed. Engine operation

state diagnosis, environment state diagnosis, SCR catalyst, NOx sensor, ammonia sensor
diagnosis, AdBlue/DEF level, AdBlue/DEF quality sensor diagnosis (The numbers below
denote displayed monitoring codes.)
• Pre-defined Monitoring (16/28) Engine operation state
1. 01002 Engine Speed
2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
• Pre-defined Monitoring (24/28) Environment state
1. 37400 Ambient Pressure
2. 19400 Ambient Temperature
3. 18400 Intake Temperature
4. 19133 Engine Room Temperature
5. 19115 AdBlue/DEF Temperature in Tank
• Pre-defined Monitoring (19/28) SCR catalyst/NOX sensor/NH3 sensor
Related 1. 19120 AdBlue/DEF Injection Quantity
information 2. 19205 SCR NH3 Concentration Corrected
3. 19202 Turbo Outlet NOx Corrected
4. 19209 SCR Outlet NOx Corrected
5. 19203 Turbo Outlet NOx Sensor State
6. 19210 SCR Outlet NOx Sensor State
• Pre-defined Monitoring (20/28) AdBlue/DEF level, quality sensor
1. 19100 AdBlue/DEF Concentration
2. 19110 AdBlue/DEF Level
3. 19111 AdBlue/DEF Level Corrected
4. 19115 AdBlue/DEF Temperature in Tank
5. 19400 Ambient Temperature
6. 19305 AdBlue/DEF Tank Heating State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correc-
tion”. After investigating the cause of the problem and completing the repair, perform
“Loaded Diagnostics Operation To Confirm Failure Correction” to make sure the failure
code is cleared. (Even if this failure code is not displayed with starting switch in ON po-
sition, completion of repair cannot be determined unless exhaust temperature becomes
high.)

No. Cause Procedure, measuring location, criteria and remarks

Defective turbocharger If failure code [CA1885], [CA3232], [CA3649], [CA3682], [CA3718], [CA3725], or
outlet NOx sensor sys- [CA3748] is displayed, perform troubleshooting for these failure codes failure codes
tem first.
1
(Open circuit, internal de-
fect, defective sensor
heater)
Defective SCR outlet If failure code [CA1887], [CA2771], [CA3545], [CA3583], [CA3681], or [CA3717] is
NOx sensor system displayed, perform troubleshooting for these failure codes first.
2 (Open circuit, internal de-
fect, defective sensor
heater)

40-484 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3151]

No. Cause Procedure, measuring location, criteria and remarks

Defective SCR tempera- If failure code [CA3142] or [CA3143] or [CA3144] or [CA3146] or [CA3147] or
ture sensor system [CA3148] or [CA3165] or [CA3229] or [CA3231] or [CA3235] or [CA4152] or
3
(Open circuit, Internal de- [CA4159] or [CA4164] or [CA4165] or [CA4166] is displayed, perform troubleshoot-
fect) ing for these failure codes first.

Defective ammonia sen- If failure code [CA3899], [CA3911], [CA3912], [CA3932], [CA3933], [CA3934],
sor system [CA3935], [CA3936] or [CA4281] is displayed, perform troubleshooting for these
4 (Open circuit, internal de- failure codes first.
fect, defective sensor
heater)
1. If failure code [CA4658] or [CA3568] is displayed, or failure code [CA4658] or
[CA3568] is displayed on the service meter display of the abnormality record
within 2 hours, perform “Loaded Diagnostics Operation To Confirm Failure
Correction”, check if failure code [CA3151], [CA3543], or [CA3582] is dis-
played.
Clogged AdBlue/DEF in-
5 2. If 19205 “Ammonia concentration (compensation value)” indicates a normal
jector
value (5 to 100 ppm) and the failure code is cleared, the repair is completed
(“Loaded Diagnostics Operation To Confirm Failure Correction” has resolved
the clogging problem and the machine has restored normal operation).
3. If the ammonia concentration indicates an abnormal value or either failure
code [CA3151], [CA3543], or [CA3582] is displayed, proceed to the next step.
1. Visually check the piping from the KDPF outlet to the SCR outlet for damage
or defective connection.
Defective mixing tube
6 2. Visually check for white crystallized AdBlue/DEF deposits on the surrounding
(exhaust gas leakage) area.
3. If defective connections or damages are found, fix or replace parts.
If crystallized AdBlue/DEF is adhered to the surrounding of hose, tank, pump, or
engine compartment, it shows AdBlue/DEF may be leaking. Refer to “TESTING
Damaged AdBlue/DEF AND ADJUSTING”, “SETTING AND OPERATION OF MACHINE MONITOR”,
7 hose, AdBlue/DEF leak- “METHOD FOR SETTING WITH TESTING MENU (SCR SERVICE TEST)” to per-
age at connection form AdBlue/DEF Pump Pressure Up Test and find the location of the AdBlue/DEF
leak.
Replace parts as necessary.
1. Check the mounting of the AdBlue/DEF quality sensor is secured and the
wiring harness connections are not loosen Repair if any abnormality is
found.
2. Turn starting switch to ON position.
3. Check if failure code [CA3866] or [CA3867] is displayed.
4. Read 19100 “AdBlue/DEF concentration” on the display and confirm that
the concentration is appropriate (29 to 36 %).
5. If failure code [CA3866] or [CA3867] is displayed and the 19100
Improper AdBlue/DEF
8 “AdBlue/DEF concentration” reading is inappropriate, drain the
quality
AdBlue /DEF tank, clean the tank, and refill with genuine AdBlue/DEF.
6. Perform “Loaded Diagnostics Operation To Confirm Failure Correction” to
check if this failure code is not cleared.
7. If the 19205 “Ammonia concentration (compensation value)” reading is
normal (5 to 100 ppm) and the failure code is not redisplayed, the repair is
completed.
8. If the ammonia concentration indicates an abnormal value or this failure
code recurs, proceed to the next step.

HB365LC-3 40-485
FAILURE CODE [CA3151] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. See “TESTING AND ADJUSTING”, “SERVICE MODE” and “METHOD FOR
SETTING WITH TESTING MENU (SCR SERVICE TEST)” of “SETTING AND
OPERATION OF MACHINE MONITOR”, and perform an “SCR Denitration Ef-
ficiency Test”.
2. If the “SCR Denitration Efficiency Test” has not been completed successfully,
proceed to cause 10.
3. If failure code [CA1694], [CA3751], or [CA3755] is displayed after the “SCR
Defective urea SCR sys- Denitration Efficiency Test”, perform troubleshooting for relevant failure code
tem first.
9 (inspection with SCR RE- 4. After the failure code in the above 3 is cleared, perform “Loaded Diagnostics
MOVAL EFFICIENCY Operation To Clear Failure Code” to check if this failure code is not cleared.
TEST)
5. If 19205 “Ammonia concentration (compensation value)” indicates a normal
value (5 to 100 ppm) and the failure code is cleared, the repair is completed.
6. If the ammonia concentration indicates an abnormal value or this failure code
is not cleared, proceed to cause 13.
7. Even if the SCR REMOVAL EFFICIENCY TEST has been completed success-
fully and any of failure code [CA1694], [CA3751], or [CA3755] is not displayed,
proceed to cause 13.
1. Refer to “TESTING AND ADJUSTING”, “SETTING AND OPERATION OF MA-
CHINE MONITOR”, “SERVICE MODE”, “METHOD FOR SETTING WITH
TESTING MENU (SCR SERVICE TEST)” to perform an “AdBlue/DEF Injection
Quantity Test” to judge the injector.
2. From the test results, confirm that the AdBlue/DEF injection amount is within
the values specified in “TESTING AND ADJUSTING”.
3. If the AdBlue/DEF injection amount is out of the range specified in “TESTING
Defective AdBlue/DEF in-
10 AND ADJUSTING”, replace the AdBlue/DEF injector.
jector
4. If the AdBlue/DEF injector has been replaced, perform the “AdBlue/DEF Injec-
tion Quantity Test” again. After confirming that the AdBlue/DEF injection
amount is within the range specified in “TESTING AND ADJUSTING”, proceed
to the next cause. (The purpose of this test for two times is to check accumu-
lated urea deposits in the AdBlue/DEF mixing tube )
5. Proceed to the next troubleshooting, even if the “AdBlue/DEF Injection Quanti-
ty Test” results were normal.
1. Check if urea deposits are accumulated in the AdBlue/DEF mixing tube and
the AdBlue/DEF injector mount.
Accumulation of urea de- 2.
If deposits are accumulated, remove the AdBlue/DEF mixing tube to remove
11 posits in AdBlue/DEF
deposits and clean the tube.
mixing tube
3. Check if urea deposits are accumulated in the SCR inlet case. If accumulated,
perform the next item.
1. If urea deposit is accumulated inside the SCR inlet case, remove the urea
Accumulated urea de- deposit as much as possible.
12
posit in SCR assembly
2. Repair AdBlue/DEF mixing tube back to normal.

40-486 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3151]

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks, the intake system may be defec-
tive.
(Offset/drift due to the deteriorated and aged MAF sensor, distorted intake system,
damaged rectifier)
1. Check for a defective air intake pipe and repair or replace any damaged or
Defective air intake sys- defective rectifier, if any.
13
tem 2. Replace mass air flow (MAF) sensor.
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction” to
check if this failure code is not cleared.
4. If 19205 “ammonia concentration (compensation value)” shows an normal
value (5 to 100ppm) and the failure code is cleared again, the repair has
been completed
If failure code is still displayed after above checks, the ammonia sensor may be de-
fective.
(Offset/drift due to the deteriorated and aged ammonia sensor)
1. Replace the ammonia sensor.
2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”,
Defective ammonia sen-
14 then check if this failure code or failure code [CA3582] is displayed.
sor
3. If 19205 “Ammonia concentration (compensation value)” indicates a nor-
mal value (5 to 100 ppm) and the failure code is cleared, the repair is com-
pleted.
4. If the ammonia concentration indicates an abnormal value or this failure
code is not cleared, proceed to the next step.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
15
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

Perform the following procedure to check that the repair is completed.
(Make sure this failure code and failure code [CA3582] are not displayed.)
1. Clear this failure code by “Engine Controller Inducement Fault Clear”.
2. Turn the starting switch to OFF position, and shut down the engine controller.
3. Turn the starting switch to ON position.
4. Start the engine.
5. Run the engine at low idle with no load for approximately 1 minute.
6. After finishing the warm-up operation, set the swing lock switch to ON position, working mode to B, and fuel
control dial to MAX position.
7. Perform arm IN relief operation for approximately 30 seconds.
REMARK
Take care not to overheat the hydraulic oil.
8. Run the engine at high idle with no load for 30 seconds.
9. Repeat above steps 6 and 7 up to 20 times.
10. If this failure code and failure code [CA3582] are not displayed, repair work is completed.
If this failure code or failure code [CA3582] is displayed:
1. Display the SCR temperature and ammonia concentration on the troubleshooting screen.
2. Perform operation so that the SCR temperature is kept 250 °C or higher.

HB365LC-3 40-487
FAILURE CODE [CA3151] 40 TROUBLESHOOTING

3. A normal value of ammonia concentration ranges from 5 to 100 (ppm). If 0 (ppm) is shown consistently or
100 (ppm) or more is shown, return to troubleshooting because the repair is not completed.
Checklist
Relieve the Arm IN Run the engine at high idle (with no load)
Operation
for 30 seconds for 30 seconds
SCR Temperature
Monitoring screen
ID: 19300
Value to be checked Around 250 °C
1st time
2nd time
3rd time
4th time
5th time
6th time
7th time
8th time
9th time
10th time
11th time
12th time
13th time
14th time
15th time
16th time
17th time
18th time
19th time
20th time

40-488 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3165]

FAILURE CODE [CA3165] (ALL-K-AF90-410-30-B)

Action level Failure code SCR outlet temperature high error

Failure
L03 CA3165 (Engine controller system)
Detail of fail-
SCR outlet temperature remains at high level.
ure
Action of • Inducement strategy is activated.
controller • Prohibits AdBlue/DEF injection.
Phenomenon • NOx emission increases because AdBlue/DEF injection is disabled.
on machine • Engine output is reduced based on Inducement strategy.
k KDPF, KDOC, and SCR are heated to 500 °C or higher. Be careful not to get burn in-
jury.
• SCR temperature sensor and SCR outlet temperature sensor are integrated into one sen-
sor, and controller of integrated sensor communicates with the engine controller through
CAN communication.
• For SCR temperature sensor replacement, see DISASSEMBLY AND ASSEMBLY, “RE-
MOVE AND INSTALL SCR TEMPERATURE SENSOR”.
• After turning starting switch to OFF position, engine controller performs AdBlue/DEF purge
(for 6 minutes in maximum) and then stops engine. To restart engine, wait until system op-
erating lamp goes out after turning starting switch to OFF position, and then turn the start-
ing switch to ON position.
• Temperature detected by SCR outlet temperature sensor can be checked with “Pre-de-
fined Monitoring” screen.
• On Pre-defined Monitoring screen, engine operation state diagnosis, AdBlue/DEF level,
and AdBlue/DEF quality sensor diagnosis are used. (The numbers below denote monitor-
ing codes).
• If regeneration is not performed, failure code [CA3235] may also be displayed.
Related • Pre-defined Monitoring (16/28) Engine operation state
1. 01002 Engine Speed
information
2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
• Pre-defined Monitoring (20/28) AdBlue/DEF level, quality sensor
1. 19100 AdBlue/DEF Concentration
2. 19110 AdBlue/DEF Level
3. 19111 AdBlue/DEF Level Corrected
4. 19115 AdBlue/DEF Temperature in Tank
5. 19400 Ambient Temperature
6. 19305 AdBlue/DEF Tank Heating State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correc-
tion”. After investigating the cause of the problem and completing the repair, perform
“Loaded Diagnostics Operation To Confirm Failure Correction” to make sure the failure
code is cleared. (Even if this failure code is not displayed with starting switch in ON po-
sition, completion of repair cannot be determined unless exhaust temperature becomes
high.)

HB365LC-3 40-489
FAILURE CODE [CA3165] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Defective SCR outlet If failure code [CA3146] or [CA3147] is displayed, perform troubleshooting for
1
temperature sensor [CA3146] or [CA3147].
1. If failure code [CA3251] is displayed, perform troubleshooting for
[CA3251].
Defective KDPF system
2. If failure code [CA3253], [CA3254], or [CA3311] is displayed, perform trou-
2 (Abnormal exhaust gas bleshooting for [CA3253], [CA3254], or [CA3311].
temperature to SCR)
3. If failure code [CA3255], [CA3256], or [CA3312] is displayed, perform trou-
bleshooting for [CA3255], [CA3256], or [CA3312].
Defective SCR tempera- See “Disassembly and assembly”, “Removal and installation of SCR temperature
3 ture sensor (installation sensor” and fix installation error, if any.
error or malfunction)
1. Turn starting switch to ON position.
2. If failure code [CA4277] is displayed or failure code [CA4277] is logged on
the abnormality record screen, perform troubleshooting these first.
3. Confirm the “AdBlue/DEF concentration” on the Pre-defined Monitoring
Improper AdBlue/DEF screen (normal value: 29 to 36 %).
4
quality
4. If failure code is still displayed after above checks, it may be contaminated.
Replace the AdBlue/DEF in the tank.
5. Replace the AdBlue/DEF injector.
6. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
1. If the failure code persists after the above checks, replace the SCR tem-
Defective SCR outlet perature sensor.
5 temperature sensor (in- 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
ternal defect)
If the failure code is cleared, the SCR temperature sensor may be defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is not displayed after this procedure.)
REMARK
If this failure code is displayed during "Loaded Diagnostics Operation To Confirm Failure Correction", return to
troubleshooting.
Check if the repair has been completed with the following procedure.
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and check the failure code is cleared. If this failure code persists,
return to troubleshooting.
3. Start the engine.
4. Set the working mode to B.
5. Run the engine at low idle for 10 minutes.
6. Run the engine at high idle for 10 minutes.
7. If this failure code is not displayed, repair work is completed.

40-490 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3229]

FAILURE CODE [CA3229] (ALL-K-AFP0-410-30-B)

Action level Failure code SCR temperature high error

Failure
L03 CA3229 (Engine controller system)
Detail of fail-
SCR temperature remains at high level (800 °C or higher).
ure
Action of • Inducement strategy is activated.
controller • Prohibits AdBlue/DEF injection.
Phenomenon • NOx emission increases because AdBlue/DEF injection is disabled.
on machine • Engine output is reduced based on Inducement strategy.
k KDPF, KDOC, and SCR are heated to 500 °C or higher. Be careful not to get burn in-
jury.
• SCR temperature sensor and SCR outlet temperature sensor are integrated into one sen-
sor, and controller of integrated sensor communicates with the engine controller through
CAN communication.
• For SCR temperature sensor replacement, see DISASSEMBLY AND ASSEMBLY, “RE-
MOVE AND INSTALL SCR TEMPERATURE SENSOR”.
• After turning starting switch to OFF position, engine controller performs AdBlue/DEF purge
(for 6 minutes in maximum) and then stops engine. To restart engine, wait until system op-
erating lamp goes out after turning starting switch to OFF position, and then turn the start-
ing switch to ON position.
• If regeneration is not performed, failure code [CA3231] may also be displayed.
• Temperature detected by SCR temperature sensor can be checked with “Pre-defined
Monitoring screen”.
• On Pre-defined Monitoring screen, engine operation state diagnosis, AdBlue/DEF level,
and AdBlue/DEF quality sensor diagnosis are used. (The numbers below denote monitor-
ing codes).
Related • Pre-defined Monitoring (16/28) Engine operation state
information 1. 01002 Engine Speed
2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
• Pre-defined Monitoring (20/28) AdBlue/DEF level, quality sensor
1. 19100 AdBlue/DEF Concentration
2. 19110 AdBlue/DEF Level
3. 19111 AdBlue/DEF Level Corrected
4. 19115 AdBlue/DEF Temperature in Tank
5. 19400 Ambient Temperature
6. 19305 AdBlue/DEF Tank Heating State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correction”.
After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to make sure the failure code is cleared.
(Even if this failure code is not displayed with starting switch in ON position, completion of
repair cannot be determined unless exhaust temperature becomes high.)

HB365LC-3 40-491
FAILURE CODE [CA3229] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Defective SCR tempera- If failure code [CA3142] or [CA3143] is displayed, perform troubleshooting for
ture sensor (internal [CA3142] or [CA3143].
1
open or short circuit to
ground)
1. If failure code [CA3251] is displayed, perform troubleshooting for
[CA3251].
Defective KDPF system
2. If failure code [CA3253], [CA3254], or [CA3311] is displayed, perform trou-
2 (Abnormal exhaust gas bleshooting for [CA3253], [CA3254], or [CA3311].
temperature to SCR)
3. If failure code [CA3255], [CA3256], or [CA3312] is displayed, perform trou-
bleshooting for [CA3255], [CA3256], or [CA3312].
Defective SCR tempera- See “DISASSEMBLY AND ASSEMBLY”, “REMOVE AND INSTALL SCR ASSEM-
3 ture sensor (installation BLY” and fix installation error, if any.
error)
1. Turn starting switch to ON position.
2. If failure code [CA4277] is displayed or failure code [CA4277] is logged on
the abnormality record screen, perform troubleshooting these first.
3. Check the “AdBlue/DEF concentration” on the troubleshooting assistance
Improper AdBlue/DEF screen (normal value: 29 to 36 %).
4
quality
4. If a failure is found by above checks, it may be contaminated. Replace the
AdBlue/DEF in the tank.
5. Replace the AdBlue/DEF injector.
6. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
1. If the failure code persists after the above checks, replace the SCR tem-
Defective SCR tempera- perature sensor.
5 ture sensor (internal de- 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
fect)
If the failure code is cleared, the SCR temperature sensor may be defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

REMARK
If this failure code is displayed during "Loaded Diagnostics Operation To Confirm Failure Correction", return to
troubleshooting.
Check if the repair has been completed with the following procedure.
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and check the failure code is cleared. If this failure code persists,
return to troubleshooting.
3. Start the engine.
4. Set the working mode to B.
5. Run the engine at low idle for 10 minutes.
6. Run the engine at high idle for 10 minutes.
7. If the failure code does not displayed again at this stage, repair work is completed.

40-492 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3231]

FAILURE CODE [CA3231] (ALL-K-AFP0-410-80-B)

Action level Failure code SCR temperature high error - Non regeneration
Failure
L03 CA3231 (Engine controller system)
Detail of fail- SCR temperature remains at high level (800 °C or higher) when active regeneration is not per-
ure formed.
Action of • Inducement strategy is activated.
controller • Prohibits AdBlue/DEF injection.
Phenomenon • NOx emission increases because AdBlue/DEF injection is disabled.
on machine • Engine output is reduced based on Inducement strategy.
k KDPF, KDOC, and SCR are heated to 500 °C or higher. Be careful not to get burn injury.
• SCR temperature sensor and SCR outlet temperature sensor are integrated into one sen-
sor, and controller of integrated sensor communicates with the engine controller through
CAN communication.
• For SCR temperature sensor replacement, see DISASSEMBLY AND ASSEMBLY, “RE-
MOVE AND INSTALL SCR TEMPERATURE SENSOR”.
• After turning starting switch to OFF position, engine controller performs AdBlue/DEF purge
(for 6 minutes in maximum) and then stops engine. To restart engine, wait until system op-
erating lamp goes out after turning starting switch to OFF position, and then turn the start-
ing switch to ON position.
• Temperature detected by SCR temperature sensor can be checked with “Pre-defined
Monitoring screen”.
• On Pre-defined Monitoring screen, engine operation state diagnosis, AdBlue/DEF level,
and AdBlue/DEF quality sensor diagnosis are used. (The numbers below denote monitor-
ing codes).
• Pre-defined Monitoring (16/28) Engine operation state
Related 1. 01002 Engine Speed
information 2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
• Pre-defined Monitoring (20/28) AdBlue/DEF level, quality sensor
1. 19100 AdBlue/DEF Concentration
2. 19110 AdBlue/DEF Level
3. 19111 AdBlue/DEF Level Corrected
4. 19115 AdBlue/DEF Temperature in Tank
5. 19400 Ambient Temperature
6. 19305 AdBlue/DEF Tank Heating State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correction”.
After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to make sure the failure code is cleared.
(Even if this failure code is not displayed with starting switch in ON position, completion of
repair cannot be determined unless exhaust temperature becomes high.)

No. Cause Procedure, measuring location, criteria and remarks

Defective SCR tempera- If failure code [CA3142] or [CA3143] is displayed, perform troubleshooting for
ture sensor (internal [CA3142] or [CA3143].
1
open or short circuit to
ground)

HB365LC-3 40-493
FAILURE CODE [CA3231] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. If failure code [CA3251] is displayed, perform troubleshooting for
[CA3251].
Defective KDPF system
2. If failure code [CA3253], [CA3254], or [CA3311] is displayed, perform trou-
2 (Abnormal exhaust gas bleshooting for [CA3253], [CA3254], or [CA3311].
temperature to SCR)
3. If failure code [CA3255], [CA3256], or [CA3312] is displayed, perform trou-
bleshooting for [CA3255], [CA3256], or [CA3312].
Defective SCR tempera- See “DISASSEMBLY AND ASSEMBLY”, “REMOVE AND INSTALL SCR ASSEM-
3 ture sensor (installation BLY” and fix installation error, if any.
error)
1. Turn starting switch to ON position.
2. If failure code [CA4277] is displayed or failure code [CA4277] is logged on
the abnormality record screen, perform troubleshooting these first.
3. Check the “AdBlue/DEF concentration” on the troubleshooting assistance
Improper AdBlue/DEF screen (normal value: 29 to 36 %).
4
quality
4. If a failure is found by above checks, it may be contaminated. Replace the
AdBlue/DEF in the tank.
5. Replace the AdBlue/DEF injector.
6. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
1. If the failure code persists after the above checks, replace the SCR tem-
Defective SCR tempera- perature sensor.
5 ture sensor (internal de- 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
fect)
If the failure code is cleared, the SCR temperature sensor may be defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

REMARK
If this failure code is displayed during "Loaded Diagnostics Operation To Confirm Failure Correction", return to
troubleshooting.
Check if the repair has been completed with the following procedure.
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and check the failure code is cleared. If this failure code persists,
return to troubleshooting.
3. Start the engine.
4. Set the working mode to B.
5. Run the engine at low idle for 10 minutes.
6. Run the engine at high idle for 10 minutes.
7. If the failure code does not displayed again at this stage, repair work is completed.

40-494 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3232]

FAILURE CODE [CA3232] (ALL-K-AFM0-410-00-B)

Action level Failure code Turbocharger Outlet NOx Sensor Datalink Timeout Error
Failure
L01 CA3232 (Engine controller system)
Detail of fail- The engine controller cannot receive the data of the turbocharger outlet NOx sensor due to error of
ure communication with the turbocharger outlet NOx sensor.
Action of • Operate using the NOx value in the memory.
controller • Advances to Inducement strategy.
• The AdBlue/DEF injection becomes inappropriate, NOx emission increases.
Phenomenon
• Engine power deration according to inducement strategy.
on machine
• Turbocharger Outlet NOx Concentration undetectable
k The turbocharger outlet, sensor fitting piping, KDPF, and KDOC become hot (Min.
500 °C). Be careful not to get burned.
k The SCR assembly, sensor fitting piping, and sensor probe become hot (Min.
400 °C). Be careful not to get burned.
k Be careful not to get burned by the sensor probe as it is heated by itself even if the
ambient temperature is not high.
• The turbocharger outlet NOx sensor is a smart sensor which performs CAN communica-
tion with the engine controller together with the other sensors.
Related • If the sensor connector or smart sensor (power supply) relay connector is disconnected,
this failure code is displayed.
information
• The failure codes of the CAN communication related to the engine sensor are [CA2771],
[CA3232], [CA3868], [CA3911], [CA4151], and [CA4152]. If all of these failure codes are
displayed, the cause may be defect of any of the 6 sensors, defective smart sensor power
supply relay, defective relay system, or ground fault, short circuit, or hot short circuit of the
harness (CAN communication line).
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective wiring harness Perform checks on causes 1 to 10 for failure code [CA2771].
1
connector
• Communication line
As CAN terminating resistors of 120 Ω are connected in parallel, therefore, when
circuit resistance is measured at connector of CAN communication, if combined re-
sistance is 60 Ω, there is no open circuit.
1. Turn starting switch to OFF position.
Open circuit and short 2. Check that system operating lamp does not light up, and then turn battery
circuit in wiring harness disconnect switch to OFF position.
2
(broken or short-circuited
3. Disconnect connectors ECM J2 and E31 and connect T-adapters to each
communication line)
female side.
Approxi-
Between E31 (female) (3) and (2)
mately 60 Ω
Resistance
Approxi-
Between ECM J2 (female) (21) and (45)
mately 60 Ω

HB365LC-3 40-495
FAILURE CODE [CA3232] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by above results, this check is not required.
Open circuit in wiring har- 1. Turn starting switch to OFF position.
ness (wire breakage or 2. Disconnect connectors R52 and E31 and connect T-adapters to each fe-
3 defective contact of con- male side.
nector) (broken power
line) Between R52 (female) (6) and E31 (female) (1) Max. 10 Ω
Resistance
Between E31 (female) (4) and ground Max. 10 Ω
• Communication line
If failure code is still displayed after above checks on cause 2, this check is not re-
quired.
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
Open circuit in wiring har- 3.
Disconnect connectors ECM J2, E26, K10, andK11 and connect T-adapt-
ness (wire breakage or
ers to each female side.
4 defective contact of con-
nector) (broken commu- Between ECM J2 (female) (21) and E26 (female) (3) Max. 10 Ω
nication line)
Between ECM J2 (female) (45) and E26 (female) (2) Max. 10 Ω
Between K10 (female) (A) and E26 (female) (3) Max. 10 Ω
Resistance
Between K10 (female) (B) and E26 (female) (2) Max. 10 Ω
Between K11 (female) (A) and E26 (female) (3) Max. 10 Ω
Between K11 (female) (B) and E26 (female) (2) Max. 10 Ω
f failure code (no open circuit) is still displayed after above checks in cause 2,
measure resistance at any one place in Hi line and Lo line.
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
3. Disconnect all related connectors, and connect T-adapter to the female
Ground fault in wiring side of the connector to be measured.
5 harness (contact with
Between one of ECM J2(female)(21),K10(female)
ground circuit)
(A),K11(female)(A),E31(female)(3),E32(female)
Min.100 kΩ
(2),E26(female)(3),E34(female)(3),E36(female)
(3),P63(female)(2) and ground
Resistance
Between one of ECM J2(female)(45), K10(female)(B),
K11(female)(B), E31(female)(2), E32(female)(3),
Min.100 kΩ
E26(female)(2), E34(female)(2), E36(female)(2),
P63(female)(1) and ground
f failure code (no open circuit) is still displayed after above checks in cause 11,
measure resistance at any one place in Hi line and Lo line.
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
3. Insert T-adapter into one of the related connectors.
Hot short circuit in wiring
6 4. Set battery disconnect switch to ON position.
harness
5. Turn starting switch to ON position.
Between one of ECM J2(21), K10(A), K11(A), E31(3),
1 to 4 V
E32(2), E26(3), E34(3), E36(3), or P63(2) and ground
Voltage
Between one of ECM J2(45), K10(B), K11(B), E31(2),
1 to 4 V
E32(3), E26(2), E34(2), E36(2), or P63(1) and ground

40-496 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3232]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Replace the turbocharger outlet NOx sensor (E31).
Defective turbocharger
7 3. Turn starting switch to ON position.
outlet NOx sensor
If this failure code is cleared, the original sensor is defective. (In case of an internal
defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
8
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-497
FAILURE CODE [CA3232] 40 TROUBLESHOOTING

Circuit diagram related to SCR system CAN communication

40-498 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3235]

FAILURE CODE [CA3235] (ALL-K-AF90-410-40-B)

Action level Failure code SCR outlet temperature high error - Non regeneration
Failure
L03 CA3235 (Engine controller system)
Detail of fail-
SCR outlet temperature remains at high level when active regeneration is not performed.
ure
Action of • Inducement strategy is activated.
controller • Prohibits AdBlue/DEF injection.
Phenomenon • NOx emission increases because AdBlue/DEF injection is disabled.
on machine • Engine output is reduced based on Inducement strategy.
k KDPF, KDOC, and SCR are heated to 500 °C or higher. Be careful not to get burn injury.
• SCR temperature sensor and SCR outlet temperature sensor are integrated into one sen-
sor, and controller of integrated sensor communicates with the engine controller through
CAN communication.
• For SCR temperature sensor replacement, see DISASSEMBLY AND ASSEMBLY, “RE-
MOVE AND INSTALL SCR TEMPERATURE SENSOR”.
• After turning starting switch to OFF position, engine controller performs AdBlue/DEF purge
(for 6 minutes in maximum) and then stops engine. To restart engine, wait until system op-
erating lamp goes out after turning starting switch to OFF position, and then turn the start-
ing switch to ON position.
• On “Pre-defined Monitoring” screen, engine operation state diagnosis, SCR catalyst, NOx
sensor, and ammonia sensor diagnosis are used. (The numbers below denote monitoring
codes).
• Temperature detected by SCR outlet temperature sensor can be checked with “Pre-de-
fined Monitoring” screen.
• Pre-defined Monitoring (16/28) Engine operation state
Related 1. 01002 Engine Speed
information 2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
• Pre-defined Monitoring (20/28) AdBlue/DEF level, quality sensor
1. 19100 AdBlue/DEF Concentration
2. 19110 AdBlue/DEF Level
3. 19111 AdBlue/DEF Level Corrected
4. 19115 AdBlue/DEF Temperature in Tank
5. 19400 Ambient Temperature
6. 19305 AdBlue/DEF Tank Heating State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correction”.
After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to make sure the failure code is cleared.
(Even if this failure code is not displayed with starting switch in ON position, completion of
repair cannot be determined unless exhaust temperature becomes high.)

No. Cause Procedure, measuring location, criteria and remarks

Defective SCR outlet If failure code [CA3146] or [CA3147] is displayed, perform troubleshooting for
1
temperature sensor [CA3146] or [CA3147].

HB365LC-3 40-499
FAILURE CODE [CA3235] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. If failure code [CA3251] is displayed, perform troubleshooting for
[CA3251].
Defective KDPF system
2. If failure code [CA3253], [CA3254], or [CA3311] is displayed, perform trou-
2 (Abnormal exhaust gas bleshooting for [CA3253], [CA3254], or [CA3311].
temperature to SCR)
3. If failure code [CA3255], [CA3256], or [CA3312] is displayed, perform trou-
bleshooting for [CA3255], [CA3256], or [CA3312].
Defective SCR tempera- See “Disassembly and assembly”, “Removal and installation of SCR temperature
3 ture sensor (installation sensor” and fix installation error, if any.
error or malfunction)
1. Turn starting switch to ON position.
2. If failure code [CA4277] is displayed or failure code [CA4277] is logged on
the abnormality record screen, perform troubleshooting these first.
3. Confirm the “AdBlue/DEF concentration” on the Pre-defined Monitoring
Improper AdBlue/DEF screen (normal value: 29 to 36 %).
4
quality
4. If failure code is still displayed after above checks, it may be contaminated.
Replace the AdBlue/DEF in the tank.
5. Replace the AdBlue/DEF injector.
6. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
1. If the failure code persists after the above checks, replace the SCR tem-
Defective SCR outlet perature sensor.
5 temperature sensor (in- 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
ternal defect)
If the failure code is cleared, the SCR temperature sensor may be defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is not displayed after this procedure.)
REMARK
If this failure code is displayed during "Loaded Diagnostics Operation To Confirm Failure Correction", return to
troubleshooting.
Check if the repair has been completed with the following procedure.
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and check the failure code is cleared. If this failure code persists,
return to troubleshooting.
3. Start the engine.
4. Set the working mode to B.
5. Run the engine at low idle for 10 minutes.
6. Run the engine at high idle for 10 minutes.
7. If this failure code is not displayed, repair work is completed.

40-500 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3239]

FAILURE CODE [CA3239] (ALL-K-AFK5-410-00-B)

Action level Failure code AdBlue/DEF Line Heater 2 Voltage High Error
Failure
L01 CA3239 (Engine controller system)
Detail of fail- High voltage error is detected in signal circuit of AdBlue/DEF line heater 2 (on high-temperature
ure pressure).
Action of
None in particular
controller
Phenomenon AdBlue/DEF line stops thawing.
on machine NOx emission increases because AdBlue/DEF injection is disabled at low temperature.
• The AdBlue/DEF line heater 2 operates in AdBlue/DEF supply system thawing, warning,
or implementation of AdBlue/DEF line heater relay 2 test.
• The AdBlue/DEF line heater 2 is operated by the AdBlue/DEF line heater relay 2 in the
AdBlue/DEF heater relay.
Related
• This failure code is detected only when the AdBlue/DEF line heater 2 is OFF.
information
• If the connectors of all heaters connected to the AdBlue/DEF line heater 2 are disconnect-
ed, this failure code is displayed.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check them.
1
connector 2. Turn the starting switch to ON position.
If this failure code is not displayed, the wiring harness connector is defective.
If failure code is still displayed after above checks, this check is not required.
1. Starting switch: OFF

Open circuit in wiring har- 2. Disconnect connectors ECM J2 and R53A, and connect T-adapters to
2 each female side.
ness
Between ECM J2 (female) (38) and R53A (female) (9) Max. 10 Ω
Resistance
Between R53A (female) (12) and ground Max. 10 Ω
1. Turn the starting switch to OFF position.
2. Disconnect connectors ECM J2, R53A, and MB06, and connect T-adapter
to female side.
Hot short circuit in wiring 3. Turn the starting switch to ON position.
3 harness (contact with 24
V circuit) Between ground and ECM J2 (female) (38) or R53A
3 V or less
(female) (9)
Voltage
Between ground and R53A (female) (4) or MB06 (fe-
3 V or less
male) (1)
1. Turn starting switch to OFF position.
Defective AdBlue/DEF 2.
4 Disconnect connector MB06B, and connect T-adapter to male side.
line heater
Resistance Between MB06B (male) (1) and (2) 5 to 40 Ω

HB365LC-3 40-501
FAILURE CODE [CA3239] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector MB06, and connect the T-adapter to female
Hot short circuit in AdBl- side.
5
ue/DEF line heater
3. Turn the starting switch to ON position.
Voltage Between MB06 (female) (1) and (2) Max. 3 V
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn the bat-
tery disconnect switch OFF.
Defective AdBlue/DEF 3. Disconnect connector R53A and R53B, and replace AdBlue/DEF heater
6 relay.
heater relay
4. Turn the battery disconnect switch ON.
5. Turn starting switch to ON position.
If this failure code is cleared, the original AdBlue/DEF heater relay is defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)

40-502 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3239]

Circuit diagram related to AdBlue/DEF line heater

HB365LC-3 40-503
FAILURE CODE [CA3241] 40 TROUBLESHOOTING

FAILURE CODE [CA3241] (ALL-K-AFK5-410-10-B)

Action level Failure code AdBlue/DEF line heater 2 voltage low error
Failure
L01 CA3241 (Engine controller system)
Detail of fail- Low voltage error is detected in signal circuit of AdBlue/DEF line heater 2 (on high-temperature
ure pressure).
Action of
None in particular
controller
Phenomenon AdBlue/DEF line stops thawing
on machine NOx emission increases because AdBlue/DEF injection is disabled at low temperature.
• AdBlue/DEF line heater 2 is driven at AdBlue/DEF supply system thawing/thermal insula-
tion or AdBlue/DEF line heater relay 2 test.
• AdBlue/DEF line heater 2 is driven by AdBlue/DEF line heater relay 2 inside AdBlue/DEF
heater relay.
Related • This failure code is detected only when AdBlue/DEF line heater 2 is turned ON.
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start the engine in low temperature (engine room temperature is Max. 12 °C)
or perform AdBlue/DEF line heater 2 test.
(See “service modes” of “SET AND OPERATE MACHINE MONITOR”, and “METHOD
FOR OPERATING TESTING MENU (SCR SERVICE TEST)”.)

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
FORMATION ON TROUBLESHOOTING”, and check them.
Defective wiring harness 2. Start the engine in low temperature (ambient temperature of 5 °C or lower)
1
connector or perform “AdBlue/DEF Line Heater Relay 1 Test”. For details, see SET
AND OPERATE MACHINE MONITOR, “SERVICE MODE” and “METHOD
FOR SETTING WITH TESTING MENU (SCR SERVICE TEST)”.
If this failure code is cleared, the wiring harness connector is defective.
If no failure is found by above checks, this check is not required.
1. Turn the starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connectors ECM J2, R53A and MB06, and connect T-adapter
Open circuit in wiring har- to each female side.
2
ness
Between ECM J2 (female) (38) and R53A (female) (9) Max. 10 Ω
Between R53A (female) (12) and ground Max. 10 Ω
Resistance
Between MB06 (female) (1) and R53A (female) (4) Max. 10 Ω
Between MB06 (female) (2) and ground Max. 10 Ω
1. Turn the starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect the connectors ECM J2, R53A and MB06, and connect the T-
Ground fault in wiring adapter to any female side.
3
harness
Between ground and ECM J2 (female) (38) or R53A
Min. 100 kΩ
(female) (9)
Resistance
Between ground and MB06 (female) (4) or R53A (fe-
Min. 100 kΩ
male) (1)

40-504 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3241]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective AdBlue/DEF 2.
4 Disconnect connector MB06B, and connect T-adapter to male side.
line heater
Resistance Between MB06B (male) (1) and (2) 5 to 40 Ω
1. Turn the starting switch to OFF position.
Defective supply voltage 2. Disconnect the connector R53B, and connect the T-adapter to female side.
5 to AdBlue/DEF line heat-
er Between R53B (female) (1) and ground 20 to 30 V
Resistance
Between R53B (female) (2) and ground 20 to 30 V
1. Starting switch: OFF
2. Disconnect connectors ECM J2 and R53A, and connect T-adapter to fe-
Short circuit in wiring har-
6 male side of ECM J2.
ness
Between ECM J2 (female) (39) and each pin other No continui-
Continuity
than pin (39) ty
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn the bat-
tery disconnect switch OFF.
Defective AdBlue/DEF 3. Disconnect connector R53A and R53B, and replace AdBlue/DEF heater
7 relay.
heater relay
4. Turn the battery disconnect switch ON.
5. Turn starting switch to ON position.
If this failure code is cleared, the original AdBlue/DEF heater relay is defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
8
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-505
FAILURE CODE [CA3241] 40 TROUBLESHOOTING

Circuit diagram related to AdBlue/DEF line heater

40-506 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3242]

FAILURE CODE [CA3242] (ALL-K-AFK0-410-10-B)

Action level Failure code AdBlue/DEF tank heating error

Failure
L01 CA3242 (Engine controller system)
Closing stick of the AdBlue/DEF tank heating valve or clogging of the engine coolant circuit.
Detail of fail-
ure (Engine controller turns 19102 AdBlue/DEF Tank HtrValve Command to ON (“1”) and opens AdBl-
ue/DEF tank heating valve. However, AdBlue/DEF tank temperature does not rise.)
Action of
None in particular
controller
Phenomenon • AdBlue/DEF line stops thawing
on machine • NOx emission increases because AdBlue/DEF injection is disabled at low temperature.
• Engine controller judges if this failure code is displayed only during thawing control of the
AdBlue/DEF tank (The value of 19305 AdBlue/DEF Tank Heating State is “1”).
• 19305 AdBlue/DEF Tank Heating State, 1: Thawing, 2: Warming, 3 or 0: OFF
• On “Pre-defined Monitoring” screen, AdBlue/DEF tank thawing control diagnosis is used.
(The numbers below denote monitoring codes).
• Pre-defined Monitoring (21/28) AdBlue/DEF tank thawing control
1. 19305 AdBlue/DEF Tank Heating State
Related 2. 19102 AdBlue/DEF Tank HtrValve Command
3. 19115 AdBlue/DEF Temperature in Tank
information
4. 04107 Engine Coolant Temperature
5. 19400 Ambient Temperature
6. 19133 Engine Room Temperature
NOTICE
For this failure code, after investigating the cause of the problem and completing the repair,
perform “Loaded Diagnostics Operation to Confirm Failure Correction” to make sure the fail-
ure code is cleared. (Completion of repair cannot be judged simply by turning the starting
switch to ON position.)

No. Cause Procedure, measuring location, criteria and remarks

Defective AdBlue/DEF If failure code [CA1683] or [CA1684] is displayed on the abnormality record screen,
1 tank heating valve sys- perform troubleshooting these first.
tem
Defective AdBlue/DEF If failure code [CA1677] or [CA1678] is displayed on the abnormality record screen,
2 tank temperature sensor perform troubleshooting these first.
system

HB365LC-3 40-507
FAILURE CODE [CA3242] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

See “TESTING AND ADJUSTING”, “SERVICE MODE” of “SETTING AND OPERA-
TION MACHINE MONITOR”, “METHOD FOR SETTING WITH TESTING MENU
(SCR SERVICE TEST)” to perform an “AdBlue/DEF TANK HEATER RELAY TEST”
and check if the AdBlue/DEF tank heater valve is driven normally.
Confirm that the AdBlue/DEF tank heating valve operates in response to 19102
“AdBlue/DEF Tank HtrValve Command” (switches between 0 and 1).
1. Remove the coolant hose from the outlet side of the AdBlue/DEF tank heating
valve, and plug the removed hose.
2. Start the engine.
3. Perform an “AdBlue/DEF TANK HEATER RELAY TEST” to drive the
AdBlue/DEF tank heating valve.
Mechanical failure of
4. Make sure that coolant flows out in response to valve open and close com-
3 AdBlue/DEF tank heating
valve mands.
REMARK
If coolant flows out in response to valve operation, the AdBlue/DEF tank
heating valve is normal.
If coolant does not flow out:
Increase the temperature of the inlet side coolant hose to make sure that the cool-
ant flows out.
1. If coolant flows out from the inlet side coolant hose, replace the AdBlue/DEF
tank heating valve.
2. If coolant does not flow out from the inlet side coolant hose, clogging of the
coolant circuit is suspected.
• Check if the engine coolant circuit in the engine or AdBlue/DEF tank is
Failure of engine coolant leaking or clogged.
4
circuit • Also check whether amount of engine coolant is appropriate. If there are
some problems, repair the relevant portions.
Perform “Loaded Diagnostics Operation To Confirm Failure Correction”. If the AdBl-
Defective AdBlue/DEF
5 ue/DEF tank temperature does not rise correctly, replace the AdBlue/DEF tank sen-
tank temperature sensor
sor.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

Check if the repair has been completed with the following procedure:
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Start the engine and confirm 19115“AdBlue/DEF tank temperature” on the Pre-defined Monitoring screen.
3. Conduct warm-up operation and raise the 4107 “engine coolant temperature” to 20 °C or more.
1) When the 19115 “AdBlue/DEF tank temperature” is less than 1 °C
If the 4107 “ engine coolant temperature” becomes 0 °C or more, the 19102 “AdBlue/DEF Tank
HtrValve Command” is issued (0 to 1).
Confirmation will be completed if the AdBlue/DEF tank temperature becomes 4 °C or more within an
hour after the AdBlue/DEF tank heating valve open and close command is issued.
2) When the 19115 “AdBlue/DEF tank temperature” is 1 °C or more
Conduct warm-up operation and raise the 4107 “engine coolant temperature” to ambient temperature
+ 20 °C or more.
3) See “TESTING AND ADJUSTING”, “Service mode” and “Inspection menu (SCR Service Test)” in “SET-
TING AND OPERATION OF MACHINE MONITOR” to perform “AdBlue/DEF tank heater relay test”.

40-508 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3242]

Confirmation will be completed if the AdBlue/DEF tank temperature becomes 5 °C or more within an
hour after starting the AdBlue/DEF tank heater relay test.
4. After the repair is completed, see “CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING” to
clear the failure code and make sure that the failure code has been cleared from the Abnormality Record
screen.
REMARK
If this failure code is cleared at this point, repair is completed, but if not, return to troubleshooting.

HB365LC-3 40-509
FAILURE CODE [CA3251] 40 TROUBLESHOOTING

FAILURE CODE [CA3251] (ALL-K-A9H2-410-10-B)

Action level Failure code

Failure KDOC Inlet Temperature High Error (Engine controller system)
L03 CA3251
Details of
KDOC inlet temperature remains at high level.
failure
Action of • EGR valve closed.
controller • Engine power deration
Phenomenon
Engine power deration
on machine

k The temperature of KDPF and KDOC becomes hot (Min. 500 °C). Be careful not to get
burned.
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
(Code: 47300 (°C))
• Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when at
low idle speed (KDPF regeneration is not executed) are approximately 100 to 250 °C, and
difference between these temperatures is approximately 10 °C. (KDOC inlet temperature >
KDOC outlet temperature > KDPF outlet temperature)
• Misfire of cylinder can induce following phenomena.
1. Combustion is impaired causing high exhaust temperature.
2. Cylinders other than disabled cylinder may increase their fuel injection in order to compen-
Related sate for torque drop, causing high exhaust temperature.
information • As to procedure for accessing KDPF temperature sensor, see “50 DISASSEMBLY AND
ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND
ASSEMBLE KDPF ASSEMBLY”.
• Engine controller stops after starting switch is turned to OFF position and AdBlue/DEF is
retracted (for up to 6 minutes). So when you restart engine, wait until the system operating
lamp goes out after starting switch is turned OFF, and then turn the starting switch to ON
position.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note the engine power deration is not canceled right after the failure
code is cleared).
NOTICE
• This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. Af-
ter investigating the cause of the problem and completing the repair, perform “Load-
ed Diagnostics Operation To Clear Failure Code” to make sure the failure code is
cleared. (This failure code is not cleared by only turning ON the starting switch
again.)
• This failure code is cleared by performing operations indicated in “TESTING AND
ADJUSTING”, “SETTING AND OPERATION OF MACHINE MONITOR”, “SERVICE
MODE”, “METHOD FOR SETTING WITH TESTING MENU (ENGINE CONTROLLER AC-
TIVE FAULT CLEAR)”.

40-510 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3251]

No. Cause Procedure, measuring location, criteria and remarks

Defective KDOC inlet If failure code [CA3313], [CA3314] or [CA3315] is displayed, perform troubleshoot-
1
temperature sensor ing for [CA3313], [CA3314] or [CA3315].
Defective intake air sys- Check intake air system hoses, clamps, and tubes for damage and loosening. Re-
2
tem pair as necessary.
Perform cylinder cutout mode operation to identify disabled cylinder (see “TEST-
3 Defective injector
ING AND ADJUSTING”, “HANDLING CYLINDER CUTOUT MODE OPERATION”).
1. Remove turbocharger exhaust connector.
2. Check inside of turbocharger exhaust connector for adhesion of oil and
fuel.
Oil leakage to turbo-
4 charger exhaust connec- NOTICE
tor
• If oil or fuel is found, visually check for oil leaks from EGR valve and
turbocharger. Repair abnormality, if any.
• Wipe off oil or fuel sticking to piping.
Check the exhaust system between the turbocharger and KDPF to check for oil or
Oil leakage into exhaust fuel flow into KDPF.
5 connector or duct to • Wipe stained oil or fuel off clean, if any.
KDPF • If there is a trace of oil or fuel flowing into KDPF, check for KDPF and
clean or replace it as necessary.
For details, see “Chapter 50 DISASSEMBLY AND ASSEMBLY”, “REMOVE AND
INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND ASSEMBLE OF KDPF
KDOC inlet temperature ASSEMBLY”. Repair as necessary.
6
sensor installation error For details, see “REMOVE AND INSTALL KDPF ASSEMBLY”, and “DISASSEM-
BLE AND ASSEMBLE OF KDPF ASSEMBLY” in Chapter 50 DISASSEMBLY AND
ASSEMBLY. Repair as necessary.
Defective KDPF temper- If the failure code is not cleared after performing above-mentioned troubleshooting,
7
ature sensor replace KDPF temperature sensor.
If this failure code is kept displayed, or is displayed again after above checks are
Defective engine control-
8 performed, engine controller is defective. (In case of an internal defect, trouble-
ler
shooting is impossible as an assembly. Replace whole assembly.)

Loaded Diagnostics Operation to Clear Failure Code

Check if the repair has been completed with the following procedure:
(Make sure this failure code is cleared after this procedure.)
1. Turn the starting switch to ON position, and start the engine.
2. Run the engine at low idle speed for approximately 15 minutes.
NOTICE
If the failure code is cleared, repair work is completed.

HB365LC-3 40-511
FAILURE CODE [CA3253] 40 TROUBLESHOOTING

FAILURE CODE [CA3253] (ALL-K-A9H2-410-20-B)

Action level Failure code KDOC Temperature Error - Non Regeneration

Failure
L03 CA3253 (Engine controller system)

Details of The temperature sensor reading at the KDOC inlet remains high even though active regeneration is
failure not activated.

• EGR valve closed.

Action of • Engine power deration.
controller • Fuel dosing stops.
• Regeneration control stops.
Phenomenon
Engine power deration
on machine

40-512 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3253]

k The temperature of KDPF and KDOC becomes hot (Min. 500 °C). Be careful not to get
burned.
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
(Code: 47300 (°C))
• Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
• If the engine runs with poor combustion, (poor fuel spray due to troubles in the fuel injec-
tors is one of the examples of root causes but not limited to it), large amount of unburnt
fuel slips out with the exhaust gas and will be trapped in the aftertreatment system. The
trapped unburnt fuel can start burning in the aftertreatment system once the exhaust gas
becomes hot and it can keep burning.
1. Combustion is impaired causing high exhaust temperature.
2. Cylinders other than disabled cylinder may increase their fuel injection in order to compen-
sate for torque drop, causing high exhaust temperature.
• As to procedure for accessing KDPF temperature sensor, see “50 DISASSEMBLY AND
ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND
ASSEMBLE KDPF ASSEMBLY”.
• Engine controller does not shut itself down immediately after turning the starting switch to
the OFF position. The AdBlue/DEF purging starts after the starting switch is turned to the
OFF position and Engine controller keeps working until the purging is completed. The
purging lasts for maximun 6 minutes. Do not re-start the engine until the system operating
Related lamp in the battery box goes out even if quick re-start becomes necessary.
information
• Engine power deration will be restored only after the following two conditions are met.
(1) Run “Loaded Diagnostics Operation To Clear failure Code” record in Engine controller.
Both Action Level “L03” in the Standard screen and the pop-up window of the failure de-
scription in the Current Abnormality screen shall go out if the failure is corrected.
(2) the starting switch shall be turned to the OFF position.
NOTICE
If this failure code is displayed, it indicates that KCSF may be damaged. After complet-
ing the repair of the problem, check the following. Replace the KCSF if the black smoke
comes out of the exhaust pipe outlet.
• Start the engine, perform the quick acceleration from low idle to high idle two times, and
then keep the engine running at high idle for 5 seconds.
• Check that the black smoke does not come out of the exhaust pipe outlet during this quick
acceleration and high idling.
NOTICE
• This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. Af-
ter investigating the cause of the problem and completing the repair, perform “Load-
ed Diagnostics Operation To Clear Failure Code” to make sure the failure code is
cleared. (This failure code is not cleared by only turning ON the starting switch
again.)
• This failure code is cleared by performing operations indicated in “TESTING AND
ADJUSTING”, “SETTING AND OPERATION OF MACHINE MONITOR”, “SERVICE
MODE”, “METHOD FOR SETTING WITH TESTING MENU (ENGINE CONTROLLER AC-
TIVE FAULT CLEAR)”.

No. Cause Procedure, measuring location, criteria and remarks

Defective KDOC inlet Perform checks on causes 1 to 7 for failure code [CA3251].
1
temperature sensor

HB365LC-3 40-513
FAILURE CODE [CA3253] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Defective KDOC outlet Perform checks on causes 1 to 7 for failure code [CA3254].
2
temperature sensor
1. Remove KDPF.
2. Remove KDOC.
NOTICE
• Check if KDOC has any cracks (change KDOC if any).
3 Defective KDOC • If KDOC of KDPF is changed, perform the reset after KDOC change,
then troubleshooting is complete without performing manual station-
ary regeneration.
(See cause 7 for failure code [CA2637].)
• Check if KDOC inlet surface is clogged with soot 50 % or more.
(Clean KDOC if it is clogged with soot.)
Defective KDPF temper- If the failure code is not cleared after performing above-mentioned troubleshooting,
4
ature sensor replace KDPF temperature sensor.
If this failure code is kept displayed, or is displayed again after above checks are
Defective engine control-
5 performed, engine controller is defective. (In case of an internal defect, trouble-
ler
shooting is impossible as an assembly. Replace whole assembly.)

Loaded Diagnostics Operation To Clear Failure Code

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is cleared after this procedure.)
1. Turn the starting switch from OFF position to ON position.
2. Start the engine and run it at low idle for 15 minutes.
If the failure code is cleared, repair work is completed. If the failure code is not cleared, perform the follow-
ing.
NOTICE
If failure code is not cleared after steps 1 and 2 are performed, following temperature requirement
needs to be satisfied for clearing of failure code. Steps 4 to 6 are the operation to satisfy the tem-
perature requirements.
• KDOC inlet temperature 200 °C or higher.
• KDOC outlet temperature 200 °C or higher.
3. Display KDOC inlet and outlet temperatures with monitoring function.
4. Use the work equipment to raise either track off ground.
5. Set the swing lock switch to ON position and working mode to B.
6. Run that track idle off ground for 15 minutes with fuel control dial at MAX position and travel speed at Hi
setting.
REMARK
When KDOC outlet temperature and KDPF outlet temperature do not exceed 200 °C, perform “Loaded Di-
agnostics Operation To Clear Failure Code” for failure code [CA1883].
7. If the failure code is cleared, repair work is completed.

40-514 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3254]

FAILURE CODE [CA3254] (ALL-K-A9H2-410-30-B)

Action level Failure code

Failure KDOC Outlet Temperature High Error 1(Engine controller system)
L01 CA3254
Details of
KDOC outlet temperature remains at high level.
failure
Action of
None
controller
Phenomenon
None
on machine

k The temperature of KDPF and KDOC becomes hot (Min. 500 °C). Be careful not to get
burned.
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
(Code: 47300 (°C))
• Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when at
low idle speed (KDPF regeneration is not executed) are approximately 100 to 250 °C, and
difference between these temperatures is approximately 10 °C. (KDOC inlet temperature >
KDOC outlet temperature > KDPF outlet temperature)
• If the engine runs with poor combustion, (poor fuel spray due to troubles in the fuel injec-
tors is one of the examples of root causes but not limited to it), large amount of unburnt
fuel slips out with the exhaust gas and will be trapped in the aftertreatment system. The
trapped unburnt fuel can start burning in the aftertreatment system once the exhaust gas
becomes hot and it can keep burning.
1. Combustion is impaired causing high exhaust temperature.
Related 2. Cylinders other than disabled cylinder may increase their fuel injection in order to compen-
information sate for torque drop, causing high exhaust temperature.
• As to procedure for accessing KDPF temperature sensor, see “50 DISASSEMBLY AND
ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND
ASSEMBLE KDPF ASSEMBLY”.
• Engine controller does not shut itself down immediately after turning the starting switch to
the OFF position. The AdBlue/DEF purging starts after the starting switch is turned to the
OFF position and Engine controller keeps working until the purging is completed. The
purging lasts for maximun 6 minutes. Do not re-start the engine until the system operating
lamp in the battery box goes out even if quick restart becomes necessary.
NOTICE
• This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. Af-
ter investigating the cause of the problem and completing the repair, perform “Load-
ed Diagnostics Operation To Clear Failure Code” to make sure the failure code is
cleared. (This failure code is not cleared by only turning ON the starting switch
again.)
• This failure code is cleared by performing operations indicated in “TESTING AND
ADJUSTING”, “SETTING AND OPERATION OF MACHINE MONITOR”, “SERVICE
MODE”, “METHOD FOR SETTING WITH TESTING MENU (ENGINE CONTROLLER AC-
TIVE FAULT CLEAR)”.

HB365LC-3 40-515
FAILURE CODE [CA3254] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Defective KDOC outlet If failure code [CA3316], [CA3317] or [CA3318] is displayed, perform troubleshoot-
1
temperature sensor ing for [CA3316], [CA3317] or [CA3318].
Defective intake air sys- Check intake air system hoses, clamps, and tubes for damage and loosening. Re-
2
tem pair as necessary.
Perform cylinder cutout mode operation to identify disabled cylinder (see “TEST-
3 Defective injector
ING AND ADJUSTING”, “HANDLING CYLINDER CUTOUT MODE OPERATION”).
1. Remove turbocharger exhaust connector.
2. Check inside of turbocharger exhaust connector for adhesion of oil and
fuel.
Oil leakage to turbo-
4 charger exhaust connec- NOTICE
tor
• If oil or fuel is found, visually check for oil leaks from EGR valve and
turbocharger. Repair abnormality, if any.
• Wipe off oil or fuel sticking to piping.
Check the exhaust system between the turbocharger and KDPF to check for oil or
Oil leakage into exhaust fuel flow into KDPF.
5 connector or duct to • Wipe stained oil or fuel off clean, if any.
KDPF • If there is a trace of oil or fuel flowing into KDPF, check for KDPF and
clean or replace it as necessary.
1. Remove KDPF.
2. Remove KDOC.
NOTICE
• Check if KDOC has any cracks (change KDOC if any).
6 Defective KDOC • If KDOC of KDPF is changed, perform the reset after KDOC change,
then troubleshooting is complete without performing manual station-
ary regeneration.
(See cause 7 for failure code [CA2637].)
• Check if KDOC inlet surface is clogged with soot 50 % or more.
(Clean KDOC if it is clogged with soot.)
For details, see “Chapter 50 DISASSEMBLY AND ASSEMBLY”, “REMOVE AND
INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND ASSEMBLE OF KDPF
KDOC outlet temperature ASSEMBLY”. Repair as necessary.
7
sensor installation error For details, see “REMOVE AND INSTALL KDPF ASSEMBLY”, and “DISASSEM-
BLE AND ASSEMBLE OF KDPF ASSEMBLY” in Chapter 50 DISASSEMBLY AND
ASSEMBLY. Repair as necessary.
Defective KDPF temper- If the failure code is not cleared after performing above-mentioned troubleshooting,
8
ature sensor replace KDPF temperature sensor.
If this failure code is kept displayed, or is displayed again after above checks are
Defective engine control-
9 performed, engine controller is defective. (In case of an internal defect, trouble-
ler
shooting is impossible as an assembly. Replace whole assembly.)

Loaded Diagnostics Operation To Clear Failure Code

Perform the procedure below to check that the repair is completed.
(Make sure that this failure code is cleared after this procedure.)
1. Turn the starting switch from OFF position to ON position.
2. Start the engine and run it at low idle speed for about 1 minute.
3. Choose manual stationary regeneration for service by Active regeneration for service screen on the moni-
tor.

40-516 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3254]

4. End active regeneration for service.

NOTICE
• Choose manual stationary regeneration for service by active regeneration for service screen on
the monitor for 15 minutes and more from its start.
• If the failure code is cleared when active regeneration for service is ended, repair is completed.

HB365LC-3 40-517
FAILURE CODE [CA3255] 40 TROUBLESHOOTING

FAILURE CODE [CA3255] (ALL-K-A9H0-410-50-B)

Action level Failure code KDPF Temperature Error - Non Regeneration (Engine controller sys-
Failure
L03 CA3255 tem)

Details of
KDPF outlet temperature remains at high level when active regeneration is not performed.
failure
• EGR valve closed.
Action of • Engine power deration
controller • Regeneration control stops.
• Fuel dosing stops.
Phenomenon
Engine power deration
on machine

40-518 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3255]

k The temperature of KDPF and KDOC becomes hot (Min. 500 °C). Be careful not to get
burned.
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
(Code: 47300 (°C))
• Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
• If the engine runs with poor combustion, (poor fuel spray due to troubles in the fuel injec-
tors is one of the examples of root causes but not limited to it), large amount of unburnt
fuel slips out with the exhaust gas and will be trapped in the aftertreatment system. The
trapped unburnt fuel can start burning in the aftertreatment system once the exhaust gas
becomes hot and it can keep burning.
• As to procedure for accessing KDPF temperature sensor, see “50 DISASSEMBLY AND
ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND
ASSEMBLE KDPF ASSEMBLY”.
• Engine controller does not shut itself down immediately after turning the starting switch to
the OFF position. The AdBlue/DEF purging starts after the starting switch is turned to the
Related OFF position and Engine controller keeps working until the purging is completed. The
purging lasts for maximun 6 minutes. Do not re-start the engine until the system operating
information
lamp in the battery box goes out even if quick restart becomes necessary.
• Engine power deration is canceled when the failure code is cleared and the starting switch
is turned OFF (not canceled only by deactivation of the failure code).
NOTICE
If this failure code is displayed, it indicates that KCSF may be damaged. After complet-
ing the repair of the problem, check the following. Replace the KCSF if the black smoke
comes out of the exhaust pipe outlet.
• Start the engine, perform the quick acceleration from low idle to high idle two times, and
then keep the engine running at high idle for 5 seconds.
• Check that the black smoke does not come out of the exhaust pipe outlet during this quick
acceleration and high idling.
NOTICE
• This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. Af-
ter investigating the cause of the problem and completing the repair, perform “Load-
ed Diagnostics Operation To Clear Failure Code” to make sure the failure code is
cleared. (This failure code is not cleared by only turning ON the starting switch
again.)
• This failure code is cleared by performing operations indicated in “TESTING AND
ADJUSTING”, “SETTING AND OPERATION OF MACHINE MONITOR”, “SERVICE
MODE”, “METHOD FOR SETTING WITH TESTING MENU (ENGINE CONTROLLER AC-
TIVE FAULT CLEAR)”.

No. Cause Procedure, measuring location, criteria and remarks

Defective KDPF outlet If failure code [CA3319], [CA3321] or [CA3322] is displayed, perform troubleshoot-
1
temperature sensor ing for [CA3319], [CA3321] or [CA3322].
Defective intake air sys- Check intake air system hoses, clamps, and tubes for damage and loosening. Re-
2
tem pair as necessary.

HB365LC-3 40-519
FAILURE CODE [CA3255] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Perform cylinder cutout mode operation to identify disabled cylinder (see “TEST-
3 Defective injector
ING AND ADJUSTING”, “HANDLING CYLINDER CUTOUT MODE OPERATION”).
1. Remove turbocharger exhaust connector.
2. Check inside of turbocharger exhaust connector for adhesion of oil and
fuel.
Oil leakage to turbo-
4 charger exhaust connec- NOTICE
tor
• If oil or fuel is found, visually check for oil leaks from EGR valve and
turbocharger. Repair abnormality, if any.
• Wipe off oil or fuel sticking to piping.
Check the exhaust system between the turbocharger and KDPF to check for oil or
Oil leakage into exhaust fuel flow into KDPF.
5 connector or duct to • Wipe stained oil or fuel off clean, if any.
KDPF • If there is a trace of oil or fuel flowing into KDPF, check for KDPF and
clean or replace it as necessary.
For details, see “Chapter 50 DISASSEMBLY AND ASSEMBLY”, “REMOVE AND
INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND ASSEMBLE OF KDPF
KDPF outlet temperature ASSEMBLY”. Repair as necessary.
6
sensor installation error For details, see “REMOVE AND INSTALL KDPF ASSEMBLY”, and “DISASSEM-
BLE AND ASSEMBLE OF KDPF ASSEMBLY” in Chapter 50 DISASSEMBLY AND
ASSEMBLY. Repair as necessary.
Defective KDPF temper- If the failure code is not cleared after performing above-mentioned troubleshooting,
7
ature sensor replace KDPF temperature sensor.
If this failure code is kept displayed, or is displayed again after above checks are
Defective engine control-
8 performed, engine controller is defective. (In case of an internal defect, trouble-
ler
shooting is impossible as an assembly. Replace whole assembly.)

Loaded Diagnostics Operation To Clear Failure Code

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is cleared after this procedure.)
1. Turn starting switch from OFF position to ON position and leave it there for 1 minute.
2. Start the engine and run it at low idle for 15 minutes.
NOTICE
If the failure code is cleared, repair work is completed. If the failure code is not cleared, perform the
following.
REMARK
If failure code is not cleared after steps 1 and 2 are performed, following temperature requirement needs to
be satisfied for clearing of failure code. Steps 4 to 6 are the operation to satisfy the temperature require-
ments.
• KDOC outlet temperature 200 °C or higher.
• KDPF outlet temperature 200 °C or higher.
3. Display the KDOC outlet temperature and KDPF outlet temperature with monitoring function.
4. Use the work equipment to raise either track off ground.
5. Set the swing lock switch to ON position and working mode to B.
6. Run that track idle off ground for 15 minutes with fuel control dial at MAX position and travel speed at Hi
setting.

40-520 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3255]

NOTICE
When KDOC outlet temperature and KDPF outlet temperature do not exceed 200 °C, perform “Load-
ed Diagnostics Operation To Clear Failure Code” for failure code [CA1883].
7. If the failure code is cleared, repair work is completed.

HB365LC-3 40-521
FAILURE CODE [CA3256] 40 TROUBLESHOOTING

FAILURE CODE [CA3256] (ALL-K-A9H0-410-60-B)

Action level Failure code KDPF Outlet Temperature High Error 1

Failure
L01 CA3256 (Engine controller system)
Details of
The SCR outlet temperature has been in a high temperature state
failure
Action of
None in particular
controller
Phenomenon
None in particular
on machine

k Since KDPF and KDOC are heated to 500 °C or above, be careful not to get burned.
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
(Code: 47300 (°C))
• Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when at
low idle speed (KDPF regeneration is not executed) are approximately 100 to 250 °C, and
difference between these temperatures is approximately 10 °C. (KDOC inlet temperature >
KDOC outlet temperature > KDPF outlet temperature)
• If the engine runs with poor combustion, (poor fuel spray due to troubles in the fuel injec-
tors is one of the examples of root causes but not limited to it), large amount of unburnt
fuel slips out with the exhaust gas and will be trapped in the aftertreatment system. The
trapped unburnt fuel can start burning in the aftertreatment system once the exhaust gas
becomes hot and it can keep burning.
1. Combustion is impaired causing high exhaust temperature.
Related
2. Cylinders other than disabled cylinder may increase their fuel injection in order to
information
compensate for torque drop, causing high exhaust temperature.
• As to procedure for accessing KDPF temperature sensor, see “50 DISASSEMBLY AND
ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND
ASSEMBLE KDPF ASSEMBLY”.
• After turning starting switch to OFF position, engine controller performs AdBlue/DEF purg-
ing (for Max. 6 minutes) and then stops. To restart engine, wait until system operating
lamp goes off after turning starting switch to OFF position, and then turn starting switch to
ON position.
NOTICE
• This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. Af-
ter investigating the cause of the problem and completing the repair, perform “Load-
ed Diagnostics Operation To Clear Failure Code” to make sure the failure code is
cleared.
• This failure code is cleared by performing operations indicated in “TESTING AND
ADJUSTING”, “SETTING AND OPERATION OF MACHINE MONITOR”, “SERVICE
MODE”, “METHOD FOR SETTING WITH TESTING MENU (ENGINE CONTROLLER AC-
TIVE FAULT CLEAR)”.

No. Cause Procedure, measuring location, criteria and remarks

Defective KDPF outlet If failure code [CA3319], [CA3321] or [CA3322] is displayed, perform troubleshoot-
1
temperature sensor ing for [CA3319], [CA3321] or [CA3322].

40-522 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3256]

No. Cause Procedure, measuring location, criteria and remarks

Defective intake air sys- Check intake air system hoses, clamps, and tubes for damage and loosening. Re-
2
tem pair as necessary.
Perform cylinder cutout mode operation to identify disabled cylinder (see “TEST-
3 Defective injector
ING AND ADJUSTING”, “HANDLING CYLINDER CUTOUT MODE OPERATION”).
1. Remove turbocharger exhaust connector.
2. Check inside of turbocharger exhaust connector for adhesion of oil and
fuel.
Oil leakage to turbo-
4 charger exhaust connec- NOTICE
tor
• If oil or fuel is found, visually check for oil leaks from EGR valve and
turbocharger. Repair abnormality, if any.
• Wipe off oil or fuel sticking to piping.
Check the exhaust system between the turbocharger and KDPF to check for oil or
Oil leakage into exhaust fuel flow into KDPF.
5 connector or duct to • Wipe stained oil or fuel off clean, if any.
KDPF • If there is a trace of oil or fuel flowing into KDPF, check for KDPF and
clean or replace it as necessary.
For details, see “Chapter 50 DISASSEMBLY AND ASSEMBLY”, “REMOVE AND
INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND ASSEMBLE OF KDPF
KDPF outlet temperature ASSEMBLY”. Repair as necessary.
6
sensor installation error For details, see “REMOVE AND INSTALL KDPF ASSEMBLY”, and “DISASSEM-
BLE AND ASSEMBLE OF KDPF ASSEMBLY” in Chapter 50 DISASSEMBLY AND
ASSEMBLY. Repair as necessary.
Defective KDPF temper- If the failure code is not cleared after performing above-mentioned troubleshooting,
7
ature sensor replace KDPF temperature sensor.
If this failure code is kept displayed, or is displayed again after above checks are
Defective engine control-
8 performed, engine controller is defective. (In case of an internal defect, trouble-
ler
shooting is impossible as an assembly. Replace whole assembly.)

Loaded Diagnostics Operation to Clear Failure Code

Check if the repair has been completed with the following procedure:
(Make sure this failure code is cleared after this procedure.)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position.
3. Run the engine at low idle speed for approximately 1 minute.
4. Choose “Manual Stationary Regeneration for Service” by “Active Regeneration for Service” screen on the
“Service Menu” screen of the machine monitor.
5. End “Active Regeneration for Service”.
NOTICE
• Perform “Active Regeneration for Service” for 15 minutes minimum from its start.
• After “Active Regeneration for Service” is ended and if failure code is cleared, repair is complet-
ed.

HB365LC-3 40-523
FAILURE CODE [CA3311] 40 TROUBLESHOOTING

FAILURE CODE [CA3311] (ALL-K-A9H2-410-40-B)

Action level Failure code KDOC Outlet Temperature High Error 2

Failure
L03 CA3311 (Engine controller system)

Details of
KDOC outlet temperature remains at very high level.
failure
• EGR valve closed.
Action of • Engine power deration
controller • Regeneration control stops.
• Fuel dosing stops.
Phenomenon
Engine power deration
on machine

k The temperature of KDPF and KDOC becomes hot (Min. 500 °C). Be careful not to get
burned.
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
(Code: 47300 (°C))
• Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
• As to procedure for accessing KDPF temperature sensor, see “50 DISASSEMBLY AND
ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND
ASSEMBLE KDPF ASSEMBLY”.
• Engine controller does not shut itself down immediately after turning the starting switch to
the OFF position. The AdBlue/DEF purging starts after the starting switch is turned to the
OFF position and Engine controller keeps working until the purging is completed. The
purging lasts for maximun 6 minutes. Do not re-start the engine until the system operating
lamp in the battery box goes out even if quick restart becomes necessary.
• Engine power deration is canceled when the failure code is cleared and the starting switch
Related is turned OFF (not canceled only by deactivation of the failure code).
information
NOTICE
If this failure code is displayed, it indicates that KCSF may be damaged. After complet-
ing the repair of the problem, check the following. Replace the KCSF if the black smoke
comes out of the exhaust pipe outlet.
• Start the engine, perform the quick acceleration from low idle to high idle two times, and
then keep the engine running at high idle for 5 seconds.
• Check that the black smoke does not come out of the exhaust pipe outlet during this quick
acceleration and high idling.
NOTICE
• This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correc-
tion”. After investigating the cause of the problem and completing the repair, per-
form “Loaded Diagnostics Operation To Confirm Failure Correction” to make sure
the failure code is cleared.
• This failure code is cleared by performing operations indicated in “TESTING AND
ADJUSTING”, “SETTING AND OPERATION OF MACHINE MONITOR”, “SERVICE
MODE”, “METHOD FOR SETTING WITH TESTING MENU (ENGINE CONTROLLER AC-
TIVE FAULT CLEAR)”.

40-524 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3311]

No. Cause Procedure, measuring location, criteria and remarks

Defective KDOC outlet If failure code [CA3316], [CA3317] or [CA3318] is displayed, perform troubleshoot-
1
temperature sensor ing for [CA3316], [CA3317] or [CA3318].
Defective intake air sys- Check intake air system hoses, clamps, and tubes for damage and loosening. Re-
2
tem pair as necessary.
Perform cylinder cutout mode operation to identify disabled cylinder (see “TEST-
3 Defective injector
ING AND ADJUSTING”, “HANDLING CYLINDER CUTOUT MODE OPERATION”).
1. Remove turbocharger exhaust connector.
2. Check inside of turbocharger exhaust connector for adhesion of oil and
fuel.
Oil leakage to turbo-
4 charger exhaust connec- NOTICE
tor
• If oil or fuel is found, visually check for oil leaks from EGR valve and
turbocharger. Repair abnormality, if any.
• Wipe off oil or fuel sticking to piping.
Check the exhaust system between the turbocharger and KDPF to check for oil or
Oil leakage into exhaust fuel flow into KDPF.
5 connector or duct to • Wipe stained oil or fuel off clean, if any.
KDPF • If there is a trace of oil or fuel flowing into KDPF, check for KDPF and
clean or replace it as necessary.
For details, see “Chapter 50 DISASSEMBLY AND ASSEMBLY”, “REMOVE AND
INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND ASSEMBLE OF KDPF
KDOC outlet temperature ASSEMBLY”. Repair as necessary.
6
sensor installation error For details, see “REMOVE AND INSTALL KDPF ASSEMBLY”, and “DISASSEM-
BLE AND ASSEMBLE OF KDPF ASSEMBLY” in Chapter 50 DISASSEMBLY AND
ASSEMBLY. Repair as necessary.
Defective KDPF temper- If the failure code is not cleared after performing above-mentioned troubleshooting,
7
ature sensor replace KDPF temperature sensor.
If this failure code is kept displayed, or is displayed again after above checks are
Defective engine control-
8 performed, engine controller is defective. (In case of an internal defect, trouble-
ler
shooting is impossible as an assembly. Replace whole assembly.)

Loaded Diagnostics Operation To Confirm Failure Correction

Check if the repair has been completed with the following procedure:
(Make sure this failure code is not displayed after this procedure.)
1. Turn the starting switch from OFF to ON.
NOTICE
The failure code is cleared once when starting switch is turned from OFF position to ON position.
Check that cleared failure code is not displayed again when engine runs at low idle speed.
2. Start the engine and run it at low idle speed without load for 2 minutes.
NOTICE
If this failure code is displayed when starting switch is turned to ON position but engine is not start-
ed, perform troubleshooting for following failure codes, too, after finishing troubleshooting and re-
pair for this code.
• [CA3316] KDOC Outlet Temperature Sensor Low Error
• [CA3317] KDOC Outlet Temperature Sensor High Error

HB365LC-3 40-525
FAILURE CODE [CA3312] 40 TROUBLESHOOTING

FAILURE CODE [CA3312] (ALL-K-A9H0-410-70-B)

Action level Failure code KDPF Outlet Temperature High Error 2

Failure
L03 CA3312 (Engine controller system)
Details of
KDPF outlet temperature remains at very high level.
failure
• EGR valve closed.
Action of • Engine power deration
controller • Regeneration control stops.
• Fuel dosing stops..
Phenomenon
Engine power deration
on machine

40-526 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3312]

k The temperature of KDPF and KDOC becomes hot (Min. 500 °C). Be careful not to get
burned.
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
(Code: 47300 (°C))
• Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature when at
low idle speed (KDPF regeneration is not executed) are approximately 100 to 250 °C, and
difference between these temperatures is approximately 10 °C. (KDOC inlet temperature >
KDOC outlet temperature > KDPF outlet temperature)
• If the engine runs with poor combustion, (poor fuel spray due to troubles in the fuel injec-
tors is one of the examples of root causes but not limited to it), large amount of unburnt
fuel slips out with the exhaust gas and will be trapped in the aftertreatment system. The
trapped unburnt fuel can start burning in the aftertreatment system once the exhaust gas
becomes hot and it can keep burning.
1. Combustion is impaired causing high exhaust temperature.
2. Cylinders other than disabled cylinder may increase their fuel injection in order to
compensate for torque drop, causing high exhaust temperature.
• As to procedure for accessing KDPF temperature sensor, see “50 DISASSEMBLY AND
ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND
ASSEMBLE KDPF ASSEMBLY”.
Related
• Engine controller does not shut itself down immediately after turning the starting switch to
information the OFF position. The AdBlue/DEF purging starts after the starting switch is turned to the
OFF position and Engine controller keeps working until the purging is completed. The
purging lasts for maximun 6 minutes. Do not re-start the engine until the system operating
lamp in the battery box goes out even if quick restart becomes necessary.
• Engine power deration is canceled when the failure code is cleared and the starting switch
is turned OFF (not canceled only by deactivation of the failure code).
NOTICE
If this failure code is displayed, it indicates that KCSF may be damaged. After complet-
ing the repair of the problem, check the following. Replace the KCSF if the black smoke
comes out of the exhaust pipe outlet.
• Start the engine, perform the quick acceleration from low idle to high idle two times, and
then keep the engine running at high idle for 5 seconds.
• Check that the black smoke does not come out of the exhaust pipe outlet during this quick
acceleration and high idling.
NOTICE
• This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correc-
tion”. After investigating the cause of the problem and completing the repair, per-
form “Loaded Diagnostics Operation To Confirm Failure Correction” to make sure
the failure code is cleared again.
• This failure code is cleared by performing operations indicated in “TESTING AND
ADJUSTING”, “SETTING AND OPERATION OF MACHINE MONITOR”, “SERVICE
MODE”, “METHOD FOR SETTING WITH TESTING MENU (ENGINE CONTROLLER AC-
TIVE FAULT CLEAR)”.

No. Cause Procedure, measuring location, criteria and remarks

Defective KDPF outlet If failure code [CA3319] or [CA3321] is displayed, perform troubleshooting for those
1
temperature sensor codes.

HB365LC-3 40-527
FAILURE CODE [CA3312] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Defective intake air sys- Check intake air system hoses, clamps, and tubes for damage and loosening. Re-
2
tem pair as necessary.
Perform cylinder cutout mode operation to identify disabled cylinder (see “TEST-
3 Defective injector
ING AND ADJUSTING”, “HANDLING CYLINDER CUTOUT MODE OPERATION”).
1. Remove turbocharger exhaust connector.
2. Check inside of turbocharger exhaust connector for adhesion of oil and
fuel.
Oil leakage to turbo-
4 charger exhaust connec- NOTICE
tor
• If oil or fuel is found, visually check for oil leaks from EGR valve and
turbocharger. Repair abnormality, if any.
• Wipe off oil or fuel sticking to piping.
Check the exhaust system between the turbocharger and KDPF to check for oil or
Oil leakage into exhaust fuel flow into KDPF.
5 connector or duct to • Wipe stained oil or fuel off clean, if any.
KDPF • If there is a trace of oil or fuel flowing into KDPF, check for KDPF and
clean or replace it as necessary.
For details, see “Chapter 50 DISASSEMBLY AND ASSEMBLY”, “REMOVE AND
INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND ASSEMBLE OF KDPF
KDPF outlet temperature ASSEMBLY”. Repair as necessary.
6
sensor installation error For details, see “REMOVE AND INSTALL KDPF ASSEMBLY”, and “DISASSEM-
BLE AND ASSEMBLE OF KDPF ASSEMBLY” in Chapter 50 DISASSEMBLY AND
ASSEMBLY. Repair as necessary.
Defective KDPF temper- If the failure code is not cleared after performing above-mentioned troubleshooting,
7
ature sensor replace KDPF temperature sensor.
If this failure code is kept displayed, or is displayed again after above checks are
Defective engine control-
8 performed, engine controller is defective. (In case of an internal defect, trouble-
ler
shooting is impossible as an assembly. Replace whole assembly.)

Loaded Diagnostics Operation To Confirm Failure Correction

Check if the repair has been completed with the following procedure:
(Make sure this failure code is not displayed after this procedure.)
1. Turn the starting switch from OFF to ON.
NOTICE
The failure code is cleared once when starting switch is turned from OFF position to ON position.
Check that cleared failure code is not displayed again when engine runs at low idle speed.
2. Start the engine and run it at low idle speed for 2 minutes.
NOTICE
If this failure code is displayed when starting switch is turned to ON position but engine is not start-
ed, perform troubleshooting for following failure codes as well after finishing troubleshooting and
repair for this code.
• [CA3319] KDPF Outlet Temperature Sensor Low Error
• [CA3321] KDPF Outlet Temperature Sensor High Error

40-528 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3313]

FAILURE CODE [CA3313] (ALL-K-A9HM-410-00-B)

Action level Failure code KDOC inlet temperature sensor low error
Failure
L03 CA3313 (Engine controller system)
Detail of fail- Ground fault or sensor circuit error in KDOC inlet temperature sensor measuring section or probe
ure (+) side
• As KDOC inlet temperature cannot be detected, substitutes KDOC outlet temperature for
KDOC inlet temperature and runs the engine (if KDOC outlet temperature sensor also has
an error, uses a fixed value (250 °C)).
Action of • Engine power deration.
controller • Closes EGR valve.
• Stops regeneration control.
• Stops fuel dosing.
• Control of active regeneration is defective.
Phenomenon
• Soot accumulation is high.
on machine
• Engine output is reduced.
k KDPF and KDOC are heated to 500 °C or higher. Be careful not to get burn injury.
• The KDOC inlet temperature sensor, KDOC outlet temperature sensor, and KDPF outlet
temperature sensor are integrated into one sensor, and controller of integrated sensor
communicates with the engine controller through CAN communication.
• If ground fault or sensor circuit error in KDOC inlet temperature sensor measuring section
or probe (+) side occurs, the information is sent to the engine controller through CAN com-
munication, and this failure code is displayed.
Related
• As to procedure for accessing KDOC inlet temperature sensor, KDOC outlet temperature
information
sensor, and KDPF outlet temperature sensor, see 50 DISASSEMBLY AND ASSEMBLY,
“REMOVE AND INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND ASSEMBLE OF
KDPF ASSEMBLY”.
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared. (This deration is not canceled by simply failure code being cleared.)

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Check the sensor connector for contamination and damage.
2. Turn starting switch to OFF position.
3. Replace KDPF temperature sensor.
Defective KDOC inlet
2 4. Turn starting switch to ON position.
temperature sensor
If this failure code is cleared, the original KDOC inlet temperature sensor is defec-
tive. (In case of an internal defect, troubleshooting is impossible as an assembly.
Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-529
FAILURE CODE [CA3314] 40 TROUBLESHOOTING

FAILURE CODE [CA3314] (ALL-K-A9HM-410-10-B)

Action level Failure code KDOC inlet temperature sensor high error
Failure
L03 CA3314 (Engine controller system)
Detail of fail- Open circuit, hot short-circuit, or sensor circuit error in KDOC inlet temperature sensor measuring
ure section or probe (+) side
• As KDOC inlet temperature cannot be detected, substitutes KDOC outlet temperature for
KDOC inlet temperature and runs the engine (if KDOC outlet temperature sensor also has
an error, uses a fixed value (250 °C)).
Action of • Engine power deration.
controller • Closes EGR valve.
• Stops regeneration control.
• Stops fuel dosing.
• Control of active regeneration is defective.
Phenomenon
• Soot accumulation is high.
on machine
• Engine output is reduced.
k KDPF and KDOC are heated to 500 °C or higher. Be careful not to get burn injury.
• The KDOC inlet temperature sensor, KDOC outlet temperature sensor, and KDPF outlet
temperature sensor are integrated into one sensor, and controller of integrated sensor
communicates with the engine controller through CAN communication.
• If ground fault or hot short circuit or sensor circuit error in KDOC inlet temperature sensor
measuring section or probe (+) side occurs, the information is sent to the engine controller
through CAN communication, and this failure code is displayed.
Related
• As to procedure for accessing KDOC inlet temperature sensor, KDOC outlet temperature
information
sensor, and KDPF outlet temperature sensor, see 50 DISASSEMBLY AND ASSEMBLY,
“REMOVE AND INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND ASSEMBLE OF
KDPF ASSEMBLY”.
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared. (This deration is not canceled by simply failure code being cleared.)

No. Cause Procedure, measuring location, criteria and remarks

Defective KDOC inlet Perform troubleshooting for failure code [CA3313].
1 temperature sensor sys-
tem

40-530 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3315]

FAILURE CODE [CA3315] (ALL-K-A9HM-410-20-B)

Action level Failure code KDOC Inlet Temperature Sensor In Range Error
Failure
L03 CA3315 (Engine controller system)
Difference between temperature sensed by KDOC inlet temperature sensor and that by KDOC out-
Details of
let temperature sensor differs from expected value.
failure
(Signal voltage is within input range.)
• Uses KDOC outlet temperature for KDOC inlet temperature to run engine. (If failure is de-
tected in KDOC outlet temperature sensor, too, controller takes it that KDOC inlet temper-
ature is at default value (250 °C) and allows engine to run.)
Action of • EGR valve closed.
controller • Engine power deration
• Regeneration control stops.
• Fuel dosing stops.
Phenomenon
Engine power deration
on machine

k The temperature of KDPF and KDOC becomes hot (Min. 500 °C). Be careful not to get
burned.
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
(Code: 47300 (°C))
• Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
• As to procedure for accessing KDPF temperature sensor, see “50 DISASSEMBLY AND
ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND
ASSEMBLE KDPF ASSEMBLY”.

Related • Engine controller stops after starting switch is turned to OFF position and AdBlue/DEF is
retracted (for up to 6 minutes). So when you restart engine, wait until the system operating
information lamp goes out after starting switch is turned OFF, and then turn the starting switch to ON
position.
• Engine power deration is canceled when the failure code is cleared and the starting switch
is turned OFF (not canceled only by deactivation of the failure code).
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note that the engine power deration is not canceled only by the failure
code is cleared).
NOTICE
• This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correc-
tion”. After investigating the cause of the problem and completing the repair, per-
form “Loaded Diagnostics Operation To Confirm Failure Correction” to make sure
the failure code is cleared again.
• Before performing “Loaded Diagnostics Operation To Confirm Failure Correction”,
firstly Setting and operating machine monitor, Service mode, Service mode (Engine
Controller Active Fault Clear) to be performed to clear this failure code.

HB365LC-3 40-531
FAILURE CODE [CA3315] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Defective KDOC inlet If failure code [CA3313] or [CA3314] is displayed, perform troubleshooting for those
1
temperature sensor codes.
Defective intake air sys- Check intake air system hoses, clamps, and tubes for damage and loosening. Re-
2
tem pair as necessary.
Perform cylinder cutout mode operation to identify disabled cylinder (see “TEST-
3 Defective injector
ING AND ADJUSTING”, “HANDLING CYLINDER CUTOUT MODE OPERATION”).
1. Remove turbocharger exhaust connector.
2. Check inside of turbocharger exhaust connector for adhesion of oil and
fuel.
Oil leakage to turbo-
4 charger exhaust connec- NOTICE
tor
• If oil or fuel is found, visually check for oil leaks from EGR valve and
turbocharger. Repair abnormality, if any.
• Wipe off oil or fuel sticking to piping.
Check the exhaust system between the turbocharger and KDPF to check for oil or
Oil leakage into exhaust fuel flow into KDPF.
5 connector or duct to • Wipe stained oil or fuel off clean, if any.
KDPF • If there is a trace of oil or fuel flowing into KDPF, check for KDPF and
clean or replace it as necessary.
For details, see “Chapter 50 DISASSEMBLY AND ASSEMBLY”, “REMOVE AND
INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND ASSEMBLE OF KDPF
KDOC inlet temperature ASSEMBLY”. Repair as necessary.
6
sensor installation error For details, see “REMOVE AND INSTALL KDPF ASSEMBLY”, and “DISASSEM-
BLE AND ASSEMBLE OF KDPF ASSEMBLY” in Chapter 50 DISASSEMBLY AND
ASSEMBLY. Repair as necessary.
1. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
Defective KDPF temper- 2. If the failure code displays after performing the preceding troubleshooting,
7
ature sensor replace the KDPF temperature sensor.
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is kept displayed, or is displayed again after above checks are
Defective engine control-
8 performed, engine controller is defective. (In case of an internal defect, trouble-
ler
shooting is impossible as an assembly. Replace whole assembly.)

Loaded Diagnostics Operation To Confirm Failure Correction

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is not displayed after this procedure.)
1. Perform “Engine Controller Active Fault Clear” from “service mode” of the machine monitor and clear this
failure code.
2. Turn the starting switch from OFF position to ON position.
3. Start the engine and run it at low idle for approximately 1 minute.
4. After finishing the warm-up operation, set the swing lock switch to ON position, working mode to B, and fuel
control dial to MAX position.
5. Perform arm IN relief for 40 seconds.
NOTICE
Take care not to overheat the oil of work equipment.
6. Be careful about overheating and operate step 5 for 30 minutes.
7. If this failure code is not displayed again, repair work is completed.

40-532 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3316]

FAILURE CODE [CA3316] (ALL-K-A9HQ-410-00-B)

Action level Failure code KDOC outlet temperature sensor low error
Failure
L03 CA3316 (Engine controller system)
Detail of fail- Ground fault or sensor circuit error in KDOC outlet temperature sensor measuring section or probe
ure (+) side
• As KDOC outlet temperature cannot be detected, substitutes KDOC inlet temperature for
KDOC outlet temperature and runs the engine (if KDOC inlet temperature sensor also has
an error, uses a fixed value (250 °C)).
Action of • Engine power deration.
controller • Closes EGR valve.
• Stops regeneration control.
• Stops fuel dosing.
• Control of active regeneration is defective.
Phenomenon
• Soot accumulation is high.
on machine
• Engine output is reduced.
k KDPF and KDOC are heated to 500 °C or higher. Be careful not to get burn injury.
• The KDOC inlet temperature sensor, KDOC outlet temperature sensor, and KDPF outlet
temperature sensor are integrated into one sensor, and controller of integrated sensor
communicates with the engine controller through CAN communication.
• If ground fault or sensor circuit error in KDOC outlet temperature sensor measuring sec-
tion or probe (+) side occurs, the information is sent to the engine controller through CAN
communication, and this failure code is displayed.
Related
• As to procedure for accessing KDOC inlet temperature sensor, KDOC outlet temperature
information
sensor, and KDPF outlet temperature sensor, see 50 DISASSEMBLY AND ASSEMBLY,
“REMOVE AND INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND ASSEMBLE OF
KDPF ASSEMBLY”.
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared. (This deration is not canceled by simply failure code being cleared.)

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Check the sensor connector for contamination and damage.
2. Turn starting switch to OFF position.
3. Replace KDPF temperature sensor.
Defective KDOC outlet
2 4. Turn starting switch to ON position.
temperature sensor
If this failure code is cleared, the original KDOC outlet temperature sensor is defec-
tive. (In case of an internal defect, troubleshooting is impossible as an assembly.
Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-533
FAILURE CODE [CA3317] 40 TROUBLESHOOTING

FAILURE CODE [CA3317] (ALL-K-A9HQ-410-10-B)

Action level Failure code KDOC outlet temperature sensor high error
Failure
L03 CA3317 (Engine controller system)
Detail of fail- Open circuit, hot short-circuit, or sensor circuit error in KDOC outlet temperature sensor measuring
ure section or probe (+)
• As KDOC outlet temperature cannot be detected, substitutes KDOC inlet temperature for
KDOC outlet temperature and runs the engine (if KDOC inlet temperature sensor also has
an error, uses a fixed value (250 °C)).
Action of • Engine power deration.
controller • Closes EGR valve.
• Stops regeneration control.
• Stops fuel dosing.
• Control of active regeneration is defective.
Phenomenon
• Soot accumulation is high.
on machine
• Engine output is reduced.
k KDPF and KDOC are heated to 500 °C or higher. Be careful not to get burn injury.
• The KDOC inlet temperature sensor, KDOC outlet temperature sensor, and KDPF outlet
temperature sensor are integrated into one sensor, and controller of integrated sensor
communicates with the engine controller through CAN communication.
• If open circuit or hot short circuit or sensor circuit error in KDOC outlet temperature sensor
measuring section or probe (+) side occurs, the information is sent to the engine controller
through CAN communication, and this failure code is displayed.
Related
• As to procedure for accessing KDOC inlet temperature sensor, KDOC outlet temperature
information
sensor, and KDPF outlet temperature sensor, see 50 DISASSEMBLY AND ASSEMBLY,
“REMOVE AND INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND ASSEMBLE OF
KDPF ASSEMBLY”.
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared. (This deration is not canceled by simply failure code being cleared.)

No. Cause Procedure, measuring location, criteria and remarks

Defective KDOC outlet Perform troubleshooting for failure code [CA3316].
1 temperature sensor sys-
tem

40-534 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3318]

FAILURE CODE [CA3318] (ALL-K-A9HQ-410-01-B)

Action level Failure code KDOC Outlet Temperature Sensor In Range Error
Failure
L03 CA3318 (Engine controller system)
Details of The difference between the temperature sensed by KDOC outlet temperature sensor and the tem-
failure perature sensed by KDOC inlet temperature sensor differs from the expected value.

• Substitute the KDOC inlet temperature for the KDOC outlet temperature, and run the en-
gine (if the KDOC inlet temperature sensor also has an error, use the KDOC outlet tem-
perature (250ºC) as a default value).
Action of • EGR valve closed.
controller • Engine power deration
• Regeneration control stops.
• Fuel dosing stops.
Phenomenon
Engine power deration
on machine

k Since KDPF and KDOC are heated to 500 °C or above, be careful not to get burned.
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
(Code: 47300 (ºC))
• Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (ºC))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (ºC))
• As to procedure for accessing KDPF temperature sensor, see “REMOVE AND INSTALL
KDPF ASSEMBLY”, and “DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY” in
Chapter 50 DISASSEMBLY AND ASSEMBLY.
Related • Engine controller does not shut itself down immediately after turning the starting switch to
information the OFF position. The AdBlue/DEF purging starts after the starting switch is turned to the
OFF position and Engine controller keeps working until the purging is completed. The
purging lasts for maximun 6 minutes. Do not re-start the engine until the system operating
lamp in the battery box goes out even if quick restart becomes necessary.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note that the engine power deration is not canceled only by the failure
code is cleared).
NOTICE
• This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correc-
tion”. After investigating the cause of the problem and completing the repair, per-
form “Loaded Diagnostics Operation To Confirm Failure Correction” to make sure
the failure code is cleared.
• Before performing “Loaded Diagnostics Operation To Confirm Failure Correction”,
firstly Setting and operating machine monitor, Service mode, Service mode (Engine
Controller Active Fault Clear) to be performed to clearer this failure code.

No. Cause Procedure, measuring location, criteria and remarks

Defective KDOC outlet If failure code [CA3316] or [CA3317] is displayed, perform troubleshooting for those
1
temperature sensor codes.
Defective intake air sys- Check intake air system hoses, clamps, and tubes for damage and loosening. Re-
2
tem pair as necessary.

HB365LC-3 40-535
FAILURE CODE [CA3318] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Perform cylinder cutout mode operation to identify disabled cylinder (see “TEST-
3 Defective injector
ING AND ADJUSTING”, “HANDLING CYLINDER CUTOUT MODE OPERATION”).
1. Remove turbocharger exhaust connector.
2. Check inside of turbocharger exhaust connector for adhesion of oil and
fuel.
Oil leakage to turbo-
4 charger exhaust connec- NOTICE
tor
• If oil or fuel is found, visually check for oil leaks from EGR valve and
turbocharger. Repair abnormality, if any.
• Wipe off oil or fuel sticking to piping.
Check the exhaust system between the turbocharger and KDPF to check for oil or
Oil leakage into exhaust fuel flow into KDPF.
5 connector or duct to • Wipe stained oil or fuel off clean, if any.
KDPF • If there is a trace of oil or fuel flowing into KDPF, check for KDPF and
clean or replace it as necessary.
For details, see “Chapter 50 DISASSEMBLY AND ASSEMBLY”, “REMOVE AND
INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND ASSEMBLE OF KDPF
KDOC outlet temperature ASSEMBLY”. Repair as necessary.
6
sensor installation error For details, see “REMOVE AND INSTALL KDPF ASSEMBLY”, and “DISASSEM-
BLE AND ASSEMBLE OF KDPF ASSEMBLY” in Chapter 50 DISASSEMBLY AND
ASSEMBLY. Repair as necessary.
1. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
Defective KDPF temper- 2. If the failure code displays after performing the preceding troubleshooting,
7
ature sensor replace the KDPF temperature sensor.
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is kept displayed, or is displayed again after above checks are
Defective engine control-
8 performed, engine controller is defective. (In case of an internal defect, trouble-
ler
shooting is impossible as an assembly. Replace whole assembly.)

Loaded Diagnostics Operation To Confirm Failure Correction

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is not displayed after this procedure.)
1. Perform “Engine Controller Active Fault Clear” from “service mode” of the machine monitor and clear this
failure code.
2. Turn the starting switch from OFF position to ON position.
3. Start the engine and run it at low idle for approximately 1 minute.
4. After finishing the warm-up operation, set the swing lock switch to ON position, working mode to B, and fuel
control dial to MAX position.
5. Perform arm IN relief for 40 seconds.
NOTICE
Take care not to overheat the oil of work equipment.
6. Be careful about overheating and operate step 5 for 30 minutes.
7. If this failure code is not displayed again, repair work is completed.

40-536 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3319]

FAILURE CODE [CA3319] (ALL-K-A9HS-410-00-B)

Action level Failure code KDPF Outlet Temperature Sensor High Error
Failure
L03 CA3319 (Engine controller system)
Detail of fail- Open circuit, hot short circuit, or sensor circuit error in KDPF outlet temperature sensor measuring
ure section or probe (+)
• Substitute the KDOC outlet temperature for the KDPF outlet temperature and run the en-
gine (if the KDOC outlet temperature sensor also has an error, use the default value of the
KDPF outlet temperature (250 °C)).
• Engine power deration
Action of • AdBlue/DEF injection stops.
controller • EGR valve closed.
• Regeneration control stops.
• Fuel dosing stops.
• Advances to Inducement strategy.
• NOx emission increases because AdBlue/DEF injection is disabled.
Phenomenon • Defective forcible regeneration control.
on machine • KDPF Soot Accumulation High.
• Engine output is reduced based on inducement strategy.
k Be careful not to get burned as the temperature of KDPF and KDOC rises up over 500 °C.
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.
• Open circuit, hot short circuit, or sensor circuit error in KDPF outlet temperature sensor
measuring section or probe (+) is sent to the engine controller via CAN communication,
and this failure code is displayed.
Related • For details of access to the KDOC inlet temperature sensor, the KDOC outlet temperature
information sensor, and the KDPF outlet temperature sensor, see “Chapter 50 DISASSEMBLY AND
ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND
ASSEMBLE KDPF ASSEMBLY”.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note that the engine power deration is not canceled only by the failure
code is cleared).

No. Cause Procedure, measuring location, criteria and remarks

Defective KDPF outlet Perform troubleshooting for failure code [CA3321].
1 temperature sensor sys-
tem

HB365LC-3 40-537
FAILURE CODE [CA3321] 40 TROUBLESHOOTING

FAILURE CODE [CA3321] (ALL-K-A9HS-410-10-B)

Action level Failure code KDPF Outlet Temperature Sensor Low Error
Failure
L03 CA3321 (Engine controller system)
Detail of fail-
Ground fault in KDPF outlet temperature sensor measuring section or probe (+)
ure
• Substitute the KDOC outlet temperature for the KDPF outlet temperature and run the en-
gine (if the KDOC outlet temperature sensor also has an error, use the default value of the
KDPF outlet temperature (250 °C).
• Engine power deration
Action of • AdBlue/DEF injection stops.
controller • EGR valve closed.
• Regeneration control stops.
• Fuel dosing stops.
• Advances to Inducement strategy.
• NOx emission increases because AdBlue/DEF injection is disabled.
Phenomenon • Defective forcible regeneration control
on machine • KDPF Soot Accumulation High
• Engine output is reduced based on inducement strategy.
k Be careful not to get burned as the temperature of KDPF and KDOC rises up over 500 °C.
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.
• Ground fault in the sensor measuring section or probe (+) is sent to the engine controller
via CAN communication, and this failure code is displayed.
Related • For details of access to the KDOC inlet temperature sensor, the KDOC outlet temperature
sensor, and the KDPF outlet temperature sensor, see “Chapter 50 DISASSEMBLY AND
information
ASSEMBLY”, “REMOVE AND INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND
ASSEMBLE KDPF ASSEMBLY”.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note that the engine power deration is not canceled only by the failure
code is cleared).

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Check the sensor connector for contamination and damage.
2. Turn starting switch to OFF position.
3. Replace KDPF temperature sensor.
Defective KDPF outlet
2 4. Turn starting switch to ON position.
temperature sensor
If this failure code is cleared, the original KDPF outlet temperature sensor is defec-
tive. (In case of an internal defect, troubleshooting is impossible as an assembly.
Replace whole assembly.)

40-538 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3321]

No. Cause Procedure, measuring location, criteria and remarks

Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-539
FAILURE CODE [CA3322] 40 TROUBLESHOOTING

FAILURE CODE [CA3322] (ALL-K-A9HS-410-20-B)

Action level Failure code KDPF Outlet Temperature Sensor In Range Error
Failure
L03 CA3322 (Engine controller system)

Details of Temperature sensed by KDPF outlet temperature sensor differs from expected value.
failure (Signal voltage is within input range.)
• Substitute the KDOC outlet temperature for the KDPF outlet temperature and run the en-
gine (if the KDOC outlet temperature sensor also has an error, use the default value of the
KDPF outlet temperature (250 °C).
• EGR valve closed.
Action of • Engine power deration
controller • Regeneration control stops.
• Fuel dosing stops.
• Advances to Inducement strategy.
• AdBlue/DEF injection stops.
• NOx emission increases because AdBlue/DEF injection is disabled.
Phenomenon
• Engine power deration.
on machine
• Engine power deration according to Inducement strategy.
k The temperature of KDPF and KDOC becomes hot (Min. 500 °C). Be careful not to get
burned.
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
(Code: 47300 (°C))
• Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
• For details, see “REMOVE AND INSTALL KDPF ASSEMBLY”, and “DISASSEMBLE AND
Related ASSEMBLE OF KDPF ASSEMBLY” in Chapter 50 DISASSEMBLY AND ASSEMBLY. Re-
pair as necessary.
information
• Engine controller does not shut itself down immediately after turning the starting switch to
the OFF position. The AdBlue/DEF purging starts after the starting switch is turned to the
OFF position and Engine controller keeps working until the purging is completed. The
purging lasts for maximun 6 minutes. Do not re-start the engine until the system operating
lamp in the battery box goes out even if quick restart becomes necessary.
NOTICE
• This failure code “Loaded Diagnostics Operation To Confirm Failure Correction”. Af-
ter investigating the cause of the problem and completing the repair, perform “Load-
ed Diagnostics Operation To Confirm Failure Correction” to make sure the failure
code is cleared again.
• Engine power deration is canceled by turning starting switch to OFF position after
this failure code is cleared (note that the engine power deration is not canceled only
by the failure code is cleared).

No. Cause Procedure, measuring location, criteria and remarks

Defective KDPF outlet If failure code [CA3319] or [CA3321] is displayed, perform troubleshooting for those
1
temperature sensor codes.

40-540 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3322]

No. Cause Procedure, measuring location, criteria and remarks

Defective intake air sys- Check intake air system hoses, clamps, and tubes for damage and loosening. Re-
2
tem pair as necessary.
Perform cylinder cutout mode operation to identify disabled cylinder (see “TEST-
3 Defective injector
ING AND ADJUSTING”, “HANDLING CYLINDER CUTOUT MODE OPERATION”).
1. Remove turbocharger exhaust connector.
2. Check inside of turbocharger exhaust connector for adhesion of oil and
fuel.
Oil leakage to turbo-
4 charger exhaust connec- NOTICE
tor
• If oil or fuel is found, visually check for oil leaks from EGR valve and
turbocharger. Repair abnormality, if any.
• Wipe off oil or fuel sticking to piping.
Check the exhaust system between the turbocharger and KDPF to check for oil or
Oil leakage into exhaust fuel flow into KDPF.
5 connector or duct to • Wipe stained oil or fuel off clean, if any.
KDPF • If there is a trace of oil or fuel flowing into KDPF, check for KDPF and
clean or replace it as necessary.
For details, see “Chapter 50 DISASSEMBLY AND ASSEMBLY”, “REMOVE AND
INSTALL KDPF ASSEMBLY” and “DISASSEMBLE AND ASSEMBLE OF KDPF
KDPF outlet temperature ASSEMBLY”. Repair as necessary.
6
sensor installation error For details, see “REMOVE AND INSTALL KDPF ASSEMBLY”, and “DISASSEM-
BLE AND ASSEMBLE OF KDPF ASSEMBLY” in Chapter 50 DISASSEMBLY AND
ASSEMBLY. Repair as necessary.
1. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
Defective KDPF temper- 2. If the failure code displays after performing the preceding troubleshooting,
7
ature sensor replace the KDPF temperature sensor.
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is kept displayed, or is displayed again after above checks are
Defective engine control-
8 performed, engine controller is defective. (In case of an internal defect, trouble-
ler
shooting is impossible as an assembly. Replace whole assembly.)

Loaded Diagnostics Operation To Confirm Failure Correction

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is not displayed after this procedure.)
1. Clear this failure code by “Engine Controller Inducement Fault Clear”.
2. Turn the starting switch from OFF position to ON position.
3. Start the engine and run it at low idle for approximately 1 minute.
4. After finishing the warm-up operation, set the swing lock switch to ON position, working mode to B, and fuel
control dial to MAX position.
5. Perform arm IN relief for 40 seconds.
NOTICE
Take care not to overheat the oil of work equipment.
6. Be careful about overheating and operate step 5 for 30 minutes.
7. If the failure code is not displayed again, repair work is completed.

HB365LC-3 40-541
FAILURE CODE [CA3419] 40 TROUBLESHOOTING

FAILURE CODE [CA3419] (ALL-K-A96J-410-00-B)

Action level Failure code Mass air flow sensor sup volt high error
Failure
L03 CA3419 (Engine controller system)
Detail of fail-
High voltage occurs in mass air flow sensor power supply (12 V) circuit.
ure
Action of
None in particular
controller
Phenomenon
Engine output lowers.
on machine
• If failure code [CA356] or [CA357] is displayed, remedy described in “Action of controller”
of their failure code is performed.

Related • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn the starting switch to ON position.
information
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is not displayed (note that the deration is not canceled right after the failure code
is not displayed).

No. Cause Procedure, measuring location, criteria and remarks

1. Perform checkup referring to descriptions of wiring harness and connec-
tors in “c Electric equipment ”of “CHECKS BEFORE TROUBLESHOOT-
Defective wiring harness ING” in “RELATED INFORMATION ON TROUBLESHOOTING”.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Starting switch: OFF
2. Disconnect connector P55.
Defective mass air flow 3. Starting switch: ON
2
sensor (internal defect)
If this failure code is cleared, mass air flow sensor is defective.
Other failure codes are displayed at the same time. This happens because the con-
nector is disconnected. So ignore other codes besides this failure code.
1. Starting switch: OFF
2. Disconnect connector ECM J1.
3. Starting switch: ON
3 Defective wiring harness If this failure code is cleared, wiring harness is defective.
REMARK
Many other failure codes appear at same time because of disconnected connector.
Ignore failure codes other than this.
1. Starting switch: OFF
2. Disconnect connector ECM J1 and connect T-adapter to male side.
3. Starting switch: ON
Defective engine control- Approxi-
4 Voltage Between ECM J1 (male) (80) and (56)
ler mately 12 V
If failure code is still displayed after above checks, engine controller is defective.
Replace engine controller. (Troubleshooting will be impossible, because this is an
internal defect.)

40-542 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3419]

Circuit diagram related to mass air flow sensor

HB365LC-3 40-543
FAILURE CODE [CA3421] 40 TROUBLESHOOTING

FAILURE CODE [CA3421] (ALL-K-A96J-410-10-B)

Action level Failure code Mass Air Flow Sensor Sup Volt Low Error
Failure
L03 CA3421 (Engine controller system)
Detail of fail-
Low voltage occurs in mass air flow sensor power supply (12 V) circuit.
ure
Action of
None in particular
controller
Phenomenon
Engine output lowers.
on machine
• If failure code [CA356] or [CA357] is displayed, remedy described in “Action of controller”
of their failure code is performed.

Related • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn the starting switch to ON position.
information
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is not displayed (note that the deration is not canceled right after the failure code
is not displayed).

No. Cause Procedure, measuring location, criteria and remarks

Defective wiring harness
1
connector
Defective mass air flow
2
sensor (internal defect)
3 Defective wiring harness
Short circuit in wiring har-
4 female side.
ness
Ground fault in wiring
5 harness (contact with
ground circuit)
1. Perform checkup referring to descriptions of wiring harness and connec-
tors in “c Electric equipment ”of “CHECKS BEFORE TROUBLESHOOT-
ING” in “RELATED INFORMATION ON TROUBLESHOOTING”.
2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Starting switch: OFF
2. Disconnect connector P55.
3. Starting switch: ON
If this failure code is cleared, mass air flow sensor is defective.
Other failure codes are displayed at the same time. This happens because the con-
nector is disconnected. So ignore other codes besides this failure code.
1. Starting switch: OFF
2. Disconnect connector ECM J1.
3. Starting switch: ON
If this failure code is cleared, wiring harness is defective.
REMARK
Many other failure codes appear at same time because of disconnected connector.
Ignore failure codes other than this.
1. Starting switch: OFF
2. Disconnect connectors ECM J1 and P55, and connect T-adapter to either
Between ECM J1 (female) (80) and (56), or between
Resistance Min. 100 kΩ
P55 (female) (2) and (3)
1. Starting switch: OFF
2. Disconnect connectors ECM J1 and P55, and connect T-adapter to either
female side.
Between ground and ECM J1 (female) (80) or P55 (fe-
Resistance Min. 100 kΩ
male) (2)

40-544 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3421]

No. Cause Procedure, measuring location, criteria and remarks

1. Starting switch: OFF
2. Disconnect connector ECM J1 and connect T-adapter to male side.
3. Starting switch: ON
Defective engine control- Approxi-
6 Voltage Between ECM J1 (male) (80) and (56)
ler mately 12 V
If failure code is still displayed after above checks, engine controller is defective.
Replace engine controller. (Troubleshooting will be impossible, because this is an
internal defect.)

Circuit diagram related to mass air flow sensor

HB365LC-3 40-545
FAILURE CODE [CA3497] 40 TROUBLESHOOTING

FAILURE CODE [CA3497] (ALL-K-AFG0-410-B0-B)

Action level Failure code AdBlue/DEF Level Low Error 1

Failure
- CA3497 (Engine controller system)
Detail of fail-
The AdBlue/DEF tank level lowered. (The tank capacity becomes 10 % or less)
ure
Action of
Advances to Inducement strategy.
controller
Phenomenon
None in particular
on machine
• The failure codes of AdBlue/DEF level low are as follows:
When AdBlue/DEF level is 10 % or less [CA3497]
When AdBlue/DEF level is 5 % or less [CA3498]
When AdBlue/DEF level is 2.5 % or less [CA1673]
Related
When AdBlue/DEF level is 0.0 % or less [CA3547]
information
• CA3498 is displayed if usage is continued without refilling AdBlue/DEF and the
AdBlue/DEF level becomes 5 % or less.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Check the sight gauge to confirm that there is sufficient amount of
AdBlue/DEF in the AdBlue/DEF tank.
1 Low AdBlue/DEF level 3. Refill AdBlue/DEF if the level is low.
4. Turn starting switch to ON position.
If this failure code is cleared, AdBlue/DEF has been insufficient.
1. Check the sensor connector for contamination and damage.
2. Turn starting switch to OFF position.
3. Replace the AdBlue/DEF tank sensor.
Defective AdBlue/DEF
2 4. Turn starting switch to ON position.
tank sensor
If this failure code is cleared, any internal parts in the original AdBlue/DEF tank
sensor is defective. (In case of an internal defect, troubleshooting is impossible as
an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

40-546 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3498]

FAILURE CODE [CA3498] (ALL-K-AFG0-410-C0-B)

Action level Failure code AdBlue/DEF Level Low Error 2

Failure
- CA3498 (Engine controller system)
Detail of fail-
The AdBlue/DEF tank level lowered. (The tank capacity becomes 5 % or less)
ure
Action of
None in particular
controller
Phenomenon
None in particular
on machine
• The failure codes of AdBlue/DEF level low are as follows:
When AdBlue/DEF level is 10 % or less [CA3497]
When AdBlue/DEF level is 5 % or less [CA3498]
When AdBlue/DEF level is 2.5 % or less [CA1673]
Related
When AdBlue/DEF level is 0.0 % or less [CA3547]
information
• CA1673 is displayed and engine output is limited significantly if usage is continued without
refilling AdBlue/DEF and the AdBlue/DEF level becomes 2.5 % or less.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Check the sight gauge to confirm that there is sufficient amount of
AdBlue/DEF in the AdBlue/DEF tank.
1 Low AdBlue/DEF level 3. Refill AdBlue/DEF if the level is low.
4. Turn starting switch to ON position.
If this failure code is cleared, AdBlue/DEF has been insufficient.
1. Check the sensor connector for contamination and damage.
2. Turn starting switch to OFF position.
3. Replace the AdBlue/DEF tank sensor.
Defective AdBlue/DEF
2 4. Turn starting switch to ON position.
tank sensor
If this failure code is cleared, any internal parts in the original AdBlue/DEF tank
sensor is defective. (In case of an internal defect, troubleshooting is impossible as
an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-547
FAILURE CODE [CA3543] 40 TROUBLESHOOTING

FAILURE CODE [CA3543] (ALL-K-AFG4-410-00-B)

Action level Failure code AdBlue/DEF quality error (SCR catalyst efficiency low)
Failure
L01 CA3543 (Engine controller system)

Detail of fail- • The SCR catalyst efficiency is poor (65 % or less) after refilling AdBlue/DEF.
ure • AdBlue/DEF quality is probably abnormal.
Action of
• Inducement strategy is activated.
controller
Phenomenon • The NOx emission has probably increased.
on machine • Engine output is reduced based on Inducement strategy.
k The turbo outlet part, KDPF, sensor fitting piping, and sensor probe are heated to
500 °C or higher. Be careful not to get burn injury.
k AdBlue/DEF mixing piping, SCR assembly, sensor installation piping, and sensor
probe are heated to 400 °C or higher. Be careful not to get burn injury.
k As for the sensor probe, be careful not to get burn injury even if the surroundings
are not hot, because sensor itself is heated.
k When removing AdBlue/DEF mixing piping or AdBlue/DEF injector, AdBlue/DEF may
leak, so be careful.
• This failure code [CA3543] is displayed after the engine controller performs “Active Regen-
eration to clean urea deposit (for approximately 1 hour)” when the failure code [CA3582] is
displayed.
• Make sure that failure code [CA3582] is not displayed when confirming the completion of
repair.
• If the ambient pressure is 80 kPa or less, and the ambient temperature is -7 °C or lower,
the engine controller does not troubleshoot this failure code (cannot determine if the repair
is completed). Confirm it on "Pre-defined Monitoring" screen.
• Under following condition, failure code is not cleared even after performing machine oper-
ation for clearing the failure code.
Related 1. Active regeneration in progress
information 2. AdBlue/DEF injection being stopped by other failure code
• For the procedure to remove and replace AdBlue/DEF injector, see DISASSEMBLY AND
ASSEMBLY, “REMOVE AND INSTALL AdBlue/DEF INJECTOR”.
• On Pre-defined Monitoring screen, following 4 diagnoses are displayed. Engine operation
state diagnosis, environment state diagnosis, SCR catalyst, NOx sensor, ammonia sensor
diagnosis, AdBlue/DEF level, AdBlue/DEF quality sensor diagnosis (The numbers below
denote displayed monitoring codes.)
• Pre-defined Monitoring (16/28) Engine operation state
1. 01002 Engine Speed
2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
• Pre-defined Monitoring (24/28) Environment state
1. 37400 Ambient Pressure
2. 19400 Ambient Temperature
3. 18400 Intake Temperature
4. 19133 Engine Room Temperature
5. 19115 AdBlue/DEF Temperature in Tank

40-548 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3543]

• Pre-defined Monitoring (19/28) SCR catalyst/NOX sensor/NH3 sensor

1. 19120 AdBlue/DEF Injection Quantity
2. 19205 SCR NH3 Concentration Corrected
3. 19202 Turbo Outlet NOx Corrected
4. 19209 SCR Outlet NOx Corrected
5. 19203 Turbo Outlet NOx Sensor State
6. 19210 SCR Outlet NOx Sensor State
• Pre-defined Monitoring (20/28) AdBlue/DEF level, quality sensor
Related 1. 19100 AdBlue/DEF Concentration
information 2. 19110 AdBlue/DEF Level
3. 19111 AdBlue/DEF Level Corrected
4. 19115 AdBlue/DEF Temperature in Tank
5. 19400 Ambient Temperature
6. 19305 AdBlue/DEF Tank Heating State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correction”.
After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to make sure the failure code is cleared.

No. Cause Procedure, measuring location, criteria and remarks

Defective turbocharger If failure code [CA1885], [CA3232], [CA3649], [CA3682], [CA3718], [CA3725], or
outlet NOx sensor sys- [CA3748] is displayed, perform troubleshooting for these failure codes failure codes
tem first.
1
(Open circuit, internal de-
fect, defective sensor
heater)
Defective SCR outlet If failure code [CA1887], [CA2771], [CA3545], [CA3583], [CA3681], or [CA3717] is
NOx sensor system displayed, perform troubleshooting for these failure codes first.
2 (Open circuit, internal de-
fect, defective sensor
heater)
Defective SCR tempera- If failure code [CA3142] or [CA3143] or [CA3144] or [CA3146] or [CA3147] or
ture sensor system [CA3148] or [CA3165] or [CA3229] or [CA3231] or [CA3235] or [CA4152] or
3
(Open circuit, Internal de- [CA4159] or [CA4164] or [CA4165] or [CA4166] or [CA4261] is displayed, perform
fect) troubleshooting for these failure codes first.

Defective ammonia sen- If failure code [CA3899], [CA3911], [CA3912], [CA3932], [CA3933], [CA3934],
sor system [CA3935], [CA3936] or [CA4281] is displayed, perform troubleshooting for these
4 (Open circuit, internal de- failure codes first.
fect, defective sensor
heater)

HB365LC-3 40-549
FAILURE CODE [CA3543] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Check the mounting of the AdBlue/DEF quality sensor is secured and the
wiring harness connections are not loosen Repair if any abnormality is
found.
2. Turn starting switch to ON position.
3. Check if failure code [CA3866] or [CA3867] is displayed.
4. Read 19100 “AdBlue/DEF concentration” on the display and confirm that
the concentration is appropriate (29 to 36 %).
5. If failure code [CA3866] or [CA3867] is displayed and the 19100
Improper AdBlue/DEF
5 “AdBlue/DEF concentration” reading is inappropriate, drain the
quality
AdBlue /DEF tank, clean the tank, and refill with genuine AdBlue/DEF.
6. Perform “Loaded Diagnostics Operation To Confirm Failure Correction” to
check if this failure code is not cleared.
7. If the 19205 “Ammonia concentration (compensation value)” reading is
normal (5 to 100 ppm) and the failure code is not redisplayed, the repair is
completed.
8. If the ammonia concentration indicates an abnormal value or this failure
code recurs, proceed to the next step.
1. If failure code [CA4658] or [CA3568] is displayed, or failure code [CA4658] or
[CA3568] is displayed on the service meter display of the abnormality record
within 2 hours, perform “Loaded Diagnostics Operation To Confirm Failure
Correction”, check if failure code [CA3151], [CA3543], or [CA3582] is dis-
played.
Clogged AdBlue/DEF in-
6 2. If 19205 “Ammonia concentration (compensation value)” indicates a normal
jector
value (5 to 100 ppm) and the failure code is cleared, the repair is completed
(“Loaded Diagnostics Operation To Confirm Failure Correction” has resolved
the clogging problem and the machine has restored normal operation).
3. If the ammonia concentration indicates an abnormal value or either failure
code [CA3151], [CA3543], or [CA3582] is displayed, proceed to the next step.
1. Visually check the piping from the KDPF outlet to the SCR outlet for damage
or defective connection.
Defective mixing tube
7 2. Visually check for white crystallized AdBlue/DEF deposits on the surrounding
(exhaust gas leakage) area.
3. If defective connections or damages are found, fix or replace parts.
If crystallized AdBlue/DEF is adhered to the surrounding of hose, tank, pump, or
engine compartment, it shows AdBlue/DEF may be leaking. Refer to “TESTING
Damaged AdBlue/DEF AND ADJUSTING”, “SETTING AND OPERATION OF MACHINE MONITOR”,
8 hose, AdBlue/DEF leak- “METHOD FOR SETTING WITH TESTING MENU (SCR SERVICE TEST)” to per-
age at connection form AdBlue/DEF Pump Pressure Up Test and find the location of the AdBlue/DEF
leak.
Replace parts as necessary.

40-550 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3543]

No. Cause Procedure, measuring location, criteria and remarks

1. See “TESTING AND ADJUSTING”, “SERVICE MODE” and “METHOD FOR
SETTING WITH TESTING MENU (SCR SERVICE TEST)” of “SETTING AND
OPERATION OF MACHINE MONITOR”, and perform an “SCR Denitration Ef-
ficiency Test”.
2. If the “SCR Denitration Efficiency Test” has not been completed successfully,
proceed to cause 10.
3. If failure code [CA1694], [CA3751], or [CA3755] is displayed after the “SCR
Defective urea SCR sys- Denitration Efficiency Test”, perform troubleshooting for relevant failure code
tem first.
9 (inspection with SCR RE- 4. After the failure code in the above 3 is cleared, perform “Loaded Diagnostics
MOVAL EFFICIENCY Operation To Clear Failure Code” to check if this failure code is not cleared.
TEST)
5. If 19205 “Ammonia concentration (compensation value)” indicates a normal
value (5 to 100 ppm) and the failure code is cleared, the repair is completed.
6. If the ammonia concentration indicates an abnormal value or this failure code
is not cleared, proceed to cause 13.
7. Even if the SCR REMOVAL EFFICIENCY TEST has been completed success-
fully and any of failure code [CA1694], [CA3751], or [CA3755] is not displayed,
proceed to cause 13.
1. Refer to “TESTING AND ADJUSTING”, “SETTING AND OPERATION OF MA-
CHINE MONITOR”, “SERVICE MODE”, “METHOD FOR SETTING WITH
TESTING MENU (SCR SERVICE TEST)” to perform an “AdBlue/DEF Injection
Quantity Test” to judge the injector.
2. From the test results, confirm that the AdBlue/DEF injection amount is within
the values specified in “TESTING AND ADJUSTING”.
3. If the AdBlue/DEF injection amount is out of the range specified in “TESTING
Defective AdBlue/DEF in-
10 AND ADJUSTING”, replace the AdBlue/DEF injector.
jector
4. If the AdBlue/DEF injector has been replaced, perform the “AdBlue/DEF Injec-
tion Quantity Test” again. After confirming that the AdBlue/DEF injection
amount is within the range specified in “TESTING AND ADJUSTING”, proceed
to the next cause. (The purpose of this test for two times is to check accumu-
lated urea deposits in the AdBlue/DEF mixing tube )
5. Proceed to the next troubleshooting, even if the “AdBlue/DEF Injection Quanti-
ty Test” results were normal.
1. Check if urea deposits are accumulated in the AdBlue/DEF mixing tube and
the AdBlue/DEF injector mount.
Accumulation of urea de- 2.
If deposits are accumulated, remove the AdBlue/DEF mixing tube to remove
11 posits in AdBlue/DEF
deposits and clean the tube.
mixing tube
3. Check if urea deposits are accumulated in the SCR inlet case. If accumulated,
perform the next item.
1. If urea deposit is accumulated inside the SCR inlet case, remove the urea
Accumulated urea de- deposit as much as possible.
12
posit in SCR assembly
2. Repair AdBlue/DEF mixing tube back to normal.

HB365LC-3 40-551
FAILURE CODE [CA3543] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks, the intake system may be defec-
tive.
(Offset/drift due to the deteriorated and aged MAF sensor, distorted intake system,
damaged rectifier)
1. Check for a defective air intake pipe and repair or replace any damaged or
Defective air intake sys- defective rectifier, if any.
13
tem 2. Replace mass air flow (MAF) sensor.
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction” to
check if this failure code is not cleared.
4. If 19205 “ammonia concentration (compensation value)” shows an normal
value (5 to 100ppm) and the failure code is cleared again, the repair has
been completed
If failure code is still displayed after above checks, the ammonia sensor may be de-
fective.
(Offset/drift due to the deteriorated and aged ammonia sensor)
1. Replace the ammonia sensor.
2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”,
Defective ammonia sen-
14 then check if this failure code or failure code [CA3582] is displayed.
sor
3. If 19205 “Ammonia concentration (compensation value)” indicates a nor-
mal value (5 to 100 ppm) and the failure code is cleared, the repair is com-
pleted.
4. If the ammonia concentration indicates an abnormal value or this failure
code is not cleared, proceed to the next step.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
15
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

Perform the following procedure to check that the repair is completed.
(Make sure this failure code and failure code [CA3582] are not displayed.)
1. Clear this failure code by “Engine Controller Inducement Fault Clear”.
2. Turn the starting switch to OFF position, and shut down the engine controller.
3. Turn the starting switch to ON position.
4. Start the engine.
5. Run the engine at low idle with no load for approximately 1 minute.
6. After finishing the warm-up operation, set the swing lock switch to ON position, working mode to B, and fuel
control dial to MAX position.
7. Perform arm IN relief operation for approximately 30 seconds.
REMARK
Take care not to overheat the hydraulic oil.
8. Run the engine at high idle with no load for 30 seconds.
9. Repeat above steps 6 and 7 up to 20 times.
10. If this failure code and failure code [CA3582] are not displayed, repair work is completed.
If this failure code or failure code [CA3582] is displayed:
1. Display the SCR temperature and ammonia concentration on the troubleshooting screen.
2. Perform operation so that the SCR temperature is kept 250 °C or higher.

40-552 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3543]

3. A normal value of ammonia concentration ranges from 5 to 100 (ppm). If 0 (ppm) is shown consistently or
100 (ppm) or more is shown, return to troubleshooting because the repair is not completed.
Checklist
Relieve the Arm IN Run the engine at high idle (with no load)
Operation
for 30 seconds for 30 seconds
SCR Temperature
Monitoring screen
ID: 19300
Value to be checked Around 250 °C
1st time
2nd time
3rd time
4th time
5th time
6th time
7th time
8th time
9th time
10th time
11th time
12th time
13th time
14th time
15th time
16th time
17th time
18th time
19th time
20th time

HB365LC-3 40-553
FAILURE CODE [CA3545] 40 TROUBLESHOOTING

FAILURE CODE [CA3545] (ALL-K-AFA0-410-40-B)

Action level Failure code SCR Outlet NOx unstable error

Failure
L01 CA3545 (Engine controller system)
Detail of fail-
The SCR outlet NOx sensor does not become measurable state.
ure
Action of • Operates at default NOx value (0 ppm).
controller • Inducement strategy is activated (EU specifications).
• AdBlue/DEF injection becomes inappropriate and the NOx emission may increase, or am-
Phenomenon
monia may be discharged.
on machine
• Engine output is reduced based on Inducement strategy (EU specifications).
k KDPF, sensor installation piping, and sensor probe are heated to 500 °C or higher.
Be careful not to get burn injury.
k SCR assembly, sensor fitting piping, and sensor probe are heated to 400 °C or high-
er. Be careful not to get burn injury.
k As for the sensor probe, be careful not to get burn injury even if the surroundings
are not hot, because sensor itself is heated.
• SCR outlet NOx sensor operates when 19302 SCR Outlet Temperature is 150 °C or higher
(19210 SCR Outlet NOx Sensor State is “1”).
• SCR outlet NOx sensor is smart sensor which communicates with engine controller with
other sensors through CAN communication.
• SCR outlet NOx sensor does not operate when SCR outlet temperature is 150 °C or lower,
and correct value is not displayed (the sensor does not operate by simply turning the start-
ing switch to ON position even when it is normal).
• On Pre-defined Monitoring screen, engine operation state diagnosis, SCR catalyst, NOx
sensor, ammonia sensor diagnosis are used.
Related • Pre-defined Monitoring (16/28) Engine operation state
information 1. 01002 Engine Speed
2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
• Pre-defined Monitoring (19/28) SCR catalyst/NOX sensor/NH3 sensor
1. 19120 AdBlue/DEF Injection Quantity
2. 19205 SCR NH3 Concentration Corrected
3. 19202 Turbo Outlet NOx Corrected
4. 19209 SCR Outlet NOx Corrected
5. 19203 Turbo Outlet NOx Sensor State
6. 19210 SCR Outlet NOx Sensor State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correction”.
After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to make sure the failure code is cleared.

No. Cause Procedure, measuring location, criteria and remarks

Defective SCR outlet If failure code [CA1887] or [CA3583] or [CA3681] or [CA3717] is displayed, perform
1
NOx sensor system troubleshooting for these failure codes first.
SCR outlet NOx sensor Check if the SCR outlet NOx sensor probe is installed securely.
2
installation error

40-554 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3545]

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by preceding checks, the SCR outlet NOx sensor is defective.
1. Turn starting switch to OFF position.
2. Replace the SCR outlet NOx sensor.
Defective SCR outlet
3 3. Turn starting switch to ON position.
NOx sensor
4. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is cleared, the original sensor is defective. (In case of an internal
defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is not displayed after this procedure.)
Clear this failure code by “Engine Controller Inducement Fault Clear” before step 1. (EU specification)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start the engine.
3. Set the working mode to B.
4. Run the engine at high idle in safe condition to raise the exhaust gas temperature and SCR catalyst tem-
perature. (Keep the engine speed so that the monitoring code 19302 “SCR Outlet Temperature” becomes
150 °C or higher. Check that the monitoring code 19210 “SCR Outlet NOx Sensor State” changes from 0 to
1.)
5. Repair is completed if failure code is not displayed after 3 minutes have passed.
REMARK
If the SCR outlet NOx sensor cannot be activated (that is, 19210 “SCR Outlet NOx Sensor State” remains as 0),
return to troubleshooting.

HB365LC-3 40-555
FAILURE CODE [CA3547] 40 TROUBLESHOOTING

FAILURE CODE [CA3547] (ALL-K-AFG0-410-D0-B)

Action level Failure code AdBlue/DEF Level Low Error 4

Failure
L04 CA3547 (Engine controller system)
Detail of fail-
The AdBlue/DEF tank level lowers. (The tank capacity becomes 0.0 % or less)
ure
Action of
Engine power is derated heavily.
controller
• Engine output reduces heavily.
Phenomenon
• If the machine continues to operate without adding, AS00ZK is displayed and engine out-
on machine
put for operation is limited to low idle.
• The failure codes of AdBlue/DEF level low are as follows:
When AdBlue/DEF level is 10 % or less [CA3497]
When AdBlue/DEF level is 5 % or less [CA3498]
When AdBlue/DEF level is 2.5 % or less [CA1673]
Related When AdBlue/DEF level is 0.0 % or less [CA3547]
information • From the machine monitor, it is possible to perform a temporary restoration from induce-
ment to clear engine output low temporarily.
• After this failure code is cleared, Engine power deration continues until the starting switch
is turned to OFF position.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Check the sight gauge to confirm that there is sufficient amount of
AdBlue/DEF in the AdBlue/DEF tank.
1 Low AdBlue/DEF level 3. Refill AdBlue/DEF if the level is low.
4. Turn starting switch to ON position.
If this failure code is cleared, AdBlue/DEF has been insufficient.
1. Check the sensor connector for contamination and damage.
2. Turn starting switch to OFF position.
3. Replace the AdBlue/DEF tank sensor.
Defective AdBlue/DEF
2 4. Turn starting switch to ON position.
tank sensor
If this failure code is cleared, any internal parts in the original AdBlue/DEF tank
sensor is defective. (In case of an internal defect, troubleshooting is impossible as
an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

40-556 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3558]

FAILURE CODE [CA3558] (ALL-K-AFH1-410-10-B)

Action level Failure code AdBlue/DEF Pump Voltage High Error

Failure
L01 CA3558 (Engine controller system)
Detail of fail-
High voltage error occurs in the AdBlue/DEF pump drive circuit.
ure
• AdBlue/DEF pump stops.
Action of
• AdBlue/DEF purging stops.
controller
• Advances to Inducement strategy.
Phenomenon • NOx emission increases because AdBlue/DEF injection is disabled.
on machine • Engine output is reduced based on inducement strategy.
• If the starting switch is turned ON while the AdBlue/DEF pump connector is removed, this
failure code is displayed.
• The AdBlue/DEF pump operates120 seconds after starting the engine, or it operates, after
Related starting the engine, if not in AdBlue/DEF thawing process, when the KDPF outlet tempera-
information ture becomes over 150 °C, or when AdBlue/DEF pump pressure raising test is implement-
ed.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position or operate the AdBlue/DEF pump.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of the failure code
“RELATED INFORMATION ON TROUBLESHOOTING”, and check it.
Defective wiring harness 2. Turn starting switch to ON position.
1
connector 3. See “SERVICE MODE” and “METHOD FOR SETTING WITH TESTING
MENU (SCR SERVICE TEST)” of SETTING AND OPERATION OF MA-
CHINE MONITOR, and perform an AdBlue/DEF Pump Pressure Up Test.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors ECM J2 and MB02, and connect T-adapter to ei-
ness (wire breakage or ther female side.
2
defective contact of con-
nector) Between ECM J2 (female) (54) and MB02 (female) (8) Max. 10 Ω
Resistance
Between ECM J2 (female) (79) and MB02 (female) (9) Max. 10 Ω
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J2 and MB02, and connect T-adapter to fe-
male side of ECM J2.
Short circuit in wiring har-
3 Between ECM J2 (female) (6) and each pin other than No continui-
ness
(6) ty
Continuity
Between ECM J2 (female) (79) and each pin other No continui-
than (79) ty
If failure code is still displayed after above checks, AdBlue/DEF pump may be de-
Defective AdBlue/DEF
4 fective. (In case of an internal defect, troubleshooting is impossible as an assembly.
pump
Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-557
FAILURE CODE [CA3558] 40 TROUBLESHOOTING

Circuit diagram related to AdBlue/DEF pump temperature sensor

40-558 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3559]

FAILURE CODE [CA3559] (ALL-K-AFH1-410-20-B)

Action level Failure code AdBlue/DEF Pump Voltage Low Error

Failure
L01 CA3559 (Engine controller system)
Detail of fail-
Low voltage error occurs in the AdBlue/DEF pump drive circuit.
ure
• AdBlue/DEF pump stops.
Action of
• AdBlue/DEF purging stops.
controller
• Advances to Inducement strategy.
Phenomenon • NOx emission increases because AdBlue/DEF injection is disabled.
on machine • Engine output is reduced based on inducement strategy.
• If the AdBlue/DEF pump connector is removed while the starting switch is ON, this failure
code is displayed.
• The AdBlue/DEF pump operates 120 seconds after starting the engine, or it operates, af-
Related ter starting the engine, if not in AdBlue/DEF thawing process, when the KDPF outlet tem-
information perature becomes over 150 °C, or when AdBlue/DEF pump pressure raising test is imple-
mented.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position or operate the AdBlue/DEF pump.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of the failure code
“RELATED INFORMATION ON TROUBLESHOOTING”, and check it.
Defective wiring harness 2. Turn starting switch to ON position.
1
connector 3. See “SERVICE MODE” and “METHOD FOR SETTING WITH TESTING
MENU (SCR SERVICE TEST)” of SETTING AND OPERATION OF MA-
CHINE MONITOR, and perform an AdBlue/DEF Pump Pressure Up Test.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J2 and MB02 and connect T-adapters to
Open circuit in wiring har- each female side.
2
ness
Between ECM J2 (female) (79) and MB02 (female) (9) Max. 10 Ω
Resistance
Between ECM J2 (female) (6) and MB02 (female) (10) Max. 10 Ω
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J2 and MB02, and connect T-adapter to ei-
ther female side.
Short circuit in wiring har-
3 Between ECM J2 (female) (6) and (54), or between
ness Min. 100 kΩ
MB02 (female) (10) and (8)
Resistance
Between ECM J2 (female) (54) and (79), or between
Min. 100 kΩ
MB02 (female) (8) and (9)

HB365LC-3 40-559
FAILURE CODE [CA3559] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J2 and MB02, and connect T-adapter to ei-
Ground fault in wiring ther female side.
4 harness (contact with Between ECM J2 (female) (6) or MB02 (female) (10)
GND circuit) Min. 100 kΩ
and ground
Resistance
Between ECM J2 (female) (79) or MB02 (female) (9)
Min. 100 kΩ
and ground
If failure code is still displayed after above checks, AdBlue/DEF pump may be de-
Defective AdBlue/DEF
5 fective. (In case of an internal defect, troubleshooting is impossible as an assembly.
pump
Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to AdBlue/DEF pump temperature sensor

40-560 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3562]

FAILURE CODE [CA3562] (ALL-K-AFKL-410-00-B)

Action level Failure code AdBlue/DEF LineHeater Relay 1 Voltage High Error
Failure
L01 CA3562 (Engine controller system)
Detail of fail-
High voltage error occurs in the AdBlue/DEF line heater relay 1 circuit.
ure
Action of
None in particular
controller
Phenomenon • AdBlue/DEF line stops thawing.
on machine • NOx emission increases because AdBlue/DEF injection is disabled at low temperature.
• The AdBlue/DEF line heater relay 1 operates in AdBlue/DEF supply system thawing,
warning, or implementation of AdBlue/DEF line heater relay 1 test.
• The AdBlue/DEF line heater relay 1 is built in the AdBlue/DEF heater relay.
• Troubleshooting of this failure code covers circuits from engine controller through
Related AdBlue/DEF heater relay to power supply.
information • This failure code is detected only when the AdBlue/DEF line heater relay 1 is ON.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Starting the engine at low temperature (ambient temperature of 5 °C or less) or
see “Service mode” and “Testing menu (SCR service test) - Operate” of Setting and oper-
ating machine monitor to perform “AdBlue/DEF line heater relay 1 test”.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
FORMATION ON TROUBLESHOOTING”, and check them.
Defective wiring harness 2. Start the engine in low temperature (ambient temperature of 5 °C or lower)
1
connector or perform “AdBlue/DEF Line Heater Relay 1 Test”. For details, see SET
AND OPERATE MACHINE MONITOR, “SERVICE MODE” and “METHOD
FOR SETTING WITH TESTING MENU (SCR SERVICE TEST)”.
If this failure code is cleared, the wiring harness connector is defective.
1. Turn the starting switch to OFF position.
2. Disconnect connector R53A, and connect T-adapter to female side.
Hot short circuit in wiring
2 3. Turn the starting switch to ON position (with connector R53A disconnect-
harness
ed).
Voltage Between R53A (female) (10) and (12) Max. 3 V
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn the bat-
tery disconnect switch OFF.
3. Disconnect connector R53A and R53B, and replace AdBlue/DEF heater
relay.
Defective AdBlue/DEF
3 4. Turn the battery disconnect switch ON.
heater relay
5. Start the engine in low temperature (ambient temperature of 5 °C or below)
or see “SERVICE MODE” of “SETTING AND OPERATION OF MACHINE
MONITOR”, and “METHOD FOR SETTING WITH TESTING MENU (SCR
SERVICE TEST)” to perform “AdBlue/DEF Line Heater Relay 1 Test”.
If this failure code is cleared, the original AdBlue/DEF heater relay is defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-561
FAILURE CODE [CA3562] 40 TROUBLESHOOTING

Circuit diagram related to AdBlue/DEF line heater

40-562 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3563]

FAILURE CODE [CA3563] (ALL-K-AFKL-410-10-B)

Action level Failure code AdBlue/DEF LineHeater Relay 1 Voltage Low Error
Failure
L01 CA3563 (Engine controller system)
Detail of fail-
Low voltage error occurs in the AdBlue/DEF line heater relay 1 circuit.
ure
Action of
Advances to Inducement strategy.
controller
• AdBlue/DEF line stops thawing.
Phenomenon
• NOx emission increases because AdBlue/DEF injection is disabled at low temperature.
on machine
• Engine power deration according to inducement strategy.
• This failure code is displayed if connector of AdBlue/DEF heater relay is removed while
the AdBlue/DEF line heater relay 1 is OFF.
• The AdBlue/DEF line heater relay 1 operates in AdBlue/DEF supply system thawing,
warning, or implementation of AdBlue/DEF line heater relay 1 test.
Related • The AdBlue/DEF line heater relay 1 is built in the AdBlue/DEF heater relay.
information • Troubleshooting of this failure code covers circuits from engine controller through
AdBlue/DEF heater relay to power supply.
• This failure code is detected only when the AdBlue/DEF line heater relay 1 is OFF.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
FORMATION ON TROUBLESHOOTING”, and check them.
Defective wiring harness 2. Start the engine in low temperature (ambient temperature of 5 °C or lower)
1
connector or perform “AdBlue/DEF Line Heater Relay 1 Test”. For details, see SET
AND OPERATE MACHINE MONITOR, “SERVICE MODE” and “METHOD
FOR SETTING WITH TESTING MENU (SCR SERVICE TEST)”.
If this failure code is cleared, the wiring harness connector is defective.
Check if fuse No. 4 in fuse box F02 is blown.
Defective fuse No. 4 in
2 REMARK
fuse box F02
If blown, perform troubleshooting for ground fault in wiring harness.
1. Turn the starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
Open circuit in wiring har- 3. Disconnect connector R53B, and connect T-adapter to female side.
3 ness (sensor relay power
4. Turn the battery disconnect switch to ON position.
supply side)
5. Turn the starting switch to ON position.
Voltage Between ground and R53B (female) (1) or (2) Min. 22 V
If failure code is still displayed after above checks, this check is not required.
1. Starting switch: OFF
Open circuit in wiring har- 2. Turn the battery disconnect switch to OFF position.
4 ness (line heater relay
drive signal side) 3. Disconnect connectors ECM J2 and R53A, and connect T-adapters to
each female side.
Resistance Between ECM J2 (female) (3) and R53A (female) (10) Max. 10 Ω

HB365LC-3 40-563
FAILURE CODE [CA3563] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Starting switch: OFF
2. Turn the battery disconnect switch to OFF position.
Ground fault in wiring
3. Disconnect connectors ECM J2 and R53A, and connect T-adapter to ei-
5 harness (contact with
ground circuit) ther female side.
Between ground and ECM J2 (female) (3) or R53A (fe-
Resistance Min. 100 kΩ
male) (10)
1. Starting switch: OFF
2. Turn the battery disconnect switch to OFF position.
Short circuit in wiring har- 3. Disconnect connectors ECM J2 and R53A, and connect T-adapter to fe-
6
ness male side of ECM J2.
Between ECM J2 (female) (3) and each pin other than No continui-
Continuity
pin (3) ty
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn the bat-
tery disconnect switch OFF.
Defective AdBlue/DEF 3. Disconnect connector R53A and R53B, and replace AdBlue/DEF heater
7 relay.
heater relay
4. Turn the battery disconnect switch ON.
5. Turn starting switch to ON position.
If this failure code is cleared, the original AdBlue/DEF heater relay is defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
8
ler an internal defect, troubleshooting cannot be performed.)

40-564 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3563]

Circuit diagram related to AdBlue/DEF line heater

HB365LC-3 40-565
FAILURE CODE [CA3567] 40 TROUBLESHOOTING

FAILURE CODE [CA3567] (ALL-K-AFJ1-410-00-B)

Action level Failure code AdBlue/DEF injector open circuit error or short circuit error
Failure
L01 CA3567 (Engine controller system)
Detail of fail-
Short circuit or open circuit is detected in AdBlue/DEF injector circuit.
ure
• Stops driving AdBlue/DEF pump.
Action of
• Stops AdBlue/DEF injection.
controller
• Inducement strategy is activated.
Phenomenon • NOx emission increases because AdBlue/DEF injection is disabled.
on machine • Engine output is reduced based on Inducement strategy.
k AdBlue/DEF injector part is heated to 400 °C or higher. Be careful not to get burn injury.
• This failure code is displayed if connector is disconnected when stopping the AdBlue/DEF
injector.
• This failure code is displayed when both ends of the connector between (+) and (-) short-
circuit in activating the AdBlue/DEF injector.
• Since the voltage between female side terminals is 20 V or more when AdBlue/DEF injec-
tor connector is disconnected and starting switch is turned to ON position, check of hot
short circuit in wiring harness of plus side line is not available.
• The AdBlue/DEF injector is activated at the time of AdBlue/DEF injection or AdBlue/DEF
purge.
• After repairing, turn the starting switch from OFF to ON position, inject AdBlue/DEF, and
this failure code is cleared.
• The AdBlue/DEF pump stops under the following 3 conditions:
1. Outside air temperature -24 °C or lower
2. AdBlue/DEF thawing in progress
3. When the failure code that the controller activates to stop the AdBlue/DEF pump or to
prohibit the AdBlue/DEF injection is displayed.
Related If the AdBlue/DEF injector cannot be driven due to any of the above-mentioned functions,
information clear the failure code from the monitor after investigating the cause and make sure that it
is not displayed when troubleshooting is possible (when AdBlue/DEF injection is activat-
ed).
• Because female connector alone is provided in “Socket” for troubleshooting for this injec-
tor, socket cannot be connected to female connector on wiring harness side of injector,
and check for wire breakage cannot be performed (T-adapter is not provided).
• On Pre-defined Monitoring screen, AdBlue/DEF pump diagnosis is used. (The numbers
below denote monitoring codes).
• Pre-defined Monitoring (18/28) AdBlue/DEF pump
1. 19120 AdBlue/DEF Injection Quantity
2. 19108 AdBlue/DEF Pump Pressure
3. 19109 AdBlue/DEF Pump Pressure Sensor Voltage
4. 19304 AdBlue/DEF Pump State
5. 19136 AdBlue/DEF Pump Temperature
6. 19114 AdBlue/DEF Reverting Valve Cmd
NOTICE
This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. After in-
vestigating the cause of the problem and completing the repair, perform “Loaded Diagnos-
tics Operation To Clear Failure Code” to make sure the failure code is cleared. (This failure
code is not cleared by simply turning the starting switch to ON position.)

40-566 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3567]

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equipment” in
“CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
Defective wiring harness TROUBLESHOOTING”, and check it.
1
connector 2. Perform “Loaded Diagnostics Operation To Clear Failure Code”.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
Defective AdBlue/DEF in- 2. Disconnect connector MB03 and connect socket to male side.
2
jector
Between MB03 (male) (1) 11.4 to
Resistance 20 °C
and (2) 12.6 Ω
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J2, and connect T-adapter to female side.
Open or short circuit in REMARK
3
wiring harness
The resistance is the same as AdBlue/DEF injector.
Between ECM J2 (female) 11.4 to
Resistance 20 °C
(77) and (53) 12.6 Ω
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J2 and MB03, and connect T-adapter to fe-
Ground fault in wiring
4 harness (contact with male side of connector ECM J2.
ground circuit) Between ECM J2 (female) (77) and ground Min. 100 kΩ
Resistance
Between ECM J2 (female) (53) and ground Min. 100 kΩ
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J2 and MB03, and connect T-adapter to fe-
Short circuit in wiring har- male side of connector ECM J2.
5
ness
No continui-
Between ECM J2 (female) (77) and each pin other
Continuity ty (no
than (77)
sound)
1. Turn starting switch to OFF position.
2. Disconnect connector MB03.
Hot short circuit in wiring
6 harness (hot short circuit 3. Insert T-adapter into connector ECM J2.
in negative line) 4. Turn starting switch to ON position (with injector disconnected).
Voltage Between ECM J2 (53) and ground Max. 3 V
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Clear Failure Code

Check if the repair has been completed with the following procedure:
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn starting switch to ON position.
3. Start engine.
4. Check if AdBlue/DEF pump pressure is around 900 kPa after running the engine at low idle speed (with no
load) for 2 minutes.
5. Turn the starting switch to OFF position, and shut down the engine controller.
6. Turn starting switch to ON position.

HB365LC-3 40-567
FAILURE CODE [CA3567] 40 TROUBLESHOOTING

REMARK
If this failure code is cleared at this point, repair is completed, but if not, return to troubleshooting.
Circuit diagram related to AdBlue/DEF injector

40-568 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3568]

FAILURE CODE [CA3568] (ALL-K-AFJ1-410-10-B)

Action level Failure code AdBlue/DEF injector malfunction

Failure
L01 CA3568 (Engine controller system)
Detail of fail- The AdBlue/DEF injector or AdBlue/DEF pressure hose is clogged or the AdBlue/DEF injector noz-
ure zle is sticking open.
Action of • Inducement strategy is activated.
controller • Stops AdBlue/DEF pump in the case of the AdBlue/DEF injector opening stick.
Phenomenon • NOx emission increases because AdBlue/DEF injection is disabled.
on machine • Engine output is reduced based on Inducement strategy.

HB365LC-3 40-569
FAILURE CODE [CA3568] 40 TROUBLESHOOTING

k AdBlue/DEF injector part is heated to 400 °C or higher. Be careful not to get burn injury.
• Engine controller does not display this failure code while AdBlue/DEF supply system is un-
der thawing control. (It cannot judge because AdBlue/DEF injection is disabled.)
• Start the engine, wait for 3 minutes, and then check that the number showing 4 conditions
below is other than 1 (Thawing). (You cannot troubleshoot this failure until thawing is com-
pleted.)
• The state of each heater is 1: Thawing control, 2: Warming, 3 or 0: OFF.
On the monitoring code screen, input following number directly to check the value.
19305 AdBlue/DEF Tank Heating State
19306 AdBlue/DEF Line Heater 1 State
19307 AdBlue/DEF Line Heater 2 State
19309 AdBlue/DEF Pump Heater State
• On Pre-defined Monitoring screen, AdBlue/DEF injector diagnosis, AdBlue/DEF pump di-
agnosis, and AdBlue/DEF level, and AdBlue/DEF quality sensor diagnosis are used. (The
numbers below denote monitoring codes).
• Pre-defined Monitoring (17/28) AdBlue/DEF injector
1. 47200 KDPF 1 Outlet Temperature
2. 19304 AdBlue/DEF Pump State
3. 19120 AdBlue/DEF Injection Quantity
Related 4. 19205 SCR NH3 Concentration Corrected
information 5. 19202 Turbo Outlet NOx Corrected
6. 19209 SCR Outlet NOx Corrected
• Pre-defined Monitoring (18/28) AdBlue/DEF pump
1. 19120 AdBlue/DEF Injection Quantity
2. 19108 AdBlue/DEF Pump Pressure
3. 19109 AdBlue/DEF Pump Pressure Sensor Voltage
4. 19304 AdBlue/DEF Pump State
5. 19136 AdBlue/DEF Pump Temperature
6. 19114 AdBlue/DEF Reverting Valve Cmd
• Pre-defined Monitoring (20/28) AdBlue/DEF level, quality sensor
1. 19100 AdBlue/DEF Concentration
2. 19110 AdBlue/DEF Level
3. 19111 AdBlue/DEF Level Corrected
4. 19115 AdBlue/DEF Temperature in Tank
5. 19400 Ambient Temperature
6. 19305 AdBlue/DEF Tank Heating State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correction”.
After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to make sure the failure code is cleared.
(Even if this failure code is not displayed with starting switch in ON position, completion of
repair cannot be determined unless exhaust temperature becomes high.)

No. Cause Procedure, measuring location, criteria and remarks

Defective AdBlue/DEF If failure code [CA3558] or [CA3559] or [CA3571] or [CA3572] is displayed on the
1
pump system abnormality record screen, perform troubleshooting these first.
Defective AdBlue/DEF in- If failure code [CA3567] is displayed on the abnormality record screen, perform
2
jector system troubleshooting these first.
Defective AdBlue/DEF Perform troubleshooting for failure code [CA3713] (excluding replacement of en-
3
line heater circuit gine controller).

40-570 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3568]

No. Cause Procedure, measuring location, criteria and remarks

See “TESTING AND ADJUSTING”, “DIAGNOSTIC TESTS MENU” and “METHOD
FOR SETTING WITH TESTING MENU (SCR SERVICE TEST)” in “SETTING AND
OPERATION OF MACHINE MONITOR” to perform “AdBlue/DEF Injector Rate
Test”.
Case 1: AdBlue/DEF injection stops
The AdBlue/DEF injector or the AdBlue/DEF pressure hose may be clogged. Pro-
ceed to cause 4 to determine the cause of the failure.
Failure of the
4 Case 2: AdBlue/DEF injection continues for more than 2 seconds without stoppage
AdBlue/DEF injector
1. The AdBlue/DEF injector is stuck open. Replace with a new one.
2. To remove the accumulated deposits of AdBlue/DEF in SCR, see “SET-
TING AND OPERATION OF MACHINE MONITOR” of “SERVICE MODE”,
and “METHOD FOR SETTING WITH TESTING MENU (SCR SERVICE
TEST)” to perform “Active Regeneration for Service” for 3 times (Refer-
ence: Approximately 2 hours is required in total (40 minutes per opera-
tion))
1. Prepare a container at the injector to receive drained AdBlue/DEF.
2. Remove the hose at AdBlue/DEF injector to allow AdBlue/DEF to drain.
3. See “TESTING AND ADJUSTING”, “SERVICE MODE” of “SETTING AND OP-
ERATION OF MACHINE MONITOR”, “METHOD FOR SETTING WITH TEST-
ING MENU (SCR SERVICE TEST)” to perform an “AdBlue/DEF Pump Pres-
sure Up Test”.
4. If AdBlue/DEF flows out from the AdBlue/DEF pressure hose while the AdBl-
Clogged AdBlue/DEF ue/DEF pump pressure does not reach 900 kPa, there is no clogging in the
5
pressure hose AdBlue/DEF pressure hose.
5. The AdBlue/DEF injector is clogged. Replace it.
6. If the AdBlue/DEF pump pressure stays at 900 kPa, there is a clogging in the
AdBlue/DEF pressure hose. Clean or replace the AdBlue/DEF hose.
REMARK
Failure code [CA1682] may be displayed if the pressure does not rise within 3
minutes while performing the “AdBlue/DEF Pump Pressure Up Test”.
If failure code is still displayed after above checks, the AdBlue/DEF injector may
Clogged AdBlue/DEF in-
have been temporarily clogged but is now normal.
6 jector
Perform “Loaded Diagnostics Operation To Confirm Failure Correction”. If this fail-
(temporarily clogged)
ure code is cleared, repair is completed.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

Check if the repair has been completed with the following procedure.
1. When inducement strategy is activated, perform “Engine Controller Inducement Fault Clear” to clear the
output deration.
2. Turn the starting switch to OFF position, and shut down the engine controller.
3. Start the engine, and perform the warm-up operation.
4. Set the working mode to B.
5. See TESTING AND ADJUSTING, “SERVICE MODE” of “SETTING AND OPERATION OF MACHINE
MONITOR” and “METHOD FOR SETTING WITH TESTING MENU (ACTIVE REGENERATION FOR
SERVICE) ”, and perform “Active Regeneration for Service”.
6. Operate at least 10 minutes cumulatively after KDPF outlet temperature is exceeded 300 °C.

HB365LC-3 40-571
FAILURE CODE [CA3568] 40 TROUBLESHOOTING

7. Stop the service regeneration (check that the monitoring code [19108] “AdBlue/DEF pump pressure” is
around 900 kPa).
8. Turn the fuel control dial to MAX position, and run the engine at high idle with no load for 2 minutes.
9. Turn the fuel control dial to MAX position, and perform the work equipment relief operation for 3 minutes.
(At this time, if the value of ammonia concentration is not within 10 to 500 (ppm), return to troubleshooting.)
10. Repeat above steps 8 and 9 twice.
11. Run the engine at low idle for 15 minutes.
12. Perform above steps 8, 9 and 10 again.
13. If this failure code is not displayed, and active regeneration is not started, repair work is completed.
REMARK
• If this failure code is displayed or active regeneration is started, return to troubleshooting.
• If active regeneration is started during "Loaded Diagnostics Operation To Confirm Failure Correction", restart
troubleshooting after shutting down the engine controller.
• If active regeneration does not stop, press the regeneration disable button to stop active regeneration and
then restart troubleshooting.

40-572 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3571]

FAILURE CODE [CA3571] (ALL-K-AFH1-410-50-B)

Action level Failure code AdBlue/DEF Pump Pressure Sensor High Error
Failure
L01 CA3571 (Engine controller system)
Detail of fail-
High voltage error is detected in signal circuit of AdBlue/DEF pump pressure sensor.
ure
Operates at fixed value (1300 kPa) of AdBlue/DEF pump pressure.
Action of AdBlue/DEF pump stop
controller AdBlue/DEF purging stops
Advances to Inducement strategy.
• NOx emission increases because AdBlue/DEF injection is disabled due to AdBlue/DEF
pump stop.
Phenomenon
• Because AdBlue/DEF purge is impossible, AdBlue/DEF in AdBlue/DEF line may be frozen
on machine at low temperature.
• Engine power deration according to inducement strategy.
• AdBlue/DEF pump pressure sensor is built in the AdBlue/DEF pump.

Related • If AdBlue/DEF pump pressure sensor is defective, see "Disassembly and assembly," “Dis-
assembly and assembly of AdBlue/DEF pump” to change the AdBlue/DEF itself.
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of the failure code
Defective wiring harness “RELATED INFORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
Defective power supply If failure code [CA1695] or [CA1696] is also displayed, perform troubleshooting
2 system of AdBlue/DEF these first.
pump pressure sensor
1. Turn starting switch to OFF position.
2. Disconnect connector MB02.
Defective AdBlue/DEF
3 3. Turn starting switch to ON position.
pressure sensor
If the displayed failure code changes from [CA3571] to [CA3572], the AdBlue/DEF
pump pressure sensor is defective.
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors ECM J2 and MB02 and connect T-adapters to
ness (wire breakage or each female side.
4
defective contact of con-
nector) Open circuit in GND line
Resistance Between ECM J2 (female) (32) and MB02 (female) (4) Max. 10 Ω
1. Turn starting switch to OFF position.
Short circuit in wiring har- 2. Disconnect connectors ECM J2 and MB02, and connect T-adapter to fe-
5
ness male side of ECM J2.
Resistance Between ECM J2 (female) (16) and (8) Min. 100 kΩ

HB365LC-3 40-573
FAILURE CODE [CA3571] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector MB02, and connect T-adapter to female side or in-
Hot short circuit in wiring sert T-adapter to connector ECM J2.
6
harness 3. Turn starting switch to ON position.
Between MB02 (female) (3) and (4), or between ECM
Voltage Max. 1 V
J2 (16) and (32)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to AdBlue/DEF pump pressure sensor

40-574 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3572]

FAILURE CODE [CA3572] (ALL-K-AFH1-410-60-B)

Action level Failure code AdBlue/DEF Pump Pressure Sensor Low Error
Failure
L01 CA3572 (Engine controller system)
Detail of fail-
Low voltage error is detected in signal circuit of AdBlue/DEF pump pressure sensor.
ure
Operates at fixed value (-100 kPa) of AdBlue/DEF pump pressure.
Action of AdBlue/DEF pump stop
controller AdBlue/DEF purging stops
Advances to Inducement strategy.
• NOx emission increases because AdBlue/DEF injection is disabled due to AdBlue/DEF
pump stop.
Phenomenon
• Because AdBlue/DEF purge is impossible, AdBlue/DEF in AdBlue/DEF line may be frozen
on machine at low temperature.
• Engine power deration according to inducement strategy.
• This failure code is displayed when AdBlue/DEF pump connector is disconnected.
• AdBlue/DEF pump pressure sensor is built in the AdBlue/DEF pump.
Related • If AdBlue/DEF pump pressure sensor is defective, see "Disassembly and assembly," “Dis-
information assembly and assembly of AdBlue/DEF pump” to change the AdBlue/DEF itself.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of the failure code
Defective wiring harness “RELATED INFORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
If failure code [CA1695] or [CA1696] is also displayed, perform troubleshooting
these first.
1. Turn starting switch to OFF position.
Defective power supply
2 system of AdBlue/DEF 2. Disconnect connector MB02, and connect T-adapter to female side.
pump pressure sensor 3. Turn starting switch to ON position.
Between MB02 (female) 4.75 to
Voltage Power supply input
(2) and (4) 5.25 V
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J2 and MB02 and connect T-adapters to
Open circuit in wiring har-
each female side.
ness (wire breakage or
3
defective contact of con- Between ECM J2 (female) (16) and MB02 (female) (3) Max. 10 Ω
nector)
Resistance Between ECM J2 (female) (8) and MB02 (female) (2) Max. 10 Ω
Between ECM J2 (female) (32) and MB02 (female) (4) Max. 10 Ω
1. Turn starting switch to OFF position.
Short circuit in wiring har- 2.
4 Disconnect connector ECM J2, and connect T-adapter to female side.
ness
Resistance Between ECM J2 (female) (16) and (32) Min. 100 kΩ

HB365LC-3 40-575
FAILURE CODE [CA3572] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect MB02, and connect T-adapter to female side or insert T-adapt-
5 harness (contact with er to connector ECM J2.
ground circuit)
Between MB02 (female) (3) or ECM J2 (16) and
Resistance Min. 100 kΩ
ground
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector ECM J2 or MB02.
Defective AdBlue/DEF 3. Turn starting switch to ON position.
6
pressure sensor
Between ECM J2 (female)
0.25 to
Voltage (16) and (32), or between Sensor output
4.75 V
MB02 (female) (3) and (4)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to AdBlue/DEF pump pressure sensor

40-576 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3574]

FAILURE CODE [CA3574] (ALL-K-AFH1-410-80-B)

Action level Failure code AdBlue/DEF pump pressure too low error
Failure
L01 CA3574 (Engine controller system)
Detail of fail- Due to defective AdBlue/DEF pump or clogging/breakage of AdBlue/DEF flow line from AdBlue/DEF
ure tank filter to AdBlue/DEF pump, AdBlue/DEF leakage occurs.
Action of • Increases the pressure of AdBlue/DEF pump again.
controller • Inducement strategy is activated.
Phenomenon • The AdBlue/DEF injection becomes insufficient, and then NOx emission increases.
on machine • Engine output is reduced based on Inducement strategy.
• Engine controller does not display this failure code while AdBlue/DEF supply system is un-
der thawing control. (It cannot judge because AdBlue/DEF injection is disabled.)
• Start the engine, wait for 3 minutes, and then check that the number showing 4 conditions
below is other than 1 (Thawing). (You cannot troubleshoot this failure until thawing is com-
pleted.)
• The state of each heater is 1: Thawing control, 2: Warming, 3 or 0: OFF. (On the monitor-
ing code screen, input the number directly to check the value.)
19305 AdBlue/DEF Tank Heating State
19306 AdBlue/DEF Line Heater 1 State
19307 AdBlue/DEF Line Heater 2 State
19309 AdBlue/DEF Pump Heater State
• If “AdBlue/DEF pump pressure” rises to around 900 kPa on “Pre-defined Monitoring”
Related screen of the AdBlue/DEF pump, this failure code is not displayed.
information • On “Pre-defined Monitoring” screen, AdBlue/DEF pump diagnosis is used. (The numbers
below denote monitoring codes).
• Pre-defined Monitoring (18/28) AdBlue/DEF pump
1. 19120 AdBlue/DEF Injection Quantity
2. 19108 AdBlue/DEF Pump Pressure
3. 19109 AdBlue/DEF Pump Pressure Sensor Voltage
4. 19304 AdBlue/DEF Pump State
5. 19136 AdBlue/DEF Pump Temperature
6. 19114 AdBlue/DEF Reverting Valve Cmd
NOTICE
This failure code requires“ Loaded Diagnostics Operation To Clear Failure Code”. After in-
vestigating the cause of the problem and completing the repair, perform “Loaded Diagnos-
tics Operation To Clear Failure Code” to make sure the failure code is cleared. (This failure
code is not cleared by simply turning the starting switch to ON position.)

No. Cause Procedure, measuring location, criteria and remarks

Defective AdBlue/DEF If failure code [CA3558] or [CA3559] or [CA3571] or [CA3572] is displayed on the
1
pump system abnormality record screen, perform troubleshooting these first.
Open circuit or short cir- If failure code [CA3713] or [CA5115] is displayed on the abnormality record screen,
2 cuit in AdBlue/DEF line perform troubleshooting these first.
heater 1
Defective AdBlue/DEF If failure code [CA2976] is also displayed, perform checks on causes 2 and after in
3 pump temperature sen- troubleshooting for this failure code.
sor system
Defective AdBlue/DEF If failure code [CA1669] or [CA3868] or [CA4732] or [CA4739] or [CA4769] is dis-
4
level sensor system played, perform troubleshooting these first.

HB365LC-3 40-577
FAILURE CODE [CA3574] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If failure code [CA1673] or [CA3497] or [CA3498] or [CA3547] is displayed, trouble-
shoot for those codes first.
5 Low AdBlue/DEF level
If the level is low, replenish AdBlue/DEF until it can be seen in the sight gauge, and
then “Loaded Diagnostics Operation To Clear Failure Code”.
If crystallized AdBlue/DEF is adhered to the surrounding of hose, tank, pump, or
engine compartment, it shows AdBlue/DEF may be leaking. Refer to “TESTING
Damaged AdBlue/DEF AND ADJUSTING”, “SETTING AND OPERATION OF MACHINE MONITOR”,
6 hose, AdBlue/DEF leak- “METHOD FOR SETTING WITH TESTING MENU (SCR SERVICE TEST)” to per-
age at connection form AdBlue/DEF Pump Pressure Up Test and find the location of the AdBlue/DEF
leak.
Replace parts as necessary.
Check the AdBlue/DEF suction hose for entry of foreign material or clogging due to
Clogged AdBlue/DEF
7 frozen AdBlue/DEF. Blow air or send AdBlue/DEF through each AdBlue/DEF hose,
suction hose
and repair or replace the hose if clogged.
Check the AdBlue/DEF tank for entry of foreign material. Check the AdBlue/DEF
Clogged AdBlue/DEF
8 tank strainer for clogging. Repair or replace the part if any abnormality is found.
tank strainer
Use AdBlue/DEF for cleaning.
1. Remove the flange from the AdBlue/DEF tank.
2. Check if a suction tube in the AdBlue/DEF tank is torn apart.
Suction tube clogged or 3. see “TESTING AND ADJUSTING”, “SETTING AND OPERATION OF MA-
9 torn apart in the CHINE MONITOR”, “SERVICE MODE”, “METHOD FOR SETTING WITH
AdBlue/DEF tank TESTING MENU (SCR SERVICE TEST)” to perform “AdBlue/DEF Pump
Pressure Up Test” to check if AdBlue/DEF is not leaking from the suction tube
in the AdBlue/DEF tank visually.
If the interval specified in the Operation and Maintenance Manual has elapsed
since the last time the AdBlue/DEF pump filter was replaced, or foreign material
Clogged AdBlue/DEF
10 was found in the check for AdBlue/DEF tank strainer, replace the AdBlue/DEF
pump filter
pump filter. (Refer to “METHOD FOR REPLACING AdBlue/DEF FILTER” in the Op-
eration and Maintenance Manual)
Defective AdBlue/DEF If the cause is not determined by above checks, replace the AdBlue/DEF pump.
11
pump
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
12
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation to Clear Failure Code

Check if the repair has been completed with the following procedure:
(Make sure this failure code is cleared after this procedure.)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start the engine.
3. Run the engine at low idle speed.
4. Check if monitoring code 19108 “AdBlue/DEF Pump Pressure” rises up 900 ± 100 kPa within 5 minutes.
REMARK
• If this failure code is cleared, repair is completed.
• In case it is not cleared, return to troubleshooting.

40-578 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3575]

FAILURE CODE [CA3575] (ALL-K-AFH1-410-90-B)

Action level Failure code AdBlue/DEF pump pressure too high error
Failure
L01 CA3575 (Engine controller system)
Detail of fail-
AdBlue/DEF injector or AdBlue/DEF pressure hose is clogged, or AdBlue/DEF pump is defective.
ure
Action of • Stops driving AdBlue/DEF pump.
controller • Inducement strategy is activated.
Phenomenon • NOx emission increases because AdBlue/DEF injection is disabled.
on machine • Engine output is reduced based on Inducement strategy.
• Engine controller does not display this failure code while AdBlue/DEF supply system is un-
der thawing control. (It cannot judge because AdBlue/DEF injection is disabled.)
• Start the engine, wait for 3 minutes, and then check that the number showing 4 conditions
below is other than 1 (Thawing). (You cannot troubleshoot this failure until thawing is com-
pleted.)
• The state of each heater is 1: Thawing control, 2: Warming, 3 or 0: OFF. (On the monitor-
ing code screen, input the number directly to check the value.)
19305 AdBlue/DEF Tank Heating State
19306 AdBlue/DEF Line Heater 1 State
19307 AdBlue/DEF Line Heater 2 State
19309 AdBlue/DEF Pump Heater State
• If “AdBlue/DEF pump pressure” rises to around 900 kPa on “Pre-defined Monitoring”
Related screen of the AdBlue/DEF pump, this failure code is not displayed.
information • On “Pre-defined Monitoring” screen, AdBlue/DEF pump diagnosis is used. (The numbers
below denote monitoring codes).
• Pre-defined Monitoring (18/28) AdBlue/DEF pump
1. 19120 AdBlue/DEF Injection Quantity
2. 19108 AdBlue/DEF Pump Pressure
3. 19109 AdBlue/DEF Pump Pressure Sensor Voltage
4. 19304 AdBlue/DEF Pump State
5. 19136 AdBlue/DEF Pump Temperature
6. 19114 AdBlue/DEF Reverting Valve Cmd
NOTICE
This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. After in-
vestigating the cause of the problem and completing the repair, perform “Loaded Diagnos-
tics Operation To Clear Failure Code” to make sure the failure code is cleared. (This failure
code is not cleared by simply turning the starting switch to ON position.)

No. Cause Procedure, measuring location, criteria and remarks

Defective AdBlue/DEF If failure code [CA3558] or [CA3559] or [CA3571] or [CA3572] is displayed on the
1
pump system abnormality record screen, perform troubleshooting these first.
Open circuit or short cir- If failure code [CA3713] or [CA5115] is displayed on the abnormality record screen,
2 cuit in AdBlue/DEF line perform troubleshooting these first.
heater 1
Check the AdBlue/DEF purging hose for entry of foreign material or clogging due to
Clogged AdBlue/DEF
3 frozen AdBlue/DEF. Blow air or send AdBlue/DEF through each AdBlue/DEF hose,
purging hose
and repair or replace the hose if clogged.
Defective AdBlue/DEF If the cause is not determined by above checks, replace the AdBlue/DEF pump.
4
pump pressure sensor

HB365LC-3 40-579
FAILURE CODE [CA3575] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation to Clear Failure Code

Check if the repair has been completed with the following procedure:
(Make sure this failure code is cleared after this procedure.)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start the engine.
3. Run the engine at low idle speed.
4. Check if monitoring code 19108 “AdBlue/DEF Pump Pressure” rises up 900 ± 100 kPa within 5 minutes.
REMARK
• If this failure code is cleared, repair is completed.
• In case it is not cleared, return to troubleshooting.

40-580 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3577]

FAILURE CODE [CA3577] (ALL-K-AFH1-410-30-B)

Action level Failure code AdBlue/DEF FCV voltage high error

Failure
L01 CA3577 (Engine controller system)
Detail of fail-
High voltage error is detected in signal circuit of FCV (valve for purge) of AdBlue/DEF pump.
ure
• AdBlue/DEF pump stop.
Action of
• AdBlue/DEF purge stop.
controller
• Advances to Inducement strategy.
Phenomenon • NOx emission increases.
on machine • The engine power deration according to inducement strategy.
• AdBlue/DEF FCV is built in the AdBlue/DEF pump.
• This failure code is displayed if MB02 connector is removed.
• AdBlue/DEF FCV operated at the time of AdBlue/DEF purge.
• AdBlue/DEF FCV operates at the end when implementing a AdBlue/DEF pump pressure
Related raise test.
information • If AdBlue/DEF FCV is defective, see “DISASSEMBLY AND ASSEMBLY”, “Disassembly
and assembly of AdBlue/DEF pump” to change the AdBlue/DEF itself.
• This failure code is detected only when the AdBlue/DEF FCV stops.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of the failure code
Defective wiring harness “RELATED INFORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
Defective AdBlue/DEF 2. Disconnect connector MB02, and connect T-adapter to male side.
2
FCV
Between MB02 (male) (11)
Resistance Temperature 23±5 °C 21.1±3 Ω
and (12)
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J2, and connect T-adapter to female side.
Open or short circuit in REMARK
3
wiring harness
The resistance value is the same as the AdBlue/DEF FCV value
Between ECM J2 (female)
Resistance Temperature 23±5 °C 21.1±3 Ω
(81) and (57)

HB365LC-3 40-581
FAILURE CODE [CA3577] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

REMARK
If failure code is still displayed after above checks on cause 3, this check is not re-
quired.
Open circuit in wiring har- 1. Turn starting switch to OFF position.
ness (wire breakage or 2. Disconnect connectors ECM J2 and MB02 and connect T-adapters to
4
defective contact of con- each female side.
nector)
Between ECM J2 (female) (81) and MB02 (female)
Max. 10 Ω
(11)
Resistance
Between ECM J2 (female) (57) and MB02 (female)
Max. 10 Ω
(12)
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector MB02, and connect T-adapter to female side.
5 harness (contact with 24
3. Turn starting switch to ON position (with the connector disconnected).
V circuit)
Voltage Between MB02 (female) (11) and (12) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J2 and MB02, and connect T-adapter to fe-
Short circuit in wiring har- male side of ECM J2.
6
ness
No continui-
Between ECM J2 (female) (81) and each pin other
Continuity ty (no
than (81)
sound)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to AdBlue/DEF FCV

40-582 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3578]

FAILURE CODE [CA3578] (ALL-K-AFH1-410-40-B)

Action level Failure code AdBlue/DEF FCV Voltage Low Error

Failure
L01 CA3578 (Engine controller system)
Detail of fail-
Low voltage error is detected in signal circuit of FCV (valve for purge) of AdBlue/DEF pump.
ure
AdBlue/DEF pump stop
Action of
AdBlue/DEF purge stop
controller
Advances to Inducement strategy.
• NOx emission increases because AdBlue/DEF injection is disabled due to AdBlue/DEF
pump stop.
Phenomenon
• Because AdBlue/DEF purge is impossible, AdBlue/DEF in AdBlue/DEF line may be frozen
on machine at low temperature.
• Engine power deration according to inducement strategy.
• AdBlue/DEF FCV is built in the AdBlue/DEF pump.
• Short circuit is detected in both ends of the connector between (+) and (-) and this failure
code is displayed when driving the AdBlue/DEF FCV.
• This failure code is cleared after implementing AdBlue/DEF FCV drive again turning the
starting switch from OFF to ON after abnormality repair.
• AdBlue/DEF FCV operated at the time of AdBlue/DEF purge.
Related
• AdBlue/DEF FCV operates at the end when implementing a AdBlue/DEF pump pressure
information
raise test.
• If AdBlue/DEF FCV is defective, see “DISASSEMBLY AND ASSEMBLY”, “Disassembly
and assembly of AdBlue/DEF pump” to change the AdBlue/DEF itself.
• This failure code is detected only when the AdBlue/DEF FCV operates.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Operating AdBlue/DEF FCV

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of the failure code
“RELATED INFORMATION ON TROUBLESHOOTING”, and check it.
Defective wiring harness 2. Turn starting switch to ON position.
1
connector 3. See “SERVICE MODE” and “METHOD FOR SETTING WITH TESTING
MENU (SCR SERVICE TEST)” of SETTING AND OPERATION OF MA-
CHINE MONITOR, and perform an AdBlue/DEF Pump Pressure Up Test.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J2, and connect T-adapter to female side.
Open or short circuit in REMARK
2
wiring harness
The resistance value is the same as the AdBlue/DEF FCV value
Between ECM J2 (female)
Resistance Temperature 23±5 °C 21.1±3 Ω
(81) and (57)

HB365LC-3 40-583
FAILURE CODE [CA3578] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors ECM J2 and MB02 and connect T-adapters to
3 harness (contact with each female side.
ground circuit) Open circuit in GND line
Resistance Between ECM J2 (female) (32) and MB02 (female) (4) Max. 10 Ω
1. Turn starting switch to OFF position.
2. Disconnect connectors ECM J2 and MB02, and connect T-adapter to fe-
Short circuit in wiring har- male side of ECM J2.
4
ness
No continui-
Between ECM J2 (female) (81) and each pin other
Continuity ty (no
than (81)
sound)
1. Turn starting switch to OFF position.
Defective AdBlue/DEF 2. Disconnect connector MB02, and connect T-adapter to male side.
5
FCV
Between MB02 (male) (11)
Resistance Temperature 23±5 °C 21.1±3 Ω
and (12)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to AdBlue/DEF FCV

40-584 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3582]

FAILURE CODE [CA3582] (ALL-K-AF00-410-20-B)

Action level Failure code SCR Catalyst Efficiency Low Error 1

Failure
- CA3582 (Engine controller system)
Detail of fail-
The SCR catalyst efficiency remains low (70 % or less).
ure
Action of • Performs clearing active regeneration (approximately one hour) of urea deposit accumula-
controller tion at failure judgment.
Phenomenon • The clearing active regeneration (approximately one hour) of urea deposit accumulation is
on machine performed automatically.
k The turbocharger outlet, KDPF, sensor fitting piping, and sensor probe are heated to
500 °Cor higher. Be careful not to get burn injury.
k SCR assembly, sensor fitting piping, and sensor probe are heated to 400 °C or high-
er. Be careful not to get burn injury.
k As for the sensor probe, be careful not to get burn injury even if the surroundings
are not hot, because sensor itself is heated.
k When removing AdBlue/DEF mixing piping or AdBlue/DEF injector, AdBlue/DEF may
leak. Be careful about adherence of AdBlue/DEF.
• When the failure state is not cleared after performing clearing active regeneration of urea
deposit accumulation, and performing failure judgment again 20 or more minutes after,
start clearing active regeneration of urea deposit accumulation again.
• If any failures occur within 20 minutes after the previous active regeneration (clearing of
soot, time management, cleaning of urea deposit accumulation), do not start active regen-
eration of urea deposit accumulation.
• When the ambient pressure is 80 kPa or less and the ambient temperature is -7 °C or low-
er, the engine controller does not troubleshoot this failure code. (Failure code is not
Related cleared even after performing machine operation for clearing the failure code.) Confirm on
information Pre-defined Monitoring screen.
• Under following condition, failure code is not cleared even after performing machine oper-
ation for clearing the failure code.
1. Active regeneration in progress
2. AdBlue/DEF injection being stopped by other failure code
• For the procedure to remove and replace AdBlue/DEF injector, see DISASSEMBLY AND
ASSEMBLY, “REMOVE AND INSTALL AdBlue/DEF INJECTOR”.
• The cause of this failure code is cleared after accumulation of urea deposit is resolved by
active regeneration. Troubleshooting is not necessary.
• This failure code is displayed for the purpose of monitoring for cause identification of the
failure codes [CA3151] and [CA3543]. It is not necessary to troubleshoot and replace parts
when this failure code is displayed alone.
• Even if cause of failure is eliminated, it takes time to detect that the cause has been elimi-
nated, so the failure code may be displayed continuously, but no action is required.
• If this failure code is displayed more than 20 times during the latest SMR 50 h, specify the
cause of failure according to following process.

HB365LC-3 40-585
FAILURE CODE [CA3582] 40 TROUBLESHOOTING

• On Pre-defined Monitoring screen, following 4 diagnoses are displayed. Engine operation

state diagnosis, environment state diagnosis, SCR catalyst, NOx sensor, ammonia sensor
diagnosis, AdBlue/DEF level, AdBlue/DEF quality sensor diagnosis (The numbers below
denote displayed monitoring codes.)
• Pre-defined Monitoring (16/28) Engine operation state
1. 01002 Engine Speed
2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
• Pre-defined Monitoring (24/28) Environment state
1. 37400 Ambient Pressure
2. 19400 Ambient Temperature
3. 18400 Intake Temperature
4. 19133 Engine Room Temperature
5. 19115 AdBlue/DEF Temperature in Tank
Related • Pre-defined Monitoring (19/28) SCR catalyst/NOX sensor/NH3 sensor
information 1. 19120 AdBlue/DEF Injection Quantity
2. 19205 SCR NH3 Concentration Corrected
3. 19202 Turbo Outlet NOx Corrected
4. 19209 SCR Outlet NOx Corrected
5. 19203 Turbo Outlet NOx Sensor State
6. 19210 SCR Outlet NOx Sensor State
• Pre-defined Monitoring (20/28) AdBlue/DEF level, quality sensor
1. 19100 AdBlue/DEF Concentration
2. 19110 AdBlue/DEF Level
3. 19111 AdBlue/DEF Level Corrected
4. 19115 AdBlue/DEF Temperature in Tank
5. 19400 Ambient Temperature
6. 19305 AdBlue/DEF Tank Heating State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. After in-
vestigating the cause of the problem and completing the repair, perform “Loaded Diagnos-
tics Operation To Clear Failure Code” to make sure the failure code is cleared. (This failure
code is not cleared by simply turning the starting switch to ON position.)

No. Cause Procedure, measuring location, criteria and remarks

Defective turbocharger If failure code [CA1885], [CA3232], [CA3649], [CA3682], [CA3718], [CA3725], or
outlet NOx sensor sys- [CA3748] is displayed, perform troubleshooting for these failure codes failure codes
tem first.
1
(Open circuit, internal de-
fect, defective sensor
heater)
Defective SCR outlet If failure code [CA1887], [CA2771], [CA3545], [CA3583], [CA3681], or [CA3717] is
NOx sensor system displayed, perform troubleshooting for these failure codes first.
2 (Open circuit, internal de-
fect, defective sensor
heater)
Defective SCR tempera- If failure code [CA3142] or [CA3143] or [CA3144] or [CA3146] or [CA3147] or
ture sensor system [CA3148] or [CA3165] or [CA3229] or [CA3231] or [CA3235] or [CA4152] or
3
(Open circuit, Internal de- [CA4159] or [CA4164] or [CA4165] or [CA4166] is displayed, perform troubleshoot-
fect) ing for these failure codes first.

40-586 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3582]

No. Cause Procedure, measuring location, criteria and remarks

Defective ammonia sen- If failure code [CA3899], [CA3911], [CA3912], [CA3932], [CA3933], [CA3934],
sor system [CA3935], [CA3936] or [CA4281] is displayed, perform troubleshooting for these
4 (Open circuit, internal de- failure codes first.
fect, defective sensor
heater)
1. If failure code [CA4658] or [CA3568] is displayed, or failure code [CA4658] or
[CA3568] is displayed on the service meter display of the abnormality record
within 2 hours, perform “Loaded Diagnostics Operation To Confirm Failure
Correction”, check if failure code [CA3151], [CA3543], or [CA3582] is dis-
played.
Clogged AdBlue/DEF in- 2.
5 If 19205 “Ammonia concentration (compensation value)” indicates a normal
jector
value (5 to 100 ppm) and the failure code is cleared, the repair is completed
(Loaded Diagnostics Operation To Confirm Failure Correction has resolved the
clogging problem and the machine has restored normal operation).
3. If the ammonia concentration indicates an abnormal value or either failure
code [CA3151], [CA3543], or [CA3582] is displayed, proceed to the next step.
1. Visually check the piping from the KDPF outlet to the SCR outlet for damage
or defective connection.
Defective mixing tube
6 2. Visually check for white crystallized AdBlue/DEF deposits on the surrounding
(exhaust gas leakage) area.
3. If defective connections or damages are found, fix or replace parts.
Defective AdBlue/DEF Perform troubleshooting for failure code [CA3713] (excluding replacement of en-
7
line heater circuit gine controller).
If crystallized AdBlue/DEF is adhered to the surrounding of hose, tank, pump, or
engine compartment, it shows AdBlue/DEF may be leaking. Refer to “TESTING
Damaged AdBlue/DEF AND ADJUSTING”, “SETTING AND OPERATION OF MACHINE MONITOR”,
8 hose, AdBlue/DEF leak- “METHOD FOR SETTING WITH TESTING MENU (SCR SERVICE TEST)” to per-
age at connection form AdBlue/DEF Pump Pressure Up Test and find the location of the AdBlue/DEF
leak.
Replace parts as necessary.
1. Check the mounting of the AdBlue/DEF quality sensor is secured and the
wiring harness connections are not loosen Repair if any abnormality is
found.
2. Turn starting switch to ON position.
3. Check if failure code [CA3866] or [CA3867] is displayed.
4. Read 19100 “AdBlue/DEF concentration” on the display and confirm that
the concentration is appropriate (29 to 36 %).
5. If failure code [CA3866] or [CA3867] is displayed and the 19100
Improper AdBlue/DEF
9 “AdBlue/DEF concentration” reading is inappropriate, drain the
quality
AdBlue /DEF tank, clean the tank, and refill with genuine AdBlue/DEF.
6. Perform “Loaded Diagnostics Operation To Confirm Failure Correction” to
check if this failure code is not cleared.
7. If the 19205 “Ammonia concentration (compensation value)” reading is
normal (5 to 100 ppm) and the failure code is not redisplayed, the repair is
completed.
8. If the ammonia concentration indicates an abnormal value or this failure
code recurs, proceed to the next step.

HB365LC-3 40-587
FAILURE CODE [CA3582] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. See “TESTING AND ADJUSTING”, “SERVICE MODE” and “METHOD FOR
SETTING WITH TESTING MENU (SCR SERVICE TEST)” of “SETTING AND
OPERATION OF MACHINE MONITOR”, and perform an “SCR Denitration Ef-
ficiency Test”.
2. If the “SCR Denitration Efficiency Test” has not been completed successfully,
proceed to cause 10.
3. If failure code [CA1694], [CA3751], or [CA3755] is displayed after the “SCR
Defective urea SCR sys- Denitration Efficiency Test”, perform troubleshooting for relevant failure code
tem first.
10 (inspection with SCR RE- 4. After the failure code in the above 3 is cleared, perform “Loaded Diagnostics
MOVAL EFFICIENCY Operation To Clear Failure Code” to check if this failure code is not cleared.
TEST)
5. If 19205 “Ammonia concentration (compensation value)” indicates a normal
value (5 to 100 ppm) and the failure code is cleared, the repair is completed.
6. If the ammonia concentration indicates an abnormal value or this failure code
is not cleared, proceed to cause 13.
7. Even if the SCR REMOVAL EFFICIENCY TEST has been completed success-
fully and any of failure code [CA1694], [CA3751], or [CA3755] is not displayed,
proceed to cause 13.
1. Refer to “TESTING AND ADJUSTING”, “SETTING AND OPERATION OF MA-
CHINE MONITOR”, “SERVICE MODE”, “METHOD FOR SETTING WITH
TESTING MENU (SCR SERVICE TEST)” to perform an “AdBlue/DEF Injection
Quantity Test” to judge the injector.
2. From the test results, confirm that the AdBlue/DEF injection amount is within
the values specified in “TESTING AND ADJUSTING”.
3. If the AdBlue/DEF injection amount is out of the range specified in “TESTING
Defective AdBlue/DEF in-
11 AND ADJUSTING”, replace the AdBlue/DEF injector.
jector
4. If the AdBlue/DEF injector has been replaced, perform the “AdBlue/DEF Injec-
tion Quantity Test” again. After confirming that the AdBlue/DEF injection
amount is within the range specified in “TESTING AND ADJUSTING”, proceed
to the next cause. (The purpose of this test for two times is to check accumu-
lated urea deposits in the AdBlue/DEF mixing tube )
5. Proceed to the next troubleshooting, even if the “AdBlue/DEF Injection Quanti-
ty Test” results were normal.
1. Check if urea deposits are accumulated in the AdBlue/DEF mixing tube and
the AdBlue/DEF injector mount.
Accumulation of urea de- 2.
If deposits are accumulated, remove the AdBlue/DEF mixing tube to remove
12 posits in AdBlue/DEF
deposits and clean the tube.
mixing tube
3. Check if urea deposits are accumulated in the SCR inlet case. If accumulated,
perform the next item.
1. If urea deposit is accumulated inside the SCR inlet case, remove the urea
Accumulated urea de- deposit as much as possible.
13
posit in SCR assembly
2. Repair AdBlue/DEF mixing tube back to normal.

40-588 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3582]

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks, the intake system may be defec-
tive.
(Offset/drift due to the deteriorated and aged MAF sensor, distorted intake system,
damaged rectifier)
1. Check for a defective air intake pipe and repair or replace any damaged or
Defective air intake sys- defective rectifier, if any.
14
tem 2. Replace mass air flow (MAF) sensor.
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction” to
check if this failure code is not cleared.
4. If 19205 “Ammonia concentration (compensation value)” indicates a nor-
mal value (5 to 100 ppm) and the failure code is cleared, the repair is com-
pleted.
If failure code is still displayed after above checks, the ammonia sensor may be de-
fective.
(Offset/drift due to the deteriorated and aged ammonia sensor)
1. Replace the ammonia sensor.
2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”,
Defective ammonia sen-
15 then check if this failure code or failure code [CA3582] is displayed.
sor
3. If 19205 “Ammonia concentration (compensation value)” indicates a nor-
mal value (5 to 100 ppm) and the failure code is cleared, the repair is com-
pleted.
4. If the ammonia concentration indicates an abnormal value or this failure
code is not cleared, proceed to the next step.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
16
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Clear Failure Code

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is cleared after this procedure.)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position.
3. Start the engine.
4. Set the working mode to B.
5. Run the engine at low idle for approximately 1 minute.
6. After finishing the warm-up operation, set the swing lock switch to ON position, working mode to B, and fuel
control dial to MAX position.
7. Perform arm IN relief operation for approximately 30 seconds.
REMARK
Take care not to overheat the hydraulic oil.
8. Run the engine at high idle for 30 seconds.
9. Repeat above steps 7 and 8 up to 20 times.
10. If this failure code is cleared, repair work is completed.
In case this failure code is displayed,
1. Display the SCR temperature and ammonia concentration on the troubleshooting screen.
2. Perform operation so that the SCR temperature is kept 250 °C or higher.

HB365LC-3 40-589
FAILURE CODE [CA3582] 40 TROUBLESHOOTING

3. A normal value of ammonia concentration ranges from 5 to 100 (ppm). If 0 (ppm) is shown consistently or
100 (ppm) or more is shown, return to troubleshooting because the repair is not completed.
Checklist
Relieve the Arm IN Run the engine at high idle (with no load)
Operation
for 30 seconds for 30 seconds
SCR Temperature
Monitoring screen
ID: 19300
Value to be checked Around 250 °C
1st time
2nd time
3rd time
4th time
5th time
6th time
7th time
8th time
9th time
10th time
11th time
12th time
13th time
14th time
15th time
16th time
17th time
18th time
19th time
20th time

40-590 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3583]

FAILURE CODE [CA3583] (ALL-K-AFA0-410-50-B)

Action level Failure code SCR outlet NOx sensor heater warming up error
Failure
L01 CA3583 (Engine controller system)
Detail of fail-
Heater part of SCR outlet NOx sensor is defective (not heated or cannot keep temperature).
ure
Action of • Operates the engine at default NOx value (0 ppm).
controller • Inducement strategy is activated (EU specifications).
• AdBlue/DEF injection becomes inappropriate and the NOx emission may increase, or am-
Phenomenon
monia may be discharged.
on machine
• Engine output is reduced based on Inducement strategy (EU specifications).
k KDPF, sensor installation piping, and sensor probe are heated to 500 °C or higher.
Be careful not to get burn injury.
k SCR assembly, sensor fitting piping, and sensor probe are heated to 400 °C or high-
er. Be careful not to get burn injury.
k As for the sensor probe, be careful not to get burn injury even if the surroundings
are not hot, because sensor itself is heated.
• SCR outlet NOx sensor operates when 19302 SCR Outlet Temperature is 150 °C or higher
(19210 SCR Outlet NOx Sensor State is “1”).
• SCR outlet NOx sensor is smart sensor which communicates with engine controller with
other sensors through CAN communication.
• SCR outlet NOx sensor does not operate when SCR outlet temperature is 150 °C or lower,
and correct value is not displayed (the sensor does not operate by simply turning the start-
ing switch to ON position even when it is normal).
• On Pre-defined Monitoring screen, engine operation state diagnosis, SCR catalyst, NOx
sensor, ammonia sensor diagnosis are used.
Related • Pre-defined Monitoring (16/28) Engine operation state
1. 01002 Engine Speed
information
2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
• Pre-defined Monitoring (19/28) SCR catalyst/NOX sensor/NH3 sensor
1. 19120 AdBlue/DEF Injection Quantity
2. 19205 SCR NH3 Concentration Corrected
3. 19202 Turbo Outlet NOx Corrected
4. 19209 SCR Outlet NOx Corrected
5. 19203 Turbo Outlet NOx Sensor State
6. 19210 SCR Outlet NOx Sensor State
NOTICE
For this failure code, after investigating the cause of the problem and completing the repair,
perform “Loaded Diagnostics Operation To Confirm Failure Correction” to make sure the
failure code is cleared. (This failure code is not cleared by simply turning the starting switch
to ON position.)

No. Cause Procedure, measuring location, criteria and remarks

Defective CAN communi- If failure code [CA2771] is displayed, perform troubleshooting for [CA2771] first.
1
cation system
Defective sensor power If failure code [CA1776] or [CA1777] is displayed, perform troubleshooting for
2
supply system [CA1776] or [CA1777] first.

HB365LC-3 40-591
FAILURE CODE [CA3583] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Defective SCR outlet If failure code [CA1887] or [CA3681] or [CA3717] is displayed, perform trouble-
NOx sensor system shooting for these failure codes first.
3 (Open circuit, internal de-
fect, defective sensor
heater)
If no failure is found by preceding checks, the SCR outlet NOx sensor is defective.
1. Turn starting switch to OFF position.
2. Replace the SCR outlet NOx sensor.
Defective SCR outlet
4 3. Turn starting switch to ON position.
NOx sensor
4. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is cleared, the original sensor is defective. (In case of an internal
defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is not displayed after this procedure.)
Clear this failure code by “Engine Controller Inducement Fault Clear” before step 1. (EU specification)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start the engine.
3. Set the working mode to B.
4. Run the engine at high idle in safe condition to raise the exhaust gas temperature and SCR catalyst tem-
perature. (Keep the engine speed so that the monitoring code 19302 “SCR Outlet Temperature” becomes
150 °C or higher. Check that the monitoring code 19210 “SCR Outlet NOx Sensor State” changes from 0 to
1.)
5. Repair is completed if failure code is not displayed after 3 minutes have passed.
REMARK
If the SCR outlet NOx sensor cannot be activated (that is, 19210 “SCR Outlet NOx Sensor State” remains as 0),
return to troubleshooting.

40-592 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3596]

FAILURE CODE [CA3596] (ALL-K-AFH0-410-30-B)

Action level Failure code AdBlue/DEF pump pressure unstable error

Failure
L01 CA3596 (Engine controller system)
Detail of fail- AdBlue/DEF pump pressure sensor is defective, or each AdBlue/DEF hose is clogged, or
ure AdBlue/DEF pump is defective.
Action of
• Inducement strategy is activated.
controller
Phenomenon
• Engine output is reduced based on Inducement strategy.
on machine
• Engine controller does not display this failure code while AdBlue/DEF supply system is un-
der thawing control. (It cannot judge because AdBlue/DEF injection is disabled.)
• Start the engine, wait for 3 minutes, and then check that the number showing 4 conditions
below is other than 1 (Thawing). (You cannot troubleshoot this failure until thawing is com-
pleted.)
• The state of each heater is 1: Thawing control, 2: Warming, 3 or 0: OFF. (On the monitor-
ing code screen, input the number directly to check the value.)
• 19305 AdBlue/DEF Tank Heating State
19306 AdBlue/DEF Line Heater 1 State
19307 AdBlue/DEF Line Heater 2 State
19309 AdBlue/DEF Pump Heater State
• If “AdBlue/DEF pump pressure” rises to around 900 kPa on “Pre-defined Monitoring”
Related screen of the AdBlue/DEF pump, this failure code is not displayed.
information • On “Pre-defined Monitoring” screen, AdBlue/DEF pump is used. (The numbers below de-
note monitoring codes).
• Pre-defined Monitoring (18/28) AdBlue/DEF pump
1. 19120 AdBlue/DEF Injection Quantity
2. 19108 AdBlue/DEF Pump Pressure
3. 19109 AdBlue/DEF Pump Pressure Sensor Voltage
4. 19304 AdBlue/DEF Pump State
5. 19136 AdBlue/DEF Pump Temperature
6. 19114 AdBlue/DEF Reverting Valve Cmd
NOTICE
This failure code requires“ Loaded Diagnostics Operation To Clear Failure Code”. After in-
vestigating the cause of the problem and completing the repair, perform “Loaded Diagnos-
tics Operation To Clear Failure Code” to make sure the failure code is cleared. (This failure
code is not cleared by simply turning the starting switch to ON position.)

No. Cause Procedure, measuring location, criteria and remarks

If failure code [CA3558] or [CA3559] or [CA3571] or [CA3572] or [CA4169] or
Defective AdBlue/DEF
1 [CA4171] or [CA4249] or [CA4251] is displayed on the abnormality record screen,
pump system
perform troubleshooting these first.
AdBlue/DEF pump pres- Perform checks on causes 1 to 3 for failure code [CA3575]. (This failure code may
2
sure raise be displayed with “[CA3575] AdBlue/DEF pump pressure high error”.)
AdBlue/DEF pump pres- Perform checks on causes 1 to 10 for failure code [CA3574]. (This failure code may
3
sure drop be displayed in place of “[CA3574] AdBlue/DEF pump pressure low error”.)

HB365LC-3 40-593
FAILURE CODE [CA3596] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
FORMATION ON TROUBLESHOOTING”, and check it.
Defective wiring harness 2. Turn starting switch to ON position.
4
connector
If this failure code is cleared, wiring harness connector is defective.
NOTICE
If this failure code is displayed, perform the following checks:
1. Turn the starting switch to OFF position.
2. Disconnect the connectors ECM J2 and MB02, and connect the T-adapter
Open circuit in wiring har-
to each female side.
ness (wire breakage or
5
defective contact of con- Between ECM J2 (female) (16) and MB02 (female) (3) Max. 1 Ω
nector)
Resistance Between ECM J2 (female) (8) and MB02 (female) (2) Max. 1 Ω
Between ECM J2 (female) (32) and MB02 (female) (4) Max. 1 Ω
Defective AdBlue/DEF Check the AdBlue/DEF tank breather for clogging.
6
tank breather
Check the AdBlue/DEF purging hose for entry of foreign material or clogging due to
Clogged AdBlue/DEF
7 frozen AdBlue/DEF. Blow air or send AdBlue/DEF through each AdBlue/DEF hose,
purging hose
and repair or replace the hose if clogged.
Check the AdBlue/DEF suction hose for entry of foreign material or clogging due to
Clogged AdBlue/DEF
8 frozen AdBlue/DEF. Blow air or send AdBlue/DEF through each AdBlue/DEF hose,
suction hose
and repair or replace the hose if clogged.
1. Remove the flange from the AdBlue/DEF tank.
2. Check if a suction tube in the AdBlue/DEF tank is torn apart.
Suction tube clogged or 3. see “TESTING AND ADJUSTING”, “SETTING AND OPERATION OF MA-
9 torn apart in the CHINE MONITOR”, “SERVICE MODE”, “METHOD FOR SETTING WITH
AdBlue/DEF tank TESTING MENU (SCR SERVICE TEST)” to perform “AdBlue/DEF Pump
Pressure Up Test” to check if AdBlue/DEF is not leaking from the suction tube
in the AdBlue/DEF tank visually.
Check the AdBlue/DEF tank for entry of foreign material. Check the AdBlue/DEF
Clogged AdBlue/DEF
10 tank strainer for clogging. Repair or replace the part if any abnormality is found.
tank strainer
Use AdBlue/DEF for cleaning.
Defective AdBlue/DEF AdBlue/DEF pump pressure sensor in AdBlue/DEF pump may be defective. Re-
11
pressure sensor place the AdBlue/DEF pump.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
12
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation to Clear Failure Code

Check if the repair has been completed with the following procedure:
(Make sure this failure code is cleared after this procedure.)
1. Turn the starting switch to ON position, and start the engine.
2. Run the engine at low idle speed.
3. Check if monitoring code 19108 “AdBlue/DEF Pump Pressure” is 900 ± 100 kPa within 5 minutes after
starting the engine.
REMARK
• If this failure code is cleared, repair is completed.
• In case it is not cleared, return to troubleshooting.

40-594 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3596]

Circuit diagram related to AdBlue/DEF pump pressure sensor

HB365LC-3 40-595
FAILURE CODE [CA3649] 40 TROUBLESHOOTING

FAILURE CODE [CA3649] (ALL-K-AFM0-410-40-B)

Action level Failure code Turbo outlet NOx sensor heater warming up error
Failure
L01 CA3649 (Engine controller system)
Detail of fail-
Heater part of turbo outlet NOx sensor is defective (not heated or cannot keep temperature).
ure
Action of • Operates using the NOx value in the memory.
controller • Inducement strategy is activated (EU specifications).
• AdBlue/DEF injection becomes inappropriate and the NOx emission may increase, or am-
Phenomenon
monia may be discharged.
on machine
• Engine output is reduced based on Inducement strategy (EU specifications).
k KDPF, sensor installation piping, and sensor probe are heated to 500 °C or higher.
Be careful not to get burn injury.
k SCR assembly, sensor fitting piping, and sensor probe are heated to 400 °C or high-
er. Be careful not to get burn injury.
k As for the sensor probe, be careful not to get burn injury even if the surroundings
are not hot, because sensor itself is heated.
• Turbo outlet NOx sensor operates when 47300 KDOC inlet temperature is 150 °C or high-
er (19203 Turbo Outlet NOx Sensor State is “1”).
• Turbo outlet NOx sensor is smart sensor which communicates with engine controller with
other sensors through CAN communication.
• The turbocharger outlet NOx sensor does not operate when KDOC inlet temperature is
150 °C or lower, and correct value is not displayed (the sensor does not operate by simply
turning the starting switch to ON even when it is normal).
• On Pre-defined Monitoring screen, engine operation state diagnosis, SCR catalyst, NOx
sensor, and ammonia sensor diagnosis are used. (The numbers below denote monitoring
codes).
Related • Pre-defined Monitoring (16/28) Engine operation state
1. 01002 Engine Speed
information
2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
• Pre-defined Monitoring (19/28) SCR catalyst/NOX sensor/NH3 sensor
1. 19120 AdBlue/DEF Injection Quantity
2. 19205 SCR NH3 Concentration Corrected
3. 19202 Turbo Outlet NOx Corrected
4. 19209 SCR Outlet NOx Corrected
5. 19203 Turbo Outlet NOx Sensor State
6. 19210 SCR Outlet NOx Sensor State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correction”.
After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to make sure the failure code is cleared.
(Even if this failure code is not displayed with starting switch in ON position, completion of
repair cannot be determined unless exhaust temperature becomes high.)

No. Cause Procedure, measuring location, criteria and remarks

CAN communication sys- If failure code [CA3232] is displayed, perform troubleshooting for [CA3232] first.
1
tem error

40-596 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3649]

No. Cause Procedure, measuring location, criteria and remarks

Defective sensor power If failure code [CA1776] or [CA1777] is displayed, perform troubleshooting for
2
supply system [CA1776] or [CA1777] first.
Defective turbocharger If failure code [CA1885] or [CA3682] or [CA3718] is displayed, perform trouble-
outlet NOx sensor sys- shooting for these failure codes first.
3 tem
(internal circuit abnormal-
ity)
If failure code is still displayed after above checks, the turbocharger outlet NOx
sensor may be defective.
(Offset/drift due to sulfur-poisoned turbocharger outlet NOx sensor)
Defective turbocharger 1. Turn starting switch to OFF position.
4
outlet NOx sensor
2. NOx sensor fails, therefore, replace the turbocharger outlet NOx sensor.
3. Turn starting switch to ON position.
4. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is not displayed after this procedure.)
Clear this failure code by “Engine Controller Inducement Fault Clear” before step 1. (EU specification)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start the engine.
3. Set the working mode to B.
4. Run the engine at high idle speed in safe condition to raise the exhaust gas temperature. (Keep the engine
speed so that the monitoring code 47300 “KDOC 1 Inlet Temperature” becomes 150 °C or higher. Check
that the monitoring code 19203 “Turbo Outlet NOx Sensor State” changes from 0 to 1.)
5. Repair is completed if failure code is not displayed after 3 minutes have passed.
REMARK
If the turbocharger outlet NOx sensor cannot be activated (that is, monitoring code 19203 “Turbo Outlet NOx
Sensor State” remains as 0), return to troubleshooting.

HB365LC-3 40-597
FAILURE CODE [CA3681] 40 TROUBLESHOOTING

FAILURE CODE [CA3681] (ALL-K-AFA0-410-70-B)

Action level Failure code SCR outlet NOx sensor power voltage error
Failure
L01 CA3681 (Engine controller system)
Detail of fail- SCR outlet NOx sensor cannot detect the value due to defective power supply of SCR outlet NOx
ure sensor.
Action of • Operates the engine at default NOx value (0 ppm).
controller • Inducement strategy is activated (EU specifications).
• AdBlue/DEF injection becomes inappropriate and the NOx emission may increase, or am-
Phenomenon
monia may be discharged.
on machine
• Engine output is reduced based on Inducement strategy (EU specifications).
k KDPF, sensor installation piping, and sensor probe are heated to 500 °C or higher.
Be careful not to get burn injury.
k SCR assembly, sensor fitting piping, and sensor probe are heated to 400 °C or high-
er. Be careful not to get burn injury.
k As for the sensor probe, be careful not to get burn injury even if the surroundings
are not hot, because sensor itself is heated.
• SCR outlet NOx sensor operates when 19302 SCR Outlet Temperature is 150 °C or higher
(19210 SCR Outlet NOx Sensor State is “1”).
• SCR outlet NOx sensor is smart sensor which communicates with engine controller with
other sensors through CAN communication.
• SCR outlet NOx sensor does not operate when SCR outlet temperature is 150 °C or lower,
and correct value is not displayed (the sensor does not operate by simply turning the start-
ing switch to ON position even when it is normal).
• On Pre-defined Monitoring screen, engine operation state diagnosis, SCR catalyst, NOx
sensor, and ammonia sensor diagnosis are used. (The numbers below denote monitoring
codes).
Related • Pre-defined Monitoring (16/28) Engine operation state
1. 01002 Engine Speed
information
2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
• Pre-defined Monitoring (19/28) SCR catalyst/NOX sensor/NH3 sensor
1. 19120 AdBlue/DEF Injection Quantity
2. 19205 SCR NH3 Concentration Corrected
3. 19202 Turbo Outlet NOx Corrected
4. 19209 SCR Outlet NOx Corrected
5. 19203 Turbo Outlet NOx Sensor State
6. 19210 SCR Outlet NOx Sensor State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correction”.
After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to make sure the failure code is cleared.
(Even if this failure code is not displayed with starting switch in ON position, completion of
repair cannot be determined unless exhaust temperature becomes high.)

No. Cause Procedure, measuring location, criteria and remarks

Defective sensor power If failure code [CA1776] or [CA1777] is displayed, perform troubleshooting for
1
supply system [CA1776] or [CA1777] first.

40-598 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3681]

No. Cause Procedure, measuring location, criteria and remarks

Defective CAN communi- If failure code [CA2771] is displayed, perform troubleshooting for [CA2771] first.
2
cation system
See descriptions of wiring harness and connectors in “Electrical equipment” in
Defective wiring harness
3 “CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
connector
TROUBLESHOOTING”, and check it.
• Power line
1. Turn starting switch to OFF position.
2. Disconnect connector E36, and connect T-adapter to female side.
3. Turn starting switch to ON position.
Open cCauseircuit in wir- If no failure is found by this check, perform checks on causes 8 and after.
ing harness (wire break-
Voltage Between E36 (female) (1) and (4) Min. 22 V
4 age or defective contact
of connector) (broken If no failure is found by above results, this check is not required.
power line) 1. Turn starting switch to OFF position.
2. Disconnect connectors R52 and E36 and connect T-adapters to each fe-
male side.
Between R52 (female) (12) and E36 (female) (1) Max. 10 Ω
Resistance
Between E36 (female) (4) and ground Max. 10 Ω
1. Perform troubleshooting with starting switch at OFF position and when starting
5 Improper battery voltage engine.
Voltage Between battery (+) and (-). 20 to 30 V
1. Turn starting switch to OFF position.
6 Defective alternator 2. Start engine. (Engine speed: Medium or higher)
Voltage alternator terminal R and ground 26 to 30.5 V
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn the bat-
tery disconnect switch OFF.
Defective sensor power 3. Disconnect connector R52, and replace sensor power supply relay.
7
supply relay
4. Turn the battery disconnect switch ON.
5. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is cleared, the original sensor power supply relay is defective.
If no failure is found by preceding checks, the SCR outlet NOx sensor is defective.
1. Turn starting switch to OFF position.
2. Replace the SCR outlet NOx sensor.
Defective SCR outlet
8 3. Turn starting switch to ON position.
NOx sensor
4. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is cleared, the original sensor is defective. (In case of an internal
defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
9
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

Perform the following procedure to check that the repair is completed.
Clear this failure code by “Engine Controller Inducement Fault Clear” before step 1. (EU specification)
1. Turn the starting switch to OFF position, and shut down the engine controller.

HB365LC-3 40-599
FAILURE CODE [CA3681] 40 TROUBLESHOOTING

2. Turn the starting switch to ON position, and start the engine.

3. Set the working mode to B.
4. Run the engine at high idle speed with safe condition in order to raise the exhaust gas temperature. (Keep
the engine speed so that the monitoring code 19302 “SCR Outlet Temperature” becomes 150 °C or higher.
Check that the monitoring code 19210 “SCR Outlet NOx Sensor State” changes from 0 to 1.)
5. Repair is completed if failure code is not displayed after 3 minutes have passed.
REMARK
If the SCR outlet NOx sensor cannot be activated (that is, 19210 “SCR Outlet NOx Sensor State” remains as 0),
return to troubleshooting.

40-600 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3681]

Circuit diagram related to SCR system CAN communication

HB365LC-3 40-601
FAILURE CODE [CA3681] 40 TROUBLESHOOTING

CIRCUIT DIAGRAM (ENGINE CONTROLLER POWER SUPPLY)

40-602 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3682]

FAILURE CODE [CA3682] (ALL-K-AFM0-410-50-B)

Action level Failure code Turbo outlet NOx sensor power voltage error
Failure
L01 CA3682 (Engine controller system)
Detail of fail- Turbo outlet NOx sensor does not display the value due to defective power supply of turbo outlet
ure NOx sensor.
Action of • Operates using the NOx value in the memory.
controller • Inducement strategy is activated (EU specifications).
• AdBlue/DEF injection becomes inappropriate and the NOx emission may increase, or am-
Phenomenon
monia may be discharged.
on machine
• Engine output is reduced based on Inducement strategy (EU specifications).
k KDPF, sensor installation piping, and sensor probe are heated to 500 °C or higher.
Be careful not to get burn injury.
k SCR assembly, sensor fitting piping, and sensor probe are heated to 400 °C or high-
er. Be careful not to get burn injury.
k As for the sensor probe, be careful not to get burn injury even if the surroundings
are not hot, because sensor itself is heated.
• Turbo outlet NOx sensor operates when 47300 KDOC inlet temperature is 150 °C or high-
er (19203 Turbo Outlet NOx Sensor State is “1”).
• Turbo outlet NOx sensor is smart sensor which communicates with engine controller with
other sensors through CAN communication.
• The turbocharger outlet NOx sensor does not operate when KDOC inlet temperature is
150 °C or lower, and correct value is not displayed (the sensor does not operate by simply
turning the starting switch to ON even when it is normal).
• On “Pre-defined Monitoring” screen, engine operation state diagnosis, SCR catalyst, NOx
sensor, and ammonia sensor diagnosis are used. (The numbers below denote monitoring
codes).
Related • Pre-defined Monitoring (16/28) Engine operation state
1. 01002 Engine Speed
information
2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
• Pre-defined Monitoring (19/28) SCR catalyst/NOX sensor/NH3 sensor
1. 19120 AdBlue/DEF Injection Quantity
2. 19205 SCR NH3 Concentration Corrected
3. 19202 Turbo Outlet NOx Corrected
4. 19209 SCR Outlet NOx Corrected
5. 19203 Turbo Outlet NOx Sensor State
6. 19210 SCR Outlet NOx Sensor State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correction”.
After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to make sure the failure code is cleared.
(Even if this failure code is not displayed with starting switch in ON position, completion of
repair cannot be determined unless exhaust temperature becomes high.)

No. Cause Procedure, measuring location, criteria and remarks

Defective sensor power If failure code [CA1776] or [CA1777] is displayed, perform troubleshooting for
1
supply system [CA1776] or [CA1777] first.

HB365LC-3 40-603
FAILURE CODE [CA3682] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Defective CAN communi- If failure code [CA2771] is displayed, perform troubleshooting for [CA2771] first.
2
cation system
See descriptions of wiring harness and connectors in “Electrical equipment” in
Defective wiring harness
3 “CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
connector
TROUBLESHOOTING”, and check it.
• Power line
1. Turn starting switch to OFF position.
2. Disconnect connector E31, and connect T-adapter to female side.
3. Turn starting switch to ON position.
Open cCauseircuit in wir- If no failure is found by this check, perform checks on causes 8 and after.
ing harness (wire break-
Voltage Between E31 (female) (1) and (4) Min. 22 V
4 age or defective contact
of connector) (broken If no failure is found by above results, this check is not required.
power line) 1. Turn starting switch to OFF position.
2. Disconnect connectors R52 and E31 and connect T-adapters to each fe-
male side.
Between R52 (female) (6) and E31 (female) (1) Max. 10 Ω
Resistance
Between E31 (female) (4) and ground Max. 10 Ω
1. Perform troubleshooting with starting switch at OFF position and when starting
5 Improper battery voltage engine.
Voltage Between battery (+) and (-). 20 to 30 V
1. Turn starting switch to OFF position.
6 Defective alternator 2. Start engine. (Engine speed: Medium or higher)
Voltage alternator terminal R and ground 26 to 30.5 V
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn the bat-
tery disconnect switch OFF.
Defective sensor power 3. Disconnect connector R52, and replace sensor power supply relay.
7
supply relay
4. Turn the battery disconnect switch ON.
5. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is cleared, the original sensor power supply relay is defective.
If failure code is still displayed after above checks, the turbocharger outlet NOx
sensor may be defective.
(Offset/drift due to sulfur-poisoned turbocharger outlet NOx sensor)
Defective turbocharger 1. Turn starting switch to OFF position.
8
outlet NOx sensor
2. NOx sensor fails, therefore, replace the turbocharger outlet NOx sensor.
3. Turn starting switch to ON position.
4. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
9
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is not displayed after this procedure.)
Clear this failure code by “Engine Controller Inducement Fault Clear” before step 1. (EU specification)

40-604 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3682]

1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start the engine.
3. Set the working mode to B.
4. Run the engine at high idle speed with safe condition in order to raise the exhaust gas temperature. (Keep
the engine speed so that the monitoring code 47300 “KDOC 1 Inlet Temperature” becomes 150 °C or high-
er. Check that the monitoring code 19203 “Turbo Outlet NOx Sensor State” changes from 0 to 1.)
5. After the state in step 3., if failure code is not displayed after 3 minutes have passed with running the en-
gine at low idle speed, repair work is completed.
REMARK
If the turbocharger outlet NOx sensor cannot be activated (that is, monitoring code 19203 “Turbo Outlet NOx
Sensor State” remains as 0), return to troubleshooting.

HB365LC-3 40-605
FAILURE CODE [CA3682] 40 TROUBLESHOOTING

Circuit diagram related to SCR system CAN communication

40-606 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3682]

CIRCUIT DIAGRAM (ENGINE CONTROLLER POWER SUPPLY)

HB365LC-3 40-607
FAILURE CODE [CA3713] 40 TROUBLESHOOTING

FAILURE CODE [CA3713] (ALL-K-AFK5-410-20-B)

Action level Failure code AdBlue/DEF Line Heater 1 Voltage High Error
Failure
L01 CA3713 (Engine controller system)
Detail of fail- High voltage error is detected in signal circuit of AdBlue/DEF line heater 1 (on low-temperature
ure pressure, intake, and purge).
Action of
None in particular
controller
Phenomenon AdBlue/DEF line stops thawing.
on machine NOx emission increases because AdBlue/DEF injection is disabled at low temperature.
• The AdBlue/DEF line heater 1 operates in AdBlue/DEF supply system thawing, warning,
or implementation of AdBlue/DEF line heater relay 1 test.
• The AdBlue/DEF line heater 1 is operated by the AdBlue/DEF line heater relay 1 in the
AdBlue/DEF heater relay.
Related
• This failure code is detected only when the AdBlue/DEF line heater 1 is OFF.
information
• If the connectors of all heaters connected to the AdBlue/DEF line heater 1 are disconnect-
ed, this failure code is displayed.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective wiring harness
1
connector
Open circuit in wiring har-
ness (wire breakage or 2. Disconnect connectors ECM J2 and R53A, and connect T-adapters to
2 each female side.
defective contact of con-
nector)
Resistance
Hot short circuit in wiring
3
harness
1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
FORMATION ON TROUBLESHOOTING”, and check them.
2. Turn the starting switch to ON position.
If this failure code is not displayed, the wiring harness connector is defective.
If failure code is still displayed after above checks, this check is not required.
1. Starting switch: OFF
Between ECM J2 (female) (39) and R53A (female) (8) Max. 10 Ω
Between R53A (female) (12) and ground Max. 10 Ω
1. Turn the starting switch to OFF position.
2. Disconnect connectors ECM J2, R53A, MB04, MB05, and MB07, and then
connect T-adapter to female side.
3. Turn the starting switch to ON position.
Between ground and ECM J2 (female) (39) or R53A
3 V or less
(female) (8)
Between ground and R53A (female) (5) or MB05 (fe-
3 V or less
male) (1)
Voltage
Between ground and R53A (female) (6) or MB04 (fe-
3 V or less
male) (1)
Between ground and R53A (female) (6) or MB07 (fe-
3 V or less
male) (1)

40-608 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3713]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connectors MB04 and MB06A, and connect T-adapters to
Defective AdBlue/DEF each male side.
4
line heater
Between MB04 (male) (1) and (2) 5 to 40 Ω
Resistance
Between MB06A (male) (1) and (2) 5 to 40 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors MB04, MB05 and MB07, and connect the T-
adapter to each male side.
Hot short circuit in AdBl- 3. Turn the starting switch to ON position.
5
ue/DEF line heater
Between MB04 (male) (1) and ground Max. 3 V
Voltage Between MB05 (male) (1) and ground Max. 3 V
Between MB07 (male) (1) and ground Max. 3 V
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn the bat-
tery disconnect switch OFF.
Defective AdBlue/DEF 3. Disconnect connector R53A and R53B, and replace AdBlue/DEF heater
6 relay.
heater relay
4. Turn the battery disconnect switch ON.
5. Turn starting switch to ON position.
If this failure code is cleared, the original AdBlue/DEF heater relay is defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-609
FAILURE CODE [CA3713] 40 TROUBLESHOOTING

Circuit diagram related to AdBlue/DEF line heater

40-610 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3717]

FAILURE CODE [CA3717] (ALL-K-AFA0-410-20-B)

Action level Failure code SCR Outlet NOx Sensor Voltage Mismatch Error
Failure
L01 CA3717 (Engine controller system)
Detail of fail- The engine controller voltage setting and SCR outlet NOx sensor voltage specifications are not con-
ure sistent. (The sensor part numbers are different)
Action of • Drive at the default NOx emission value (0 ppm)
controller • Advances to Inducement strategy. (EU Specification)
• NOx emission may increase or ammonia may be exhausted because AdBlue/DEF injec-
Phenomenon
tion works inappropriately.
on machine
• Engine power deration according to inducement strategy. (EU Specification)
k The SCR assembly, sensor fitting piping, and sensor probe become hot (Min.
400 °C). Be careful not to get burned.
k Be careful not to get burned by the sensor probe as it is heated by itself even if the
Related ambient temperature is not high.
information • A sensor different from genuine spare parts may have been installed when changing this
sensor.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective CAN communi- If failure code [CA2771] is displayed, perform troubleshooting for [CA2771] first.
1
cation system
Defective sensor power If failure code [CA1776] or [CA1777] is displayed, perform troubleshooting for
2
supply system [CA1776] or [CA1777] first.
1. Turn starting switch to OFF position.
2. Check the Part No. of the NOx sensor.
Defective SCR outlet 3. Replace the SCR outlet NOx sensor.
3
NOx sensor
4. Turn starting switch to ON position.
If this failure code is cleared, the SCR outlet NOx sensor is defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-611
FAILURE CODE [CA3718] 40 TROUBLESHOOTING

FAILURE CODE [CA3718] (ALL-K-AFM0-410-30-B)

Action level Failure code Turbocharger Outlet NOx Sensor Voltage Mismatch Error
Failure
L01 CA3718 (Engine controller system)
Detail of fail- ne controller voltage setting and turbocharger outlet NOx sensor voltage specifications are not con-
ure sistent. (The sensor part numbers are different)
Action of • Operate using the NOx value in the memory.
controller • Advances to Inducement strategy (EU Specification)
Phenomenon • The AdBlue/DEF injection becomes inappropriate, NOx emission increases.
on machine • Engine power deration according to inducement strategy. (EU Specification)
k The SCR assembly, sensor fitting piping, and sensor probe become hot (Min.
400 °C). Be careful not to get burned.
k Be careful not to get burned by the sensor probe as it is heated by itself even if the
Related ambient temperature is not high.
information • A sensor different from genuine spare parts may have been installed when changing this
sensor.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

CAN communication sys- If failure code [CA3232] is displayed, perform troubleshooting for [CA3232] first.
1
tem error
Defective sensor power If failure code [CA1776] or [CA1777] is displayed, perform troubleshooting for
2
supply system [CA1776] or [CA1777] first.
1. Turn starting switch to OFF position.
2. Check the Part No. of the NOx sensor.
Defective turbocharger 3. NOx sensor fails, therefore, replace the turbocharger outlet NOx sensor.
3
outlet NOx sensor 4. Turn starting switch to ON position.
If this failure code is cleared, the original sensor is defective. (In case of an internal
defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

40-612 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3725]

FAILURE CODE [CA3725] (ALL-K-AFM0-410-60-B)

Action level Failure code Turbo outlet NOx sensor unstable error
Failure
L01 CA3725 (Engine controller system)
Detail of fail-
The turbocharger NOx sensor does not become measurable state.
ure
Action of • Operates using the NOx value in the memory.
controller • Inducement strategy is activated (EU specifications).
• AdBlue/DEF injection becomes inappropriate and the NOx emission may increase, or am-
Phenomenon
monia may be discharged.
on machine
• Engine output is reduced based on Inducement strategy (EU specifications).

HB365LC-3 40-613
FAILURE CODE [CA3725] 40 TROUBLESHOOTING

k KDPF, sensor fitting piping, and sensor probe are heated to 500 °C or higher. Be
careful not to get burn injury.
k SCR assembly, sensor fitting piping, and sensor probe are heated to 400 °C or high-
er. Be careful not to get burn injury.
k As for the sensor probe, be careful not to get burn injury even if the surroundings
are not hot, because sensor itself is heated.
• Turbo outlet NOx sensor operates when 47300 KDOC inlet temperature is 150 °C or high-
er (19203 Turbo Outlet NOx Sensor State is “1”).
• Turbo outlet NOx sensor is smart sensor which communicates with engine controller with
other sensors through CAN communication.
• The turbocharger outlet NOx sensor does not operate when KDOC inlet temperature is
150 °C or lower, and correct value is not displayed (the sensor does not operate by simply
turning the starting switch to ON even when it is normal).
• The engine controller refers to the fluctuation of KDPF differential pressure sensor and
KDPF outlet pressure sensor to judge the error of this failure code only when the exhaust
gas pressure is stable.
• KDPF differential pressure sensor and KDPF outlet pressure sensor are provided as a
unit.
• If failure code is cleared immediately after displayed, it is suspected that detection of tur-
bocharger outlet NOx sensor was unstable for a moment.
(When load is applied at low idle for a long time repeatedly, for example)
REMARK
Related
Turbocharger outlet NOx sensor is not defective, therefore it has no problems if this failure
information code does not appear repeatedly or continuously.
• On Pre-defined Monitoring screen, engine operation state diagnosis, SCR catalyst, NOx
sensor, and ammonia sensor diagnosis are used. (The numbers below denote monitoring
codes).
• Pre-defined Monitoring (16/28) Engine operation state
1. 01002 Engine Speed
2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
• Pre-defined Monitoring (19/28) SCR catalyst/NOX sensor/NH3 sensor
1. 19120 AdBlue/DEF Injection Quantity
2. 19205 SCR NH3 Concentration Corrected
3. 19202 Turbo Outlet NOx Corrected
4. 19209 SCR Outlet NOx Corrected
5. 19203 Turbo Outlet NOx Sensor State
6. 19210 SCR Outlet NOx Sensor State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correction”.
After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to make sure the failure code is cleared.
(Even if this failure code is not displayed with starting switch in ON position, completion of
repair cannot be determined unless exhaust temperature becomes high.)

No. Cause Procedure, measuring location, criteria and remarks

CAN communication sys- If failure code [CA3232] is displayed, perform troubleshooting for [CA3232] first.
1
tem error

40-614 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3725]

No. Cause Procedure, measuring location, criteria and remarks

Defective KDPF differen- If failure code [CA1879] or [CA1881] or [CA1883] is displayed, perform trouble-
2 tial pressure sensor sys- shooting for these failure codes first.
tem
Defective KDPF outlet If failure code [CA3133] or [CA3134] or [CA3135] is displayed, perform trouble-
3
pressure sensor system shooting for these failure codes first.
Defective turbocharger If failure code [CA1885], [CA3649], [CA3682], and [CA3718] is displayed, perform
4 outlet NOx sensor sys- troubleshooting for these failure codes first.
tem
Defective turbocharger Check if the turbocharger outlet NOx sensor is installed securely.
5 outlet NOx sensor instal-
lation error
If failure code is still displayed after above checks, the turbocharger outlet NOx
sensor may be defective.
(Offset/drift due to sulfur-poisoned turbocharger outlet NOx sensor)
Defective turbocharger 1. Turn starting switch to OFF position.
6
outlet NOx sensor
2. NOx sensor fails, therefore, replace the turbocharger outlet NOx sensor.
3. Turn starting switch to ON position.
4. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is not displayed after this procedure.)
Clear this failure code by “Engine Controller Inducement Fault Clear” before step 1. (EU specification)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start the engine.
3. Set the working mode to B.
4. Run the engine at high idle speed with safe condition in order to raise the exhaust gas temperature. (Keep
the engine speed so that the monitoring code 47300 “KDOC 1 Inlet Temperature” becomes 150 °C or high-
er. Check that the monitoring code 19203 “Turbo Outlet NOx Sensor State” changes from 0 to 1.)
5. After the state in step 3., if failure code is not displayed after 3 minutes have passed with running the en-
gine at low idle speed, repair work is completed.
REMARK
If the turbocharger outlet NOx sensor cannot be activated (that is, monitoring code 19203 “Turbo Outlet NOx
Sensor State” remains as 0), return to troubleshooting.

HB365LC-3 40-615
FAILURE CODE [CA3741] 40 TROUBLESHOOTING

FAILURE CODE [CA3741] (ALL-K-AE2E-410-00-B)

Action level Failure code Common Rail Pressure Valve Trip Error
Failure
L03 CA3741 (Engine controller system)
Details of
Engine controller determines that common rail pressure limiter valve opens.
failure
Action of • Lowers set value of common rail pressure.
controller • Regeneration control stops.
Phenomenon Engine power deration.
on machine Engine may not start again.
• Signal voltage from common rail pressure sensor can be checked with monitoring func-
tion. (Code: 36401 (V))
Related • Pressure sensed by common rail pressure sensor can be checked with monitoring func-
information tion. (Code: 36400 (MPa))
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Common rail pressure Perform troubleshooting for failure code [CA449].
1
limiter valve is open.

40-616 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3748]

FAILURE CODE [CA3748] (ALL-K-AFM0-410-20-B)

Action level Failure code Turbo outlet NOx sensor stuck in range error
Failure
L01 CA3748 (Engine controller system)
Detail of fail-
Operation state of engine is changing but engine outlet NOx does not change.
ure
Action of
Operates using the NOx value in the memory.
controller
Phenomenon AdBlue/DEF injection becomes inappropriate and the NOx emission may increase, or ammonia may
on machine be discharged.

k The turbo outlet part, KDPF, sensor fitting piping, and sensor probe are heated to
500 °C or higher. Be careful not to get burn injury.
k As for the sensor probe, be careful not to get burn injury even if the surroundings
are not hot, because sensor itself is heated.
• Turbo outlet NOx sensor operates when 47300 “KDOC inlet temperature” is 150 °C or
higher (19203 Turbo Outlet NOx Sensor State is “1”).
• KDPF temperature sensor consists of KDOC inlet temperature sensor, KDOC outlet tem-
perature sensor, and KDPF outlet temperature sensor. The controller of integrated sensor
communicates with the engine controller through CAN communication.
• For KDPF temperature sensor replacement, see DISASSEMBLY AND ASSEMBLY, “DIS-
ASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY”
• On “Pre-defined Monitoring” screen, engine operation state diagnosis, SCR catalyst, NOx
sensor, ammonia sensor diagnosis are used.
• Pre-defined Monitoring (16/28) Engine operation state
Related 1. 01002 Engine Speed
2. 18600 Inject Fueling Command
information 3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
• Pre-defined Monitoring (19/28) SCR catalyst/NOX sensor/NH3 sensor
1. 19120 AdBlue/DEF Injection Quantity
2. 19205 SCR NH3 Concentration Corrected
3. 19202 Turbo Outlet NOx Corrected
4. 19209 SCR Outlet NOx Corrected
5. 19203 Turbo Outlet NOx Sensor State
6. 19210 SCR Outlet NOx Sensor State
NOTICE
For this failure code, after investigating the cause of the problem and completing the repair,
perform “Loaded Diagnostics Operation To Clear Failure Code” to make sure the failure code
is cleared. (This failure code is not cleared by simply turning the starting switch to ON posi-
tion.)

No. Cause Procedure, measuring location, criteria and remarks

Defective turbocharger If failure code [CA1885], [CA3232], [CA3649], [CA3682], or [CA3718] is displayed,
outlet NOx sensor sys- perform troubleshooting for these failure codes first.
tem
1
(Open circuit, internal de-
fect, defective sensor
heater)

HB365LC-3 40-617
FAILURE CODE [CA3748] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Check if the turbocharger outlet NOx sensor is disconnected from the exhaust
Turbocharger outlet NOx
2 pipe or loose.
sensor installation error
3. After repair is completed, perform “Loaded Diagnostics Operation To Clear
Failure Code”.
1. If failure code [CA3313], [CA3314] or [CA3315] is displayed, perform trou-
bleshooting for [CA3313], [CA3314] or [CA3315] first.
Defective KDOC inlet 2. If the KDOC inlet temperature does not rise up to 150 °C during “Loaded
3 temperature sensor sys- Diagnostics Operation To Clear Failure Code”, replace the KDPF tempera-
tem ture sensor.
3. After repair is completed, perform “Loaded Diagnostics Operation To Clear
Failure Code”.
If failure code is still displayed after above checks, the turbocharger outlet NOx
Defective turbocharger sensor may be defective.
outlet NOx sensor 1. Turn starting switch to OFF position.
4
(Clogged sensor due to 2. NOx sensor fails, therefore, replace the turbocharger outlet NOx sensor.
soot, etc.)
3. Perform “Loaded Diagnostics Operation To Clear Failure Code”.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Clear Failure Code

Perform the following procedure to check that the repair is completed.
(Make sure that this failure code is cleared after this procedure.)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Start the engine.
3. Set the working mode to B.
4. Run the engine at high idle speed with safe condition to raise the exhaust gas temperature. (Keep the en-
gine speed so that monitoring code 47300 “KDOC Inlet Temperature” becomes 150 °C or higher.
5. After the state in step 3, check that the turbocharger outlet NOx sensor can be activated within 3 minutes.
(OK as far as 19203 “Turbo Outlet NOx Sensor State” changes from “0” to “1”)
6. After checking step 4, set the swing lock switch to ON position, working mode to B, and fuel control dial to
MAX position.
7. Perform arm IN relief operation for approximately 30 seconds.
REMARK
Take care not to overheat the hydraulic oil.
8. Run the engine at high idle for 30 seconds.
9. Repeat above steps 7 and 8 up to 20 times until this failure code is cleared.
10. If this failure code is cleared, repair work is completed.
REMARK
If this failure code is not cleared, return to troubleshooting.
Checklist
Relieve the Arm IN Run the engine at high idle (with no load)
Operation
for 30 seconds for 30 seconds
1st time
2nd time

40-618 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3748]

Relieve the Arm IN Run the engine at high idle (with no load)
Operation
for 30 seconds for 30 seconds
3rd time
4th time
5th time
6th time
7th time
8th time
9th time
10th time
11th time
12th time
13th time
14th time
15th time
16th time
17th time
18th time
19th time
20th time

HB365LC-3 40-619
FAILURE CODE [CA3751] 40 TROUBLESHOOTING

FAILURE CODE [CA3751] (ALL-K-AF10-410-00-B)

Action level Failure code SCR Catalyst Degradation Error

Failure
L03 CA3751 (Engine controller system)
Detail of fail-
Denitration efficiency does not increase though the AdBlue/DEF injection amount is sufficient.
ure
Action of
None in particular
controller
Phenomenon It is possible that the NOx emission increases, or ammonia is discharged due to insufficient denitra-
on machine tion efficiency.

k The temperature of aftertreatment devices such as SCR assembly and AdBlue/DEF

mixing piping becomes high (Min. 400 °C). Be careful not to get burned.
k Be careful of the attachment of AdBlue/DEF because AdBlue/DEF leaks when remov-
ing AdBlue/DEF mixing piping or AdBlue/DEF injector.
REMARK
• This failure code occurs only in the “SCR Denitration Efficiency Test” implemented to locate
Related the failure points when a failure code such as [CA3151], [CA3543], and [CA3582] is dis-
information played.
• The SCR catalyst cannot be replaced alone. (SCR assembly needs to be changed)
NOTICE
• For this failure code, after investigating the cause of the problem and completing the
repair, perform “Loaded Diagnostics Operation To Clear Failure Code” to make sure
the failure code is cleared. (This failure code is not cleared by only turning ON the
starting switch.)

No. Cause Procedure, measuring location, criteria and remarks

Defective SCR catalyst 1. Deterioration, dissolution, or damage of SCR catalyst can be suspected.
1 (Deterioration, dissolu- Replace the SCR assembly.
tion, damage) 2. Perform “Loaded Diagnostics Operation To Clear failure Code”.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
2
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation to Clear Failure Code

Check if the repair has been completed with the following procedure:
(Make sure this failure code is cleared after this procedure.)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start engine.
3. Run the engine at low idle speed for approximately 1 minute.
4. See “TESTING AND ADJUSTING”, “Service mode” and “Test menu (SCR Service Test)” in “SETTING AND
OPERATION OF MACHINE MONITOR” to perform “SCR removal efficiency test” (maximum duration of the
removal efficiency: 1.5 h).
5. The test condition on the monitor changes from “0” to “10”, then to “20”. (“14” may be shown during few
minutes due to temperature transition)
6. When the test is completed after the test condition on the monitor shows “20”, stop the engine and shut
down the engine controller (wait for a few minutes after the shutdown, then the starting switch to OFF posi-
tion).
7. Turn the starting switch to ON position again to check if this failure code is cleared. If the failure code is
cleared, repair work is completed.

40-620 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3751]

REMARK
• If this failure code is cleared, repair is completed.
• In case it is not cleared, return to troubleshooting.

HB365LC-3 40-621
FAILURE CODE [CA3755] 40 TROUBLESHOOTING

FAILURE CODE [CA3755] (ALL-K-AF00-410-10-B)

Action level Failure code AdBlue/DEF Dosing Performance Degradation Error

Failure
L03 CA3755 (Engine controller system)
Detail of fail-
Actual AdBlue/DEF dosing performance is less than that which is indicated.
ure
Action of
None in particular
controller
Phenomenon
The AdBlue/DEF injection becomes inappropriate, and then NOx emission increases.
on machine
k The AdBlue/DEF mixing piping, SCR assembly, sensor fitting piping, and sensor
probe become hot (Min. 400 °C). Be careful not to get burned.
k Be careful that AdBlue/DEF leaks when removing AdBlue/DEF mixing piping or AdBl-
ue/DEF injector.
• This failure code occurs only in the “SCR Denitration Efficiency Test”(denitration efficiency
test time is up to 1.5 hours) implemented to locate the failure points when a failure code
Related such as [CA3151], [CA3543], and [CA3582] is displayed.
information • For the procedure to remove and change the AdBlue/DEF injector, see “Disassembly and
assembly of AdBlue/DEF injector”.
NOTICE
For this failure code, after investigating the cause of the problem and completing the re-
pair, perform “Loaded Diagnostics Operation To Clear Failure Code” to make sure the
failure code is cleared. (This failure code is not cleared by turning ON the starting
switch.)

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Remove the AdBlue/DEF injector.
3. Refer to “Testing and adjusting”, “SETTING AND OPERATION OF MA-
Defective AdBlue/DEF in-
1 CHINE MONITOR”, “Service mode”, “Operation method of testing menu
jector
(SCR Service Test)” to perform an “AdBlue/DEF injector injection amount
test” to judge the injector.
4. Perform “Loaded Diagnostics Operation To Clear Failure Code”.
1. Remove the hose at AdBlue/DEF injector to allow AdBlue/DEF to drain.
2. Prepare a container at the injector to receive drained AdBlue/DEF.
3. See Testing and adjusting, “service modes” of “setting and operating ma-
chine monitor”, “operating method of testing menu (SCR service test)” to
Clogged AdBlue/DEF perform an “AdBlue/DEF pump pressure rising test”.
2
supply line 4. If the AdBlue/DEF pump pressure stays at 900 kPa, there is a clogging in
the AdBlue/DEF pressure hose. Clean or replace the AdBlue/DEF hose.
REMARK
Failure code [CA1682] may be displayed if the pressure does not rise within 3
minutes while performing the “AdBlue/DEF pump pressure rising test”.

40-622 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3755]

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks, the turbocharger outlet NOx
sensor may be defective.
(Offset/drift due to sulfur-poisoned turbocharger outlet NOx sensor)
Defective turbocharger 1. Turn starting switch to OFF position.
3
outlet NOx sensor
2. NOx sensor fails, therefore, replace the turbocharger outlet NOx sensor.
3. Turn starting switch to ON position.
4. Performing “Loaded Diagnostics Operation To Clear Failure Code”.
If no failure is found by preceding checks, the SCR outlet NOx sensor is defective.
(Offset/drift due to sulfur-poisoned SCR outlet NOx sensor)
Defective SCR outlet 1. Turn starting switch to OFF position.
4
NOx sensor 2. Replace the SCR outlet NOx sensor.
3. Turn starting switch to ON position.
4. Perform “Loaded Diagnostics Operation To Clear Failure Code”.
If failure code is still displayed after above checks, the intake system may be defec-
tive.
(Offset/drift due to the deteriorated and aged MAF sensor, distorted intake system,
damaged rectifier)
Defective air intake sys- 1. Check for a defective air intake pipe and repair or replace any damaged or
5
tem defective rectifier, if any.
2. Replace mass air flow (MAF) sensor.
3. Turn starting switch to ON position.
4. Performing “Loaded Diagnostics Operation To Clear Failure Code”.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation to Clear Failure Code

Check if the repair has been completed with the following procedure:
(Make sure this failure code is cleared after this procedure.)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start engine.
3. Run the engine at low idle speed for approximately 1 minute.
4. See “TESTING AND ADJUSTING”, “Service mode” and “Test menu (SCR Service Test)” in “SETTING AND
OPERATION OF MACHINE MONITOR” to perform “SCR removal efficiency test” (maximum duration of the
removal efficiency: 1.5 h).
5. The test condition on the monitor changes from “0” to “10”, then to “20”. (“14” may be shown during few
minutes due to temperature transition)
6. When the test is completed after the test condition on the monitor shows “20”, stop the engine and shut
down the engine controller (wait for a few minutes after the shutdown, then the starting switch to OFF posi-
tion).
7. Turn the starting switch to ON position again to check if this failure code is cleared. If the failure code is
cleared, repair work is completed.
REMARK
• If this failure code is cleared, repair is completed.
• In case it is not cleared, return to troubleshooting.

HB365LC-3 40-623
FAILURE CODE [CA3866] 40 TROUBLESHOOTING

FAILURE CODE [CA3866] (ALL-K-AFD0-410-20-B)

Action level Failure code AdBlue/DEF low concentration error 2

Failure
L01 CA3866 (Engine controller system)
Detail of fail-
As NOx emission increases, AdBlue/DEF concentration decreases.
ure
• Inducement strategy is activated. (*1)
• Stops AdBlue/DEF injection. (*1)

Action of
• Stops AdBlue/DEF pump. (*1)
*1: It corresponds to machines of EU, Japan, and North America specification which equipped with
controller
engines compatible with EPA and California regulations since 2017.
REMARK
EPA and California regulations can be checked on the nameplate of the engine serial number.
• Engine output is reduced based on Inducement strategy. (*1)
• NOx conversion rate is lower.
Phenomenon *1: It corresponds to machines of EU, Japan, and North America specification which equipped with
on machine engines compatible with EPA and California regulations since 2017.
REMARK
EPA and California regulations can be checked on the nameplate of the engine serial number.

40-624 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3866]

• If SCR efficiency is deteriorated due to low concentration of AdBlue/DEF, failure code

[CA3582] SCR Catalyst Efficiency Low Error 1 may also be displayed.
• When machine is operated on slopes or travels on rough ground, top surface of
AdBlue/DEF in the tank fluctuates largely, and the level or concentration of AdBlue/DEF
may not be detected correctly.
• If AdBlue/DEF level monitor lights up in red or warning for concentration is displayed when
machine is operated on slopes or travels on rough ground, immediately move the machine
to level ground, clear the failure code related to concentration according to step 3 “Conta-
minated AdBlue/DEF” and subsequent procedures, and add AdBlue/DEF. If these phe-
nomena occur repeatedly, increase the AdBlue/DEF in AdBlue/DEF tank.
• When AdBlue/DEF temperature in tank is 0 °C or lower, the engine controller does not
troubleshoot this failure code. (Failure code is not cleared even after performing machine
operation for clearing the failure code.)
• Check that AdBlue/DEF temperature in tank is 0 °C or higher on Pre-defined Monitoring
screen, and then troubleshoot this failure code.
• When AdBlue/DEF level in tank is 0 %, the engine controller does not troubleshoot this
failure code. (Failure code is not cleared even after performing machine operation for
clearing the failure code.)
Related
• Check that AdBlue/DEF level is 20 % or more on Pre-defined Monitoring screen, and then
information troubleshoot this failure code.
• For details of drain method and clean method of AdBlue/DEF tank, see TESTING AND
ADJUSTING, “CLEAN AdBlue/DEF TANK”.
• For AdBlue/DEF level sensor replacement, see DISASSEMBLY AND ASSEMBLY, “RE-
MOVE AND INSTALL AdBlue/DEF LEVEL SENSOR”.
• On Pre-defined Monitoring screen, AdBlue/DEF level and quality sensor are used. (The
numbers below denote monitoring codes).
• Pre-defined Monitoring (19/23) AdBlue/DEF level, quality sensor
1. 19100 AdBlue/DEF Concentration
2. 19110 AdBlue/DEF Level
3. 19111 AdBlue/DEF Level Corrected
4. 19115 AdBlue/DEF Temperature in Tank
5. 19400 Ambient Temperature
6. 19305 AdBlue/DEF Tank Heating State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. After in-
vestigating the cause of the problem and completing the repair, perform “Loaded Diagnos-
tics Operation To Clear Failure Code” to make sure the failure code is cleared.

No. Cause Procedure, measuring location, criteria and remarks

1. If failure code [CA1669] or [CA1677] or [CA1678] or [CA1686] or [CA1714]
or [CA1715] or [CA3868] or [CA4277] or [CA4731] or [CA4732] or
Defective AdBlue/DEF [CA4739] or [CA4768] or [CA4769] is displayed, perform troubleshooting
1 these first.
tank sensor system
2. If troubleshooting has been performed, carry out “Loaded Diagnostics Op-
eration To Clear Failure Code” topics.

HB365LC-3 40-625
FAILURE CODE [CA3866] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Check that the “AdBlue/DEF concentration” displayed on the Pre-defined
Monitoring screen is in the normal range (29 to 36 %).
2. If the “AdBlue/DEF concentration” is normal, perform “Loaded Diagnostics
Operation To Clear Failure Code”.
3. If the “AdBlue/DEF concentration” falls outside of this range, use a porta-
Low AdBlue/DEF con-
ble concentration meter to recheck the concentration. If the concentration
2 centration (entrained wa-
still falls outside of the range of 31.5 to 33.5 %, drain all of the AdBlue/DEF
ter, etc.)
from the tank and refill with fresh AdBlue/DEF.
4. If the “AdBlue/DEF concentration” is in 29 to 36 % after the work finished,
perform “Loaded Diagnostics Operation To Clear Failure Code”.
5. If the portable concentration meter reading is in the range of 31.5 to
33.5 %, proceed to the next troubleshooting.
1. Drain more than 1 ℓ of AdBlue/DEF to check that it is not contaminated
with foreign material, etc.
2. If the drained AdBlue/DEF is contaminated, drain all of the AdBlue/DEF
and refill with fresh AdBlue/DEF.
Contaminated 3. If it is heavily contaminated with sand, dirt, etc., clean the AdBlue/DEF
3
AdBlue/DEF tank.
4. If the “AdBlue/DEF concentration” is in 29 to 36 % after the work finished,
perform “Loaded Diagnostics Operation To Clear Failure Code”.
5. If the “AdBlue/DEF concentration” is out of the normal range, proceed to
the next troubleshooting.
1. Remove the AdBlue/DEF level sensor so that you can reach the
AdBlue/DEF concentration detection part (end of sensor).
2. Clean up the AdBlue/DEF concentration detection part with dry and clean
cloth, and install the AdBlue/DEF level sensor.
3. If AdBlue/DEF concentration is within the range from 29 to 36 % on "Pre-
defined Monitoring" screen, perform “Loaded Diagnostics Operation to
Clear Failure Code” to complete the repair work.
Foreign matter adhered 4. If AdBlue/DEF concentration is out of the normal range, proceed to the
4 to the sensing part of the next troubleshooting.
AdBlue/DEF tank sensor
REMARK
• If the new AdBlue/DEF has not been added as described in Cause “Conta-
minated AdBlue/DEF”, and if it takes time to remove the sensor, drain the
total amount of AdBlue/DEF, refill with new AdBlue/DEF again, and check
the sensor output.
• For details of removing AdBlue/DEF tank sensor, see DISASSEMBLY AND
ASSEMBLY, “REMOVE AND INSTALL AdBlue/DEF TANK SENSOR
FLANGE ASSEMBLY”.
1. Replace the AdBlue/DEF tank sensor.
2. If the “AdBlue/DEF concentration” displayed on the Pre-defined Monitoring
Defective AdBlue/DEF
screen falls in the range of 29 to 36%, perform “Loaded Diagnostics Oper-
5 tank sensor (internal de-
ation To Clear Failure Code” topics to complete the repair.
fect)
3. If the “AdBlue/DEF concentration” falls outside of this range, proceed to
the next troubleshooting.

40-626 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3866]

No. Cause Procedure, measuring location, criteria and remarks

1. Replace the engine controller.
Defective engine control- 2. If “AdBlue/DEF concentration” ranges from 29 to 36 % on the Trouble-
6
ler shooting Pre-defined Monitoring screen, perform “Loaded Diagnostics Op-
eration To Clear Failure Code” and repair is completed.

Loaded Diagnostics Operation to Clear Failure Code

Check if the repair has been completed with the following procedure:
(Make sure this failure code is cleared after this procedure.)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position.
3. Display monitoring code 19115 “AdBlue/DEF Temperature in Tank” on “Pre-defined Monitoring” screen.
4. Stand by with the lever and pedal of the machine not operated.
Standby time depends on the initial value of the AdBlue/DEF Temperature in tank as follows.
• When the value is 0 °C or below, run the engine and wait for 0 °C or above in tank temperature (about
60 minutes).
• When the value ranges from 0 to 5 °C, stand by for 30 minutes. (engine may be either started or not.)
• When the value is 5 °C or above, stand by for 10 minutes. (engine may be either started or not.)
5. If this failure code is cleared, repair is completed.

HB365LC-3 40-627
FAILURE CODE [CA3867] 40 TROUBLESHOOTING

FAILURE CODE [CA3867] (ALL-K-AFD0-410-00-B)

Action level Failure code AdBlue/DEF low concentration error 1

Failure
- CA3867 (Engine controller system)
Detail of fail-
Low concentration (25 % or less) of AdBlue/DEF is detected.
ure
Action of
None in particular
controller
Phenomenon
AdBlue/DEF consumption is increased.
on machine
No error is displayed on the machine monitor.
When machine is operated on slopes or travels on rough ground, top surface of AdBlue/DEF in the
tank fluctuates largely, and the level or concentration of AdBlue/DEF may not be detected correctly.
If AdBlue/DEF level monitor lights up in red or warning for concentration is displayed, immediately
move the machine to level ground and add the AdBlue/DEF. If these phenomena occur repeatedly,
increase the AdBlue/DEF in AdBlue/DEF tank.
• When AdBlue/DEF temperature in tank is 0 °C or lower, the engine controller does not
troubleshoot this failure code. (Failure code is not cleared even after performing machine
operation for clearing the failure code.)
• Check that AdBlue/DEF temperature in tank is 0 °C or higher on Pre-defined Monitoring
screen, and then troubleshoot this failure code.
• When AdBlue/DEF level is 0 %, the engine controller does not troubleshoot this failure
code. (Failure code is not cleared even after performing machine operation for clearing the
failure code.)
• Check that AdBlue/DEF level is 20 % or more on Pre-defined Monitoring screen, and then
troubleshoot this failure code.
Related
• For details of drain method and clean method of AdBlue/DEF tank, see TESTING AND
information
ADJUSTING, “CLEAN AdBlue/DEF TANK”.
• For AdBlue/DEF level sensor replacement, see DISASSEMBLY AND ASSEMBLY, “RE-
MOVE AND INSTALL AdBlue/DEF TANK SENSOR”.
• On Pre-defined Monitoring screen, AdBlue/DEF level and quality sensor are used.
• Pre-defined Monitoring (19/23) AdBlue/DEF level, quality sensor
1. 19100 AdBlue/DEF Concentration
2. 19110 AdBlue/DEF Level
3. 19111 AdBlue/DEF Level Corrected
4. 19115 AdBlue/DEF Temperature in Tank
5. 19400 Ambient Temperature
6. 19305 AdBlue/DEF Tank Heating State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. After
investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Clear Failure Code” to make sure the failure code is cleared.
(This failure code is not cleared by simply turning the starting switch to ON position.)

No. Cause Procedure, measuring location, criteria and remarks

1. If failure code [CA1669] or [CA1677] or [CA1678] or [CA1686] or [CA1714]
or [CA1715] or [CA3868] or [CA4277] or [CA4731] or [CA4732] or
Defective AdBlue/DEF [CA4739] or [CA4768] or [CA4769] is displayed, perform troubleshooting
1 these first.
tank sensor system
2. If troubleshooting has been performed, carry out “Loaded Diagnostics Op-
eration To Clear Failure Code” topics.

40-628 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3867]

No. Cause Procedure, measuring location, criteria and remarks

1. Check that the “AdBlue/DEF concentration” displayed on the Pre-defined
Monitoring screen is in the normal range (29 to 36 %).
2. If the “AdBlue/DEF concentration” is normal, perform “Loaded Diagnostics
Operation To Clear Failure Code”.
3. If the “AdBlue/DEF concentration” falls outside of this range, use a porta-
Low AdBlue/DEF con-
ble concentration meter to recheck the concentration. If the concentration
2 centration (entrained wa-
still falls outside of the range of 31.5 to 33.5 %, drain all of the AdBlue/DEF
ter, etc.)
from the tank and refill with fresh AdBlue/DEF.
4. If the “AdBlue/DEF concentration” is in 29 to 36 % after the work finished,
perform “Loaded Diagnostics Operation To Clear Failure Code”.
5. If the portable concentration meter reading is in the range of 31.5 to
33.5 %, proceed to the next troubleshooting.
1. Drain more than 1 ℓ of AdBlue/DEF to check that it is not contaminated
with foreign material, etc.
2. If the drained AdBlue/DEF is contaminated, drain all of the AdBlue/DEF
and refill with fresh AdBlue/DEF.
Contaminated 3. If it is heavily contaminated with sand, dirt, etc., clean the AdBlue/DEF
3
AdBlue/DEF tank.
4. If the “AdBlue/DEF concentration” is in 29 to 36 % after the work finished,
perform “Loaded Diagnostics Operation To Clear Failure Code”.
5. If the “AdBlue/DEF concentration” is out of the normal range, proceed to
the next troubleshooting.
1. Remove the AdBlue/DEF level sensor so that you can reach the
AdBlue/DEF concentration detection part (end of sensor).
2. Clean up the AdBlue/DEF concentration detection part with dry and clean
cloth, and install the AdBlue/DEF level sensor.
3. If AdBlue/DEF concentration is within the range from 29 to 36 % on "Pre-
defined Monitoring" screen, perform “Loaded Diagnostics Operation to
Clear Failure Code” to complete the repair work.
Foreign matter adhered 4. If AdBlue/DEF concentration is out of the normal range, proceed to the
4 to the sensing part of the next troubleshooting.
AdBlue/DEF tank sensor
REMARK
• If the new AdBlue/DEF has not been added as described in Cause “Conta-
minated AdBlue/DEF”, and if it takes time to remove the sensor, drain the
total amount of AdBlue/DEF, refill with new AdBlue/DEF again, and check
the sensor output.
• For details of removing AdBlue/DEF tank sensor, see DISASSEMBLY AND
ASSEMBLY, “REMOVE AND INSTALL AdBlue/DEF TANK SENSOR
FLANGE ASSEMBLY”.
1. Replace the AdBlue/DEF tank sensor.
2. If the “AdBlue/DEF concentration” displayed on the Pre-defined Monitoring
Defective AdBlue/DEF
screen falls in the range of 29 to 36%, perform “Loaded Diagnostics Oper-
5 tank sensor (internal de-
ation To Clear Failure Code” topics to complete the repair.
fect)
3. If the “AdBlue/DEF concentration” falls outside of this range, proceed to
the next troubleshooting.

HB365LC-3 40-629
FAILURE CODE [CA3867] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Replace the engine controller.
Defective engine control- 2. If “AdBlue/DEF concentration” ranges from 29 to 36 % on the Trouble-
6
ler shooting Pre-defined Monitoring screen, perform “Loaded Diagnostics Op-
eration To Clear Failure Code” and repair is completed.

Loaded Diagnostics Operation to Clear Failure Code

Check if the repair has been completed with the following procedure:
(Make sure this failure code is cleared after this procedure.)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position.
3. Display monitoring code 19115 “AdBlue/DEF Temperature in Tank” on “Pre-defined Monitoring” screen.
4. Stand by with the lever and pedal of the machine not operated.
Standby time depends on the initial value of the AdBlue/DEF Temperature in tank as follows.
• When the value is 0 °C or below, run the engine and wait for 0 °C or above in tank temperature (about
60 minutes).
• When the value ranges from 0 to 5 °C, stand by for 30 minutes. (engine may be either started or not.)
• When the value is 5 °C or above, stand by for 10 minutes. (engine may be either started or not.)
5. If this failure code is cleared, repair is completed.

40-630 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3868]

FAILURE CODE [CA3868] (ALL-K-AFG0-410-A0-B)

Action level Failure code AdBlue/DEF Tank Sensor Datalink Timeout Error
Failure
L01 CA3868 (Engine controller system)
Detail of fail- The engine controller cannot receive the data of the AdBlue/DEF tank sensor due to error of com-
ure munication with the AdBlue/DEF tank sensor.
Action of
Advances to Inducement strategy.
controller
• The AdBlue/DEF level, quality, and temperature cannot be measured.
Phenomenon • NOx emission may increase or ammonia may be exhausted because AdBlue/DEF injec-
on machine tion works inappropriately.
• Engine power deration according to inducement strategy.
• The AdBlue/DEF tank is a smart sensor which performs CAN communication with the en-
gine controller together with the other sensors.
• If the sensor connector or smart sensor (power supply) relay connector is disconnected,
this failure code is displayed.
• The failure codes of the CAN communication related to the engine sensor are [CA2771],
[CA3232], [CA3868], [CA3911], [CA4151], and [CA4152]. If all of these failure codes are
displayed, the cause may be defective smart sensor power supply relay, defective relay
Related system, or ground fault, short circuit, or hot short circuit of the harness (CAN communica-
information tion line).
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
• The AdBlue/DEF tank sensor is composed of the AdBlue/DEF level sensor, AdBlue/DEF
temperature sensor, and AdBlue/DEF quality sensor and provides CAN communication
with the engine controller integrated into one sensor controller.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective wiring harness Perform checks on causes 1 to 10 for failure code [CA2771].
1
connector
• Communication line
As CAN terminating resistors of 120 Ω are connected in parallel, therefore, when
circuit resistance is measured at connector of CAN communication, if combined re-
sistance is 60 Ω
, there is no open circuit.
1. Turn starting switch to OFF position.
Open circuit and short
circuit in wiring harness 2. Check that system operating lamp does not light up, and then turn battery
2 disconnect switch to OFF position.
(broken or short-circuited
communication line) 3. Disconnect connectors ECM J2 and P63 and connect T-adapters to each
female side.
Approxi-
Between P63 (female) (2) and (1)
mately 60 Ω
Resistance
Approxi-
Between ECM J2 (female) (21) and (45)
mately 60 Ω

HB365LC-3 40-631
FAILURE CODE [CA3868] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

• Power line
1. Turn starting switch to OFF position.
2. Disconnect connector P63, and connect T-adapter to female side.
3. Turn starting switch to ON position.
Open circuit in wiring har-
ness (wire breakage or Voltage Between P63 (female) (4) and (3) Min. 22 V
3 defective contact of con- If no failure is found by above results, this check is not required.
nector) (broken power 1. Turn starting switch to OFF position.
line)
2. Disconnect connectors R52 and P63 and connect T-adapters to each fe-
male side.
Between R52 (female) (11) and P63 (female) (4) Max. 10 Ω
Resistance
Between P63 (female) (3) and ground Max. 10 Ω
• Communication line
If failure code is still displayed after above checks on cause 2, this check is not re-
quired.
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
Open circuit in wiring har- 3.
Disconnect connectors ECM J2, P63, K10, and K11 and connect T-adapt-
ness (wire breakage or
ers to each female side.
4 defective contact of con-
nector) (broken commu- Between ECM J2 (female) (21) and P63 (female) (2) Max. 10 Ω
nication line)
Between ECM J2 (female) (45) and P63 (female) (1) Max. 10 Ω
Between K10 (female) (A) and P63 (female) (2) Max. 10 Ω
Resistance
Between K10 (female) (B) and P63 (female) (1) Max. 10 Ω
Between K11 (female) (A) and P63 (female) (2) Max. 10 Ω
Between K11 (female) (B) and P63 (female) (1) Max. 10 Ω
f failure code (no open circuit) is still displayed after above checks in cause 2,
measure resistance at any one place in Hi line and Lo line.
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
3. Disconnect all related connectors, and connect T-adapter to the female
Ground fault in wiring side of the connector to be measured.
5 harness (contact with
Between one of ECM J2(female)(21),K10(female)
ground circuit)
(A),K11(female)(A),E31(female)(3),E32(female)
Min.100 kΩ
(2),E26(female)(3),E34(female)(3),E36(female)
(3),P63(female)(2) and ground
Resistance
Between one of ECM J2(female)(45), K10(female)(B),
K11(female)(B), E31(female)(2), E32(female)(3),
Min.100 kΩ
E26(female)(2), E34(female)(2), E36(female)(2),
P63(female)(1) and ground

40-632 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3868]

No. Cause Procedure, measuring location, criteria and remarks

f failure code (no open circuit) is still displayed after above checks in cause 11,
measure resistance at any one place in Hi line and Lo line.
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
3. Insert T-adapter into one of the related connectors.
Hot short circuit in wiring
6 4. Set battery disconnect switch to ON position.
harness
5. Turn starting switch to ON position.
Between one of ECM J2(21), K10(A), K11(A), E31(3),
1 to 4 V
E32(2), E26(3), E34(3), E36(3), or P63(2) and ground
Voltage
Between one of ECM J2(45), K10(B), K11(B), E31(2),
1 to 4 V
E32(3), E26(2), E34(2), E36(2), or P63(1) and ground
1. Turn starting switch to OFF position.
2. Replace AdBlue/DEF tank sensor (P63).
Defective AdBlue/DEF
7 3. Turn starting switch to ON position.
tank sensor
If this failure code is cleared, the original sensor is defective. (In case of an internal
defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
8
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-633
FAILURE CODE [CA3868] 40 TROUBLESHOOTING

Circuit diagram related to SCR system CAN communication

40-634 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3899]

FAILURE CODE [CA3899] (ALL-K-AFN0-410-10-B)

Action level Failure code SCR NH3 sensor circuit error

Failure
L01 CA3899 (Engine controller system)
Detail of fail-
Ammonia sensor controller detects circuit error of ammonia sensor.
ure
Action of • Controls AdBlue/DEF injection without using ammonia sensor.
controller • Inducement strategy is activated. (EU specification only)
• AdBlue/DEF injection becomes inappropriate and the NOx emission may increase, or am-
Phenomenon
monia may be discharged.
on machine
• Engine output is reduced based on Inducement strategy (EU specifications).
k SCR assembly, sensor fitting piping, and sensor probe are heated to 400 °C or high-
er. Be careful not to get burn injury.
k As for the sensor probe, be careful not to get burn injury even if the surroundings
are not hot, because sensor itself is heated.
• If ammonia sensor controller detects the circuit error of ammonia sensor, the information is
sent to the engine controller through CAN communication, and this failure code is dis-
played.
• When the connector at sensor probe side is disconnected while machine operation, this
failure code is displayed. In this case, failure code [CA3935] is displayed when the starting
switch is turned to ON position next time.
• This sensor does not detect the value when the exhaust gas temperature is low as 150 °C
or lower (the sensor does not operate by simply turning the starting switch to ON position
Related even when it is normal).
information • On “Pre-defined Monitoring” screen, AdBlue/DEF injector and engine operation state are
used. (The numbers below denote monitoring codes).
• Pre-defined Monitoring (15/23) Engine operation state
1. 01002 Engine Speed
2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correction”.
After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to make sure the failure code is cleared.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equipment” in
“CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
Defective wiring harness TROUBLESHOOTING”, and check it.
1
connector 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is cleared, wiring harness connector is defective.
If the failure code persists after the above checks, the sensor may be defective.
1. Turn starting switch to OFF position.
Defective ammonia sen- 2. Replace the ammonia sensor.
2
sor
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code is cleared, the original ammonia sensor may be defective.

HB365LC-3 40-635
FAILURE CODE [CA3899] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Perform the above checks and “Loaded Diagnostics Operation To Confirm
Failure Correction”.
2. If this failure code is displayed in above diagnosis, replace an ammonia sensor
Defective ammonia sen- controller.
3
sor controller
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code is cleared, the original ammonia sensor controller may be defec-
tive.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation to Confirm Failure Correction

Check if the repair has been completed with the following procedure:
(Make sure this failure code is not displayed after this procedure.)
Clear this failure code by “Engine Controller Inducement Fault Clear” before step 1. (EU Specification)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start the engine.
3. Run the engine at high idle speed to raise the exhaust temperature. (Keep the engine speed so that moni-
toring code 19300 “SCR temperature” is 150 °C or higher.)
4. Check if this failure code is not displayed after 1 minute.
REMARK
• If this failure code is not displayed, repair is completed.
• In case it is displayed, return to troubleshooting.

40-636 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3911]

FAILURE CODE [CA3911] (ALL-K-AFN0-410-00-B)

Action level Failure code SCR NH3 Sensor Datalink Timeout Error
Failure
L01 CA3911 (Engine controller system)
Detail of fail- The engine controller does not receive ammonia sensor data due to a communication error with the
ure ammonia sensor.
Action of • Uses AdBlue/DEF injection control without using the ammonia sensor.
controller • Advances to Inducement strategy.
• NOx emission may increase or ammonia may be exhausted because AdBlue/DEF injec-
Phenomenon tion works inappropriately.
on machine • Engine output is reduced based on inducement strategy.
• Ammonia concentration is undetectable.
k SCR assembly, the sensor installation piping, and the sensor probe become hot
(Min. 400 °C). Be careful not to get burned.
k Be careful not to get burned by the sensor probe as it is heated by itself even if the
ambient temperature is not high.
• The ammonia sensor is separated from the sensor controller and communicated via CAN
with the engine controller along with other sensors.
• This failure code is displayed if the sensor controller's connector or a smart sensor (power
Related supply) relay connector is disconnected.
information • CAN communication failure codes related to engine sensors include [CA2771], [CA3232],
[CA3868], [CA3911], [CA4151], and [CA4152]. If all of these failure codes are displayed, a
defect in any of the 6 sensors, a defective smart sensor power supply relay/relay system,
or a ground fault, short circuit, or hot short circuit in wiring harness (CAN communication
line) can be suspected.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective wiring harness Perform checks on causes 1 to 10 for failure code [CA2771].
1
connector
• Communication line
As CAN terminating resistors of 120 Ω are connected in parallel, therefore, when
circuit resistance is measured at connector of CAN communication, if combined re-
sistance is 60 Ω, there is no open circuit.
1. Turn starting switch to OFF position.
Open circuit and short 2. Check that system operating lamp does not light up, and then turn battery
circuit in wiring harness disconnect switch to OFF position.
2
(broken or short-circuited
communication line) 3. Disconnect connectors ECM J2 and E32 and connect T-adapters to each
female side.
Approxi-
Between E32 (female) (2) and (3)
mately 60 Ω
Resistance
Approxi-
Between ECM J2 (female) (21) and (45)
mately 60 Ω

HB365LC-3 40-637
FAILURE CODE [CA3911] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by above results, this check is not required.
Open circuit in wiring har- 1. Turn starting switch to OFF position.
ness (wire breakage or 2. Disconnect connectors R52 and E32 and connect T-adapters to each fe-
3 defective contact of con- male side.
nector) (broken power
line) Between R52 (female) (7) and E32 (female) (1) Max. 10 Ω
Resistance
Between E32 (female) (4) and ground Max. 10 Ω
• Communication line
If failure code (no open circuit) is still displayed after above checks in cause 2, this
check is not required.
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
Open circuit in wiring har- 3.
Disconnect connectors ECM J2, E26, K10, and K11 and connect T-adapt-
ness (wire breakage or
ers to each female side.
4 defective contact of con-
nector) (broken commu- Between ECM J2 (female) (21) and E32 (female) (2) Max. 10 Ω
nication line)
Between ECM J2 (female) (45) and E32 (female) (3) Max. 10 Ω
Between K10 (female) (A) and E32 (female) (2) Max. 10 Ω
Resistance
Between K10 (female) (B) and E32 (female) (3) Max. 10 Ω
Between K11 (female) (A) and E32 (female) (2) Max. 10 Ω
Between K11 (female) (B) and E32 (female) (3) Max. 10 Ω
f failure code (no open circuit) is still displayed after above checks in cause 2,
measure resistance at any one place in Hi line and Lo line.
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
3. Disconnect all related connectors, and connect T-adapter to the female
Ground fault in wiring side of the connector to be measured.
5 harness (contact with
Between one of ECM J2(female)(21),K10(female)
ground circuit)
(A),K11(female)(A),E31(female)(3),E32(female)
Min.100 kΩ
(2),E26(female)(3),E34(female)(3),E36(female)
(3),P63(female)(2) and ground
Resistance
Between one of ECM J2(female)(45), K10(female)(B),
K11(female)(B), E31(female)(2), E32(female)(3),
Min.100 kΩ
E26(female)(2), E34(female)(2), E36(female)(2),
P63(female)(1) and ground
f failure code (no open circuit) is still displayed after above checks in cause 11,
measure resistance at any one place in Hi line and Lo line.
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
3. Insert T-adapter into one of the related connectors.
Hot short circuit in wiring
6 4. Set battery disconnect switch to ON position.
harness
5. Turn starting switch to ON position.
Between one of ECM J2(21), K10(A), K11(A), E31(3),
1 to 4 V
E32(2), E26(3), E34(3), E36(3), or P63(2) and ground
Voltage
Between one of ECM J2(45), K10(B), K11(B), E31(2),
1 to 4 V
E32(3), E26(2), E34(2), E36(2), or P63(1) and ground

40-638 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3911]

No. Cause Procedure, measuring location, criteria and remarks

Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)
1. Turn starting switch to OFF position.
2. Replace the ammonia sensor (E32).
Defective ammonia sen-
8 3. Turn starting switch to ON position.
sor
If this failure code is cleared, the original sensor is defective. (In case of an internal
defect, troubleshooting is impossible as an assembly. Replace whole assembly.)

HB365LC-3 40-639
FAILURE CODE [CA3911] 40 TROUBLESHOOTING

Circuit diagram related to SCR system CAN communication

40-640 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3912]

FAILURE CODE [CA3912] (ALL-K-AFN0-410-30-B)

Action level Failure code SCR NH3 sensor heater warming up error
Failure
L01 CA3912 (Engine controller system)
Detail of fail-
Temperature control of ammonia sensor does not work normally.
ure
Action of • Controls AdBlue/DEF injection without using ammonia sensor.
controller • Inducement strategy is activated. (EU specification only)
• AdBlue/DEF injection becomes inappropriate and the NOx emission may increase, or am-
Phenomenon
monia may be discharged.
on machine
• Engine output is reduced based on Inducement strategy (EU specifications).
k SCR assembly, sensor fitting piping, and sensor probe are heated to 400 °C or high-
er. Be careful not to get burn injury.
k As for the sensor probe, be careful not to get burn injury even if the surroundings
are not hot, because sensor itself is heated.
• If ammonia sensor controller detects the circuit error of ammonia sensor, the information is
sent to the engine controller through CAN communication, and this failure code is dis-
played.
• On “Pre-defined Monitoring” screen, engine operation state is used. (The numbers below
denote monitoring codes).
Related
• Pre-defined Monitoring (15/23) Engine operation state
information 1. 01002 Engine Speed
2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correction”.
After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to make sure the failure code is cleared.

No. Cause Procedure, measuring location, criteria and remarks

Defective ammonia sen- If failure code [CA3899], [CA3911], [CA3932], [CA3933], [CA3934], [CA3935] or
sor system [CA3936] is displayed, perform troubleshooting for these failure codes first.
1 (Open circuit, internal de-
fect, defective sensor
heater)
1. See descriptions of wiring harness and connectors in “Electrical equipment” in
“CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
Defective wiring harness TROUBLESHOOTING”, and check it.
2
connector 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is cleared, wiring harness connector is defective.
If the failure code persists after the above checks, the sensor may be defective.
1. Turn starting switch to OFF position.
Defective ammonia sen- 2. Replace the ammonia sensor.
3
sor
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code is cleared, the original ammonia sensor may be defective.

HB365LC-3 40-641
FAILURE CODE [CA3912] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. If this failure code is displayed in above diagnosis, replace an ammonia
Defective ammonia sen- sensor controller.
4
sor controller 3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code is cleared, the original ammonia sensor controller may be defec-
tive.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation to Confirm Failure Correction

Check if the repair has been completed with the following procedure:
(Make sure this failure code is not displayed after this procedure.)
Clear this failure code by “Engine Controller Inducement Fault Clear” before step 1. (EU Specification)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start the engine.
3. Run the engine at high idle speed to raise the exhaust temperature. (Keep the engine speed so that moni-
toring code 19300 “SCR temperature” is 150 °C or higher.)
4. Check if this failure code is not displayed after 1 minute.
REMARK
• If this failure code is not displayed, repair is completed.
• In case it is displayed, return to troubleshooting.

40-642 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3932]

FAILURE CODE [CA3932] (ALL-K-AFN0-410-40-B)

Action level Failure code SCR NH3 sensor heater voltage high error
Failure
L01 CA3932 (Engine controller system)
Detail of fail-
Ammonia sensor controller determines that heater control voltage is excessive.
ure
Action of • Controls AdBlue/DEF injection without using ammonia sensor.
controller • Inducement strategy is activated. (EU specification only)
• AdBlue/DEF injection becomes inappropriate and the NOx emission may increase, or am-
Phenomenon
monia may be discharged.
on machine
• Engine output is reduced based on Inducement strategy (EU specifications).
k SCR assembly, sensor fitting piping, and sensor probe are heated to 400 °C or high-
er. Be careful not to get burn injury.
k As for the sensor probe, be careful not to get burn injury even if the surroundings
are not hot, because sensor itself is heated.
• If ammonia sensor controller detects the circuit error of ammonia sensor, the information is
sent to the engine controller through CAN communication, and this failure code is dis-
played.
• On “Pre-defined Monitoring” screen, engine operation state is used.
(The numbers below denote monitoring codes.)
Related
• Pre-defined Monitoring (15/23) Engine operation state
information 1. 01002 Engine Speed
2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correction”.
After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to make sure the failure code is cleared.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equipment” in
“CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
Defective wiring harness TROUBLESHOOTING”, and check it.
1
connector 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is cleared, wiring harness connector is defective.
If the failure code persists after the above checks, the sensor may be defective.
1. Turn starting switch to OFF position.
Defective ammonia sen- 2. Replace the ammonia sensor.
2
sor
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code is cleared, the original ammonia sensor may be defective.
1. Turn starting switch to OFF position.
2. If this failure code is displayed in above diagnosis, replace an ammonia
Defective ammonia sen- sensor controller.
3
sor controller 3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code is cleared, the original ammonia sensor controller may be defec-
tive.

HB365LC-3 40-643
FAILURE CODE [CA3932] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation to Confirm Failure Correction

Check if the repair has been completed with the following procedure:
(Make sure this failure code is not displayed after this procedure.)
Clear this failure code by “Engine Controller Inducement Fault Clear” before step 1. (EU Specification)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start the engine.
3. Run the engine at high idle speed to raise the exhaust temperature. (Keep the engine speed so that moni-
toring code 19300 “SCR temperature” is 150 °C or higher.)
4. Check if this failure code is not displayed after 1 minute.
REMARK
• If this failure code is not displayed, repair is completed.
• In case it is displayed, return to troubleshooting.

40-644 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3933]

FAILURE CODE [CA3933] (ALL-K-AFN0-410-50-B)

Action level Failure code SCR NH3 sensor heater voltage low error
Failure
L01 CA3933 (Engine controller system)
Detail of fail-
Ammonia sensor controller determines that heater control voltage is too low.
ure
Action of • Controls AdBlue/DEF injection without using ammonia sensor.
controller • Inducement strategy is activated. (EU specification only)
• AdBlue/DEF injection becomes inappropriate and the NOx emission may increase, or am-
Phenomenon
monia may be discharged.
on machine
• Engine output is reduced based on Inducement strategy (EU specifications).
k SCR assembly, sensor fitting piping, and sensor probe are heated to 400 °C or high-
er. Be careful not to get burn injury.
k As for the sensor probe, be careful not to get burn injury even if the surroundings
are not hot, because sensor itself is heated.
• If ammonia sensor controller detects the circuit error of ammonia sensor, the information is
sent to the engine controller through CAN communication, and this failure code is dis-
played.
• On “Pre-defined Monitoring” screen, engine operation state is used. (The numbers below
denote monitoring codes).
Related
• Pre-defined Monitoring (15/23) Engine operation state
information 1. 01002 Engine Speed
2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correction”.
After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to make sure the failure code is cleared.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equipment” in
“CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
Defective wiring harness TROUBLESHOOTING”, and check it.
1
connector 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is cleared, wiring harness connector is defective.
If the failure code persists after the above checks, the sensor may be defective.
1. Turn starting switch to OFF position.
Defective ammonia sen- 2. Replace the ammonia sensor.
2
sor
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code is cleared, the original ammonia sensor may be defective.
1. Turn starting switch to OFF position.
2. If this failure code is displayed in above diagnosis, replace an ammonia
Defective ammonia sen- sensor controller.
3
sor controller 3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code is cleared, the original ammonia sensor controller may be defec-
tive.

HB365LC-3 40-645
FAILURE CODE [CA3933] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation to Confirm Failure Correction

Check if the repair has been completed with the following procedure:
(Make sure this failure code is not displayed after this procedure.)
Clear this failure code by “Engine Controller Inducement Fault Clear” before step 1. (EU Specification)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start the engine.
3. Run the engine at high idle speed to raise the exhaust temperature. (Keep the engine speed so that moni-
toring code 19300 “SCR temperature” is 150 °C or higher.)
4. Check if this failure code is not displayed after 1 minute.
REMARK
• If this failure code is not displayed, repair is completed.
• In case it is displayed, return to troubleshooting.

40-646 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3934]

FAILURE CODE [CA3934] (ALL-K-AFN0-410-20-B)

Action level Failure code SCR NH3 sensor power interrupt error
Failure
L01 CA3934 (Engine controller system)
Detail of fail-
Interrupt error of ammonia sensor power supply occurs.
ure
Action of • Controls AdBlue/DEF injection without using ammonia sensor.
controller • Inducement strategy is activated. (EU specification only)
• AdBlue/DEF injection becomes inappropriate and the NOx emission may increase, or am-
Phenomenon
monia may be discharged.
on machine
• Engine output is reduced based on Inducement strategy (EU specifications).
k SCR assembly, sensor fitting piping, and sensor probe are heated to 400 °C or high-
er. Be careful not to get burn injury.
k As for the sensor probe, be careful not to get burn injury even if the surroundings
are not hot, because sensor itself is heated.
• Cause of interrupt error is mainly defective contact. Check visually the wiring harness for
wear of coating.
• When measuring the resistance, shake the wiring harness and check if resistance varies
in order to detect incomplete breakage of wiring.
• This sensor does not detect the value when the exhaust gas temperature is low as 150 °C
or lower (the sensor does not operate by simply turning the starting switch to ON position
even when it is normal).
Related
• On “Pre-defined Monitoring” screen, engine operation state is used. (The numbers below
information denote monitoring codes).
• Pre-defined Monitoring (15/23) Engine operation state
1. 01002 Engine Speed
2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correction”.
After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to make sure the failure code is cleared.

No. Cause Procedure, measuring location, criteria and remarks

Defective sensor power Perform troubleshooting for failure code [CA1776].
1
supply relay system
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
Defective sensor power 3. Insert T-adapter into connector R52.
2 supply relay (defective in- 4.
Disconnect connector E32.
ternal circuit)
5. Turn the battery disconnect switch ON.
6. Turn starting switch to ON position.
Voltage Between R52 (7) and (4) Min. 22 V

HB365LC-3 40-647
FAILURE CODE [CA3934] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connector E32, and connect T-adapter to female side.
3
ness 3. Turn starting switch to ON position.
Voltage Between E32 (female) (1) and (4) Min. 22 V
1. Perform the above checks and “Loaded Diagnostics Operation To Confirm
Failure Correction”.
2. If this failure code is displayed in above diagnosis, replace an ammonia sensor
Defective ammonia sen- controller.
4
sor controller
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code is cleared, the original ammonia sensor controller may be defec-
tive.
1. If the failure code persists after the above checks, replace the engine con-
Defective engine control-
troller.
5 2.
ler Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code disappeared, the engine controller may be defective.
1. If the failure code persists after the above checks, replace the engine harness.
6 Defective engine harness 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is cleared, the engine harness may be defective.

Loaded Diagnostics Operation to Confirm Failure Correction

Check if the repair has been completed with the following procedure:
(Make sure this failure code is not displayed after this procedure.)
Clear this failure code by “Engine Controller Inducement Fault Clear” before step 1. (EU Specification)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start the engine.
3. Run the engine at high idle speed to raise the exhaust temperature. (Keep the engine speed so that moni-
toring code 19300 “SCR temperature” is 150 °C or higher.)
4. Check if this failure code is not displayed after 1 minute.
REMARK
• If this failure code is not displayed, repair is completed.
• In case it is displayed, return to troubleshooting.

40-648 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3934]

CIRCUIT DIAGRAM (AMMONIA SENSOR)

HB365LC-3 40-649
FAILURE CODE [CA3935] 40 TROUBLESHOOTING

FAILURE CODE [CA3935] (ALL-K-AFN0-410-60-B)

Action level Failure code SCR NH3 sensor trim resistance error
Failure
L01 CA3935 (Engine controller system)
Detail of fail-
Ammonia sensor controller cannot recognize the value of trim resistance on the probe.
ure
Action of • Controls AdBlue/DEF injection without using ammonia sensor.
controller • Inducement strategy is activated. (EU specification only)
• AdBlue/DEF injection becomes inappropriate and the NOx emission may increase, or am-
Phenomenon
monia may be discharged.
on machine
• Engine output is reduced based on Inducement strategy (EU specifications).
k SCR assembly, sensor fitting piping, and sensor probe are heated to 400 °C or high-
er. Be careful not to get burn injury.
k As for the sensor probe, be careful not to get burn injury even if the surroundings
are not hot, because sensor itself is heated.
• This failure code is displayed if the connector of sensor side is disconnected when setting
the starting switch to ON position.
• If ammonia sensor controller detects the circuit error of ammonia sensor, the information is
sent to the engine controller through CAN communication, and this failure code is dis-
played.
• On “Pre-defined Monitoring” screen, engine operation state is used. (The numbers below
Related denote monitoring codes).
information • Pre-defined Monitoring (15/23) Engine operation state
1. 01002 Engine Speed
2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correction”.
After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to make sure the failure code is cleared.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equipment” in
“CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
Defective wiring harness TROUBLESHOOTING”, and check it.
1
connector 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is cleared, wiring harness connector is defective.
If the failure code persists after the above checks, the sensor may be defective.
1. Turn starting switch to OFF position.
Defective ammonia sen- 2. Replace the ammonia sensor.
2
sor
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code is cleared, the original ammonia sensor may be defective.

40-650 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3935]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. If this failure code is displayed in above diagnosis, replace an ammonia
Defective ammonia sen- sensor controller.
3
sor controller 3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code is cleared, the original ammonia sensor controller may be defec-
tive.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation to Confirm Failure Correction

Check if the repair has been completed with the following procedure:
(Make sure this failure code is not displayed after this procedure.)
Clear this failure code by “Engine Controller Inducement Fault Clear” before step 1. (EU Specification)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start the engine.
3. Run the engine at high idle speed to raise the exhaust temperature. (Keep the engine speed so that moni-
toring code 19300 “SCR temperature” is 150 °C or higher.)
4. Check if this failure code is not displayed after 1 minute.
REMARK
• If this failure code is not displayed, repair is completed.
• In case it is displayed, return to troubleshooting.

HB365LC-3 40-651
FAILURE CODE [CA3936] 40 TROUBLESHOOTING

FAILURE CODE [CA3936] (ALL-K-AFN0-410-70-B)

Action level Failure code SCR NH3 sensor internal circuit error
Failure
L01 CA3936 (Engine controller system)
Detail of fail-
Ammonia sensor controller determines the internal circuit abnormality.
ure
Action of • Controls AdBlue/DEF injection without using ammonia sensor.
controller • Inducement strategy is activated. (EU specification only)
• AdBlue/DEF injection becomes inappropriate and the NOx emission may increase, or am-
Phenomenon
monia may be discharged.
on machine
• Engine output is reduced based on Inducement strategy (EU specifications).
k SCR assembly, sensor fitting piping, and sensor probe are heated to 400 °C or high-
er. Be careful not to get burn injury.
k As for the sensor probe, be careful not to get burn injury even if the surroundings
are not hot, because sensor itself is heated.
• Sensor controller itself has an internal defect.
• If ammonia sensor controller detects the circuit error of ammonia sensor, the information is
sent to the engine controller through CAN communication, and this failure code is dis-
played.
• On “Pre-defined Monitoring” screen, engine operation state is used. (The numbers below
Related denote monitoring codes).
information • Pre-defined Monitoring (15/23) Engine operation state
1. 01002 Engine Speed
2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
NOTICE
This failure code requires “Loaded Diagnostics Operation To Confirm Failure Correction”.
After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to make sure the failure code is cleared.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equipment” in
“CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
Defective wiring harness TROUBLESHOOTING”, and check it.
1
connector 2. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. If this failure code is displayed in above diagnosis, replace an ammonia
Defective ammonia sen- sensor controller.
2
sor controller 3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code is cleared, the original ammonia sensor controller may be defec-
tive.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

40-652 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA3936]

Loaded Diagnostics Operation to Confirm Failure Correction

Check if the repair has been completed with the following procedure:
(Make sure this failure code is not displayed after this procedure.)
Clear this failure code by “Engine Controller Inducement Fault Clear” before step 1. (EU Specification)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start the engine.
3. Run the engine at high idle speed to raise the exhaust temperature. (Keep the engine speed so that moni-
toring code 19300 “SCR temperature” is 150 °C or higher.)
4. Check if this failure code is not displayed after 1 minute.
REMARK
• If this failure code is not displayed, repair is completed.
• In case it is displayed, return to troubleshooting.

HB365LC-3 40-653
FAILURE CODE [CA4151] 40 TROUBLESHOOTING

FAILURE CODE [CA4151] (ALL-K-A9KA-410-00-B)

Action level Failure code KDOC and KDPF Temperature Sensor Datalink Timeout Error
Failure
L03 CA4151 (Engine controller system)

• The engine controller does not receive data from KDOC inlet temperature sensor, KDOC
outlet temperature sensor, and KDPF outlet temperature sensor due to a communication
Detail of fail- error with KDPF temperature sensor.
ure • This occurs when information on the KDOC inlet temperature sensor, the KDOC outlet
temperature sensor, and the KDPF outlet temperature sensor cannot be received for a
certain amount of time.
• Run the engine by using the default value of the KDOC inlet temperature, KDOC outlet
temperature, and the KDPF outlet temperature (250 °C).
• Engine power deration
Action of • AdBlue/DEF injection stops
controller • EGR valve closed.
• Regeneration control stops.
• Fuel dosing stops.
• Advances to Inducement strategy.
• NOx emission increases because AdBlue/DEF injection is disabled.
• Defective forcible regeneration control.
Phenomenon • KDPF Soot Accumulation High.
on machine • KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature detec-
tion error.
• Engine output is reduced based on inducement strategy.
k Be careful not to get burned as the temperature of KDPF and KDOC rises up over
500 °C.
k The turbocharger outlet, the sensor installation piping, KDPF, and KDOC become hot
(Min. 500 °C). Be careful not to get burned.
• This failure code is displayed if the sensor connector or a smart sensor (power supply) re-
lay connector is removed.
• CAN communication failure codes related to engine sensors include [CA2771], [CA3232],
[CA3868], [CA3911], [CA4151], and [CA4152]. If all of these failure codes are displayed, a
defect in any of the 6 sensors, a defective smart sensor power supply relay/relay system,
or a ground fault, short circuit, or hot short circuit in wiring harness (CAN communication
line) can be suspected.
Related
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
information
using multimeter.
• The KDPF temperature sensor consists of the KDOC inlet temperature sensor, the KDOC
outlet temperature sensor, and the KDPF outlet temperature sensor and is integrated into
one sensor controller which provides CAN communication with the engine controller.
• For replacement of the KDPF temperature sensor, see DISASSEMBLY AND ASSEMBLY,
“DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY”.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note that the engine power deration is not canceled only by the failure
code is cleared).

40-654 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4151]

No. Cause Procedure, measuring location, criteria and remarks

Defective wiring harness Perform checks on causes 1 to 10 for failure code [CA2771].
1
connector
• Communication line
As CAN terminating resistors of 120 Ω are connected in parallel, therefore, when
circuit resistance is measured at connector of CAN communication, if combined re-
sistance is 60 Ω, there is no open circuit.
1. Turn starting switch to OFF position.
Open circuit and short 2. Check that system operating lamp does not light up, and then turn battery
circuit in wiring harness disconnect switch to OFF position.
2
(broken or short-circuited
3. Disconnect connectors ECM J2 and E26 and connect T-adapters to each
communication line)
female side.
Approxi-
Between E26 (female) (3) and (2)
mately 60 Ω
Resistance
Approxi-
Between ECM J2 (female) (21) and (45)
mately 60 Ω
• Power line
1. Turn starting switch to OFF position.
2. Disconnect connector E26, and connect T-adapter to female side.
3. Turn starting switch to ON position.
Open circuit in wiring har-
ness (wire breakage or Voltage Between E26 (female) (4) and (1) Min. 22 V
3 defective contact of con- If no failure is found by above results, this check is not required.
nector) (broken power 1. Turn starting switch to OFF position.
line)
2. Disconnect connectors R52 and E26 and connect T-adapters to each fe-
male side.
Between R52 (female) (8) and E26 (female) (4) Max. 10 Ω
Resistance
Between E26 (female) (1) and ground Max. 10 Ω
• Communication line
If failure code is still displayed after above checks on cause 2, this check is not re-
quired.
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
Open circuit in wiring har- 3.
Disconnect connectors ECM J2, E26, K10, and K11 and connect T-adapt-
ness (wire breakage or
ers to each female side.
4 defective contact of con-
nector) (broken commu- Between ECM J2 (female) (21) and E26 (female) (3) Max. 10 Ω
nication line)
Between ECM J2 (female) (45) and E26 (female) (2) Max. 10 Ω
Between K10 (female) (A) and E26 (female) (3) Max. 10 Ω
Resistance
Between K10 (female) (B) and E26 (female) (2) Max. 10 Ω
Between K11 (female) (A) and E26 (female) (3) Max. 10 Ω
Between K11 (female) (B) and E26 (female) (2) Max. 10 Ω

HB365LC-3 40-655
FAILURE CODE [CA4151] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

f failure code (no open circuit) is still displayed after above checks in cause 2,
measure resistance at any one place in Hi line and Lo line.
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
3. Disconnect all related connectors, and connect T-adapter to the female
Ground fault in wiring side of the connector to be measured.
5 harness (contact with
Between one of ECM J2(female)(21),K10(female)
ground circuit)
(A),K11(female)(A),E31(female)(3),E32(female)
Min.100 kΩ
(2),E26(female)(3),E34(female)(3),E36(female)
(3),P63(female)(2) and ground
Resistance
Between one of ECM J2(female)(45), K10(female)(B),
K11(female)(B), E31(female)(2), E32(female)(3),
Min.100 kΩ
E26(female)(2), E34(female)(2), E36(female)(2),
P63(female)(1) and ground
f failure code (no open circuit) is still displayed after above checks in cause 11,
measure resistance at any one place in Hi line and Lo line.
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
3. Insert T-adapter into one of the related connectors.
Hot short circuit in wiring
6 4. Set battery disconnect switch to ON position.
harness
5. Turn starting switch to ON position.
Between one of ECM J2(21), K10(A), K11(A), E31(3),
1 to 4 V
E32(2), E26(3), E34(3), E36(3), or P63(2) and ground
Voltage
Between one of ECM J2(45), K10(B), K11(B), E31(2),
1 to 4 V
E32(3), E26(2), E34(2), E36(2), or P63(1) and ground
1. Turn starting switch to OFF position.
2. Replace KDPF temperature sensor.
Defective KDPF temper-
7 3. Turn starting switch to ON position.
ature sensor
If this failure code is cleared, the original sensor is defective. (In case of an internal
defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
8
ler an internal defect, troubleshooting cannot be performed.)

40-656 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4151]

Circuit diagram related to SCR system CAN communication

HB365LC-3 40-657
FAILURE CODE [CA4152] 40 TROUBLESHOOTING

FAILURE CODE [CA4152] (ALL-K-AFP0-410-20-B)

Action level Failure code SCR Temperature Sensor Datalink Timeout Error
Failure
L01 CA4152 (Engine controller system)
Detail of fail- The engine controller does not receive SCR temperature sensor data due to a communication error
ure with the SCR temperature sensor.
• Stops AdBlue/DEF injection.
Action of • Runs the SCR temperature sensor and the SCR outlet temperature sensor using the last
controller normal values.
• Advances to Inducement strategy.
• NOx emission increases because AdBlue/DEF injection is disabled.
Phenomenon
• Engine output is reduced based on inducement strategy.
on machine
• SCR temperature and SCR outlet temperature detection error.
k SCR assembly, the sensor installation piping, and the sensor probe become hot (Min.
400 °C). Be careful not to get burned.
• This failure code is displayed if the sensor connector or a smart sensor (power supply) re-
lay connector is removed.
• CAN communication failure codes related to engine sensors include [CA2771], [CA3232],
[CA3868], [CA3911], [CA4151], and [CA4152]. If all of these failure codes are displayed, a
defect in any of the 6 sensors, a defective smart sensor power supply relay/relay system,
or a ground fault, short circuit, or hot short circuit in wiring harness (CAN communication
Related line) can be suspected.
information • Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
• The SCR temperature sensor and the SCR outlet temperature sensor are integrated into
one sensor controller which provides CAN communication with the engine controller.
• For replacement of the SCR temperature sensor, see DISASSEMBLY AND ASSEMBLY,
“Remove and install SCR temperature sensor”.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective wiring harness Perform checks on causes 1 to 10 for failure code [CA2771].
1
connector
• Communication line
As CAN terminating resistors of 120 Ω are connected in parallel, therefore, when
circuit resistance is measured at connector of CAN communication, if combined re-
sistance is 60 Ω, there is no open circuit.
1. Turn starting switch to OFF position.
Open circuit and short 2. Check that system operating lamp does not light up, and then turn battery
circuit in wiring harness disconnect switch to OFF position.
2
(broken or short-circuited
communication line) 3. Disconnect connectors ECM J2 and E34 and connect T-adapters to each
female side.
Approxi-
Between E34 (female) (3) and (2)
mately 60 Ω
Resistance
Approxi-
Between ECM J2 (female) (21) and (45)
mately 60 Ω

40-658 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4152]

No. Cause Procedure, measuring location, criteria and remarks

• Power line
1. Turn starting switch to OFF position.
2. Disconnect connector E34, and connect T-adapter to female side.
3. Turn starting switch to ON position.
Open circuit in wiring har-
ness (wire breakage or Voltage Between E34 (female) (4) and (1) Min. 22 V
3 defective contact of con- If no failure is found by above results, this check is not required.
nector) (broken power 1. Turn starting switch to OFF position.
line)
2. Disconnect connectors R52 and E34 and connect T-adapters to each fe-
male side.
Between R52 (female) (9) and E34 (female) (4) Max. 10 Ω
Resistance
Between E34 (female) (1) and ground Max. 10 Ω
• Communication line
If failure code is still displayed after above checks on cause 2, this check is not re-
quired.
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
Open circuit in wiring har- 3.
Disconnect connectors ECM J2, E34, K10, and K11 and connect T-adapt-
ness (wire breakage or
ers to each female side.
4 defective contact of con-
nector) (broken commu- Between ECM J2 (female) (21) and E34 (female) (3) Max. 10 Ω
nication line)
Between ECM J2 (female) (45) and E34 (female) (2) Max. 10 Ω
Between K10 (female) (A) and E34 (female) (3) Max. 10 Ω
Resistance
Between K10 (female) (B) and E34 (female) (2) Max. 10 Ω
Between K11 (female) (A) and E34 (female) (3) Max. 10 Ω
Between K11 (female) (B) and E34 (female) (2) Max. 10 Ω
f failure code (no open circuit) is still displayed after above checks in cause 2,
measure resistance at any one place in Hi line and Lo line.
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
3. Disconnect all related connectors, and connect T-adapter to the female
Ground fault in wiring side of the connector to be measured.
5 harness (contact with
Between one of ECM J2(female)(21),K10(female)
ground circuit)
(A),K11(female)(A),E31(female)(3),E32(female)
Min.100 kΩ
(2),E26(female)(3),E34(female)(3),E36(female)
(3),P63(female)(2) and ground
Resistance
Between one of ECM J2(female)(45), K10(female)(B),
K11(female)(B), E31(female)(2), E32(female)(3),
Min.100 kΩ
E26(female)(2), E34(female)(2), E36(female)(2),
P63(female)(1) and ground

HB365LC-3 40-659
FAILURE CODE [CA4152] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

f failure code (no open circuit) is still displayed after above checks in cause 11,
measure resistance at any one place in Hi line and Lo line.
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery
disconnect switch to OFF position.
3. Insert T-adapter into one of the related connectors.
Hot short circuit in wiring
6 4. Set battery disconnect switch to ON position.
harness
5. Turn starting switch to ON position.
Between one of ECM J2(21), K10(A), K11(A), E31(3),
1 to 4 V
E32(2), E26(3), E34(3), E36(3), or P63(2) and ground
Voltage
Between one of ECM J2(45), K10(B), K11(B), E31(2),
1 to 4 V
E32(3), E26(2), E34(2), E36(2), or P63(1) and ground
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)
1. Turn starting switch to OFF position.
2. Replace SCR temperature sensor (E34).
Defective SCR tempera-
8 3. Turn starting switch to ON position.
ture sensor
If this failure code is cleared, the original sensor is defective. (In case of an internal
defect, troubleshooting is impossible as an assembly. Replace whole assembly.)

40-660 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4152]

Circuit diagram related to SCR system CAN communication

HB365LC-3 40-661
FAILURE CODE [CA4155] 40 TROUBLESHOOTING

FAILURE CODE [CA4155] (ALL-K-AFKL-410-50-B)

Action level Failure code AdBlue/DEF Pump Heater Relay Voltage High Error
Failure
L01 CA4155 (Engine controller system)
Detail of fail-
A high voltage error is detected in AdBlue/DEF pump heater relay circuit.
ure
Action of
Advances to Inducement strategy.
controller
• Engine output is reduced based on inducement strategy.
Phenomenon
• AdBlue/DEF thawing defective.
on machine
• NOx emission increases because AdBlue/DEF injection is disabled at low temperature.
• AdBlue/DEF pump heater relay is driven at AdBlue/DEF supply system thawing/thermal
insulation or an AdBlue/DEF pump heater relay test.
• AdBlue/DEF pump heater relay is integrated in the AdBlue/DEF heater relay.
• Troubleshooting of this failure code covers circuits from engine controller through
Related
AdBlue/DEF heater relay to ground.
information
• This failure code is detected only when the AdBlue/DEF pump heater relay is turned OFF.
• This failure code is displayed if the connector is removed.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equipment” in
“CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
TROUBLESHOOTING”, and check it.
Defective wiring harness 2. See “service modes” of “setting and operating machine monitor”, “operating
1
connector method of testing menu (SCR service test)” to perform an “AdBlue/DEF pump
heater relay test”.
If this failure code is cleared, wiring harness connector is defective.
1.Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors ECM J2, R53A and MB02, and connect T-adapters to
ness (wire breakage or each female side.
2
defective contact of con-
nector) Between R53A (female) (12) and ground Max. 10 Ω
Resistance
Between ECM J2 (female) (83) and R53A (female) (3) Max. 10 Ω
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector R53A, and connect T-adapter to female side.
3
harness 3. Turn starting switch to ON position.
Voltage Between R53A (female) (3) and (12) Max. 4.5 V
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn the bat-
tery disconnect switch OFF.
Defective AdBlue/DEF 3. Disconnect connector R53A and R53B, and replace AdBlue/DEF heater
4 relay.
heater relay
4. Turn the battery disconnect switch ON.
5. Turn starting switch to ON position.
If this failure code is cleared, the original AdBlue/DEF heater relay is defective.

40-662 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4155]

No. Cause Procedure, measuring location, criteria and remarks

Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)

Electrical circuit diagram related to AdBlue/DEF heater relay

HB365LC-3 40-663
FAILURE CODE [CA4156] 40 TROUBLESHOOTING

FAILURE CODE [CA4156] (ALL-K-AFKL-410-40-B)

Action level Failure code AdBlue/DEF Pump Heater Relay Voltage Low Error
Failure
L01 CA4156 (Engine controller system)
Detail of fail-
A low voltage error is detected in AdBlue/DEF pump heater relay circuit.
ure
Action of
None in particular
controller
Phenomenon • AdBlue/DEF thawing defective.
on machine • NOx emission increases because AdBlue/DEF injection is disabled at low temperature.
• AdBlue/DEF pump heater relay is driven at AdBlue/DEF supply system thawing/thermal
insulation or “a AdBlue/DEF pump heater relay test”.
• AdBlue/DEF pump heater relay is integrated in the AdBlue/DEF heater relay.
• Troubleshooting of this failure code covers circuits from engine controller through
Related AdBlue/DEF heater relay to ground.
information • This failure code is detected only when the AdBlue/DEF pump heater relay is turned ON.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start the engine in low temperature (ambient temperature of 5 °C or below) or
see “service modes” of “setting and operating machine monitor”, and “explanation of oper-
ating method of testing menu (SCR service test)” to perform “AdBlue/DEF pump heater re-
lay test”.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equipment” in
“CHECKS BEFORE TROUBLESHOOTING” of “RELATED INFORMATION ON
TROUBLESHOOTING”, and check it.
Defective wiring harness 2. See “service modes” of “setting and operating machine monitor”, “operating
1
connector method of testing menu (SCR service test)” to perform an “AdBlue/DEF pump
heater relay test”.
If this failure code is cleared, wiring harness connector is defective.
Check if fuse No. 3 in fuse box F02 is blown.
Defective fuse No. 3 in
2 REMARK
fuse box F02
If blown, perform troubleshooting for ground fault in wiring harness.
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors ECM J2, R53A and MB02, and connect T-adapters to
ness (wire breakage or each female side.
3
defective contact of con-
nector) Between R53A (female) (12) and ground Max. 10 Ω
Resistance
Between ECM J2 (female) (83) and R53A (female) (3) Max. 10 Ω
1. Turn starting switch to OFF position.
Ground fault in wiring
2. Disconnect connectors ECM J2, and R53A, and connect T-adapter to any of
harness
4 female sides.
(Contact with ground cir-
cuit) Between ECM J2 (female) (83) and ground, or be-
Resistance Min. 100 kΩ
tween R53A (female) (3) and ground

40-664 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4156]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn the bat-
tery disconnect switch OFF.
Defective AdBlue/DEF 3. Disconnect connector R53A and R53B, and replace AdBlue/DEF heater
5 relay.
heater relay
4. Turn the battery disconnect switch ON.
5. Turn starting switch to ON position.
If this failure code is cleared, the original AdBlue/DEF heater relay is defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-665
FAILURE CODE [CA4156] 40 TROUBLESHOOTING

Electrical circuit diagram related to AdBlue/DEF heater relay

40-666 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4157]

FAILURE CODE [CA4157] (ALL-K-AFH1-410-A0-B)

Action level Failure code AdBlue/DEF FCV malfunction

Failure
L01 CA4157 (Engine controller system)
Detail of fail-
FCV (valve for purge) inside the AdBlue/DEF pump may be defective.
ure
Action of
Stops purging AdBlue/DEF.
controller
Phenomenon
AdBlue/DEF pump may break when it is frozen and it may result in failure of AdBlue/DEF injection.
on machine
• Engine controller does not display this failure code while AdBlue/DEF supply system is un-
der thawing control. (It cannot judge because AdBlue/DEF injection is disabled.)
• Start the engine, wait for 3 minutes, and then check that the number showing 4 conditions
below is other than 1 (Thawing). (You cannot troubleshoot this failure until thawing is com-
pleted.)
• The state of each heater is 1: Thawing control, 2: Warming, 3 or 0: OFF. (On the monitor-
ing code screen, input the number directly to check the value.)
19305 AdBlue/DEF Tank Heating State
19306 AdBlue/DEF Line Heater 1 State
19307 AdBlue/DEF Line Heater 2 State
19309 AdBlue/DEF Pump Heater State
• On “Pre-defined Monitoring” screen, AdBlue/DEF pump diagnosis and aftertreatment relat-
ed devices are used. (The numbers below denote monitoring codes).
• Pre-defined Monitoring (18/28) AdBlue/DEF pump
Related 1. 19120 AdBlue/DEF Injection Quantity
information
2. 19108 AdBlue/DEF Pump Pressure
3. 19109 AdBlue/DEF Pump Pressure Sensor Voltage
4. 19304 AdBlue/DEF Pump State
5. 19136 AdBlue/DEF Pump Temperature
6. 19114 AdBlue/DEF Reverting Valve Cmd
• Pre-defined Monitoring (6/28) Aftertreatment related devices
1. 47000 KDPF Outlet Pressure
2. 47100 KDPF Differential Pressure
3. 47200 KDPF 1 Outlet Temperature
4. 47300 KDOC 1 Inlet Temperature
5. 47400 KDOC 1 Outlet Temperature
6. 36400 Common Rail Pressure
NOTICE
For this failure code, after investigating the cause of the problem and completing the re-
pair, perform “Loaded Diagnostics Operation To Clear Failure Code” to make sure the
failure code is cleared. (This failure code is not cleared by simply turning the starting
switch to ON position.)

No. Cause Procedure, measuring location, criteria and remarks

If failure code [CA2976] or [CA3558] or [CA3559] or [CA3571] or [CA3572] or
Defective AdBlue/DEF
1 [CA3577] or [CA3578] is displayed on the abnormality record screen, perform trou-
pump system
bleshooting these first.
Defective AdBlue/DEF If the cause is not determined by above checks, replace the AdBlue/DEF pump.
2
pump

HB365LC-3 40-667
FAILURE CODE [CA4157] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation to Clear Failure Code

Check if the repair has been completed with the following procedure:
(Make sure this failure code is cleared after this procedure.)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position, and start the engine.
3. See “TESTING AND ADJUSTING”, “Service mode” and “Diagnostic Tests menu (Active Regeneration for
Service)” in “SETTING AND OPERATION OF MACHINE MONITOR” to perform “Manual Stationary Regen-
eration”.
4. Check monitoring code 47200 “KDPF 1 Outlet Temperature” exceeds 300 °C and monitoring code 19108
“AdBlue/DEF Pump Pressure” is 900 ± 100 kPa on “Pre-defined Monitoring” screen.
REMARK
For judgment criteria of this troubleshooting, it is necessary for KDPF outlet temperature to be 300 °C or
more in step 7. So raise exhaust temperature by using manual stationary regeneration.
5. Stop “Manual Stationary Regeneration”.
6. Turn the starting switch to OFF position while the KDPF outlet temperature is 300 °C or more and stop the
engine.
REMARK
If the KDPF outlet temperature is 400 °C or more, do not stop the engine to protect devices.
7. Shut down the engine controller, and turn the starting switch to ON position.
REMARK
• If this failure code is cleared, repair is completed.
• In case it is not cleared, return to troubleshooting.

40-668 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4158]

FAILURE CODE [CA4158] (ALL-K-A9KA-410-10-B)

Action level Failure code KDOC and KDPF Temperature Sensor Internal Circuit Error
Failure
L03 CA4158 (Engine controller system)
Detail of fail- An abnormality was detected in any of the sensor circuits: KDOC inlet temperature sensor, KDOC
ure outlet temperature sensor, and KDPF outlet temperature sensor.
• Operate with the KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet
temperature set to the default value (250 °C).
• Engine power deration
Action of • AdBlue/DEF injection stops
controller • EGR valve closed.
• Regeneration control stops.
• Fuel dosing stops.
• Advances to Inducement strategy.
• NOx emission increases because AdBlue/DEF injection is disabled.
• Defective forcible regeneration control.
Phenomenon • KDPF Soot Accumulation High.
on machine • Any of the KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet tempera-
ture cannot be detected.
• Engine power deration according to inducement strategy.
k Be careful not to get burned as the temperature of KDPF and KDOC rises up over 500 °C.
• The KDPF temperature sensor is composed of the KDOC inlet temperature sensor, the
KDOC outlet temperature sensor, and the KDPF outlet temperature sensor and provides
CAN communication with the engine controller integrated into one sensor controller.
Related • For the replacement procedure of the KDPF temperature sensor, see “DISASSEMBLY
AND ASSEMBLY”, “DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY”.
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note that the engine power deration is not canceled only by the failure
code is cleared).

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector
2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Replace KDPF temperature sensor.
Defective KDPF temper-
2 3. Turn starting switch to ON position.
ature sensor
If this failure code is cleared, the original sensor is defective. (In case of an internal
defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-669
FAILURE CODE [CA4159] 40 TROUBLESHOOTING

FAILURE CODE [CA4159] (ALL-K-AFP0-410-40-B)

Action level Failure code SCR Temperature Sensor Internal Circuit Error
Failure
L01 CA4159 (Engine controller system)
Detail of fail- An abnormality is detected in either of the sensor circuits: SCR temperature sensor and SCR outlet
ure temperature sensor.
• The SCR temperature sensor and SCR outlet temperature sensor operate at the latest
Action of normal value.
controller • Advances to Inducement strategy.
• AdBlue/DEF injection stops
• Defective detection of SCR temperature or SCR outlet temperature
Phenomenon
• NOx emission increases because AdBlue/DEF injection is disabled.
on machine
• Engine power deration according to inducement strategy.
k The SCR assembly, sensor fitting piping, and sensor probe become hot (Min. 400 °C). Be
careful not to get burned.
• The SCR temperature sensor and SCR outlet temperature sensor are integrated into one
Related sensor controller which provides CAN communication with the engine controller.
information • For the replacement procedure of the SCR temperature sensor, see “Disassembly and as-
sembly”, “Removal and installation of SCR temperature sensor”.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector
2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Replace SCR temperature sensor.
Defective SCR tempera-
2 ture sensor (internal de- 3. Turn starting switch to ON position.
fect) If this failure code is cleared, the original SCR temperature sensor is defective. (In
case of an internal defect, troubleshooting is impossible as an assembly. Replace
whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

40-670 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4161]

FAILURE CODE [CA4161] (ALL-K-A9KA-410-30-B)

Action level Failure code KDOC and KDPF Temperature Sensor ECU Voltage High Error
Failure
L03 CA4161 (Engine controller system)
Detail of fail-
A battery high voltage error is detected in the KDPF temperature sensor controller.
ure
• Run the engine by using the fixed value of the KDOC inlet temperature, KDOC outlet tem-
perature, and the KDPF outlet temperature (250 °C).
• Engine power deration
Action of • AdBlue/DEF injection stops
controller • EGR valve closed.
• Regeneration control stops.
• Fuel dosing stops.
• Advances to Inducement strategy.
• NOx emission increases because AdBlue/DEF injection is disabled.
• Defective forcible regeneration control.
Phenomenon • KDPF accumulated soot level is high.
on machine • All of the KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet tempera-
ture cannot be detected.
• Engine output is reduced based on inducement strategy.
k Be careful not to get burned as the temperature of KDPF and KDOC rises up over 500 °C.
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.
Related • For replacement of the KDPF temperature sensor, see DISASSEMBLY AND ASSEMBLY,
“DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY”.
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note that the engine power deration is not canceled only by the failure
code is cleared).

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector
2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Check that system operating lamp is not illuminated, and then turn the battery
disconnect switch to OFF position.
3. Disconnect connector R52, and connect T-adapter to female side.
4. Turn the battery disconnect switch to ON position.
2 High battery voltage
5. Turn starting switch to ON position.
Between R52 (female) (1) and (4) 22 to 30 V
Voltage Between R52 (female) (2) and (4) 22 to 30 V
Between R52 (female) (3) and (4) 22 to 30 V

HB365LC-3 40-671
FAILURE CODE [CA4161] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Replace KDPF temperature sensor.
Defective KDPF temper-
3 3. Turn starting switch to ON position.
ature sensor
If this failure code is cleared, the original sensor is defective. (In case of an internal
defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

40-672 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4161]

Circuit diagram related to KDOC/KDPF temperature sensor

HB365LC-3 40-673
FAILURE CODE [CA4162] 40 TROUBLESHOOTING

FAILURE CODE [CA4162] (ALL-K-A9KA-410-40-B)

Action level Failure code KDOC and KDPF Temperature Sensor ECU Voltage Low Error
Failure
L03 CA4162 (Engine controller system)
Detail of fail-
A battery low voltage error is detected in the KDPF temperature sensor controller.
ure
• Run the engine by using the fixed value of the KDOC inlet temperature, KDOC outlet tem-
perature, and the KDPF outlet temperature (250 °C).
• Engine power deration
Action of • AdBlue/DEF injection stops
controller • EGR valve closed.
• Regeneration control stops.
• Fuel dosing stops.
• Advances to Inducement strategy.
• NOx emission increases because AdBlue/DEF injection is disabled.
• Defective forcible regeneration control.
Phenomenon • KDPF Soot Accumulation High.
on machine • All of the KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet tempera-
ture cannot be detected.
• Engine output is reduced based on inducement strategy.
k Be careful not to get burned as the temperature of KDPF and KDOC rises up over 500 °C.
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.
Related
• For replacement of the KDPF temperature sensor, see DISASSEMBLY AND ASSEMBLY,
information
“DISASSEMBLE AND ASSEMBLE KDPF ASSEMBLY”.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note that the engine power deration is not canceled only by the failure
code is cleared).

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector
2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Replace KDPF temperature sensor.
Defective KDPF temper-
2 3. Turn starting switch to ON position.
ature sensor
If this failure code is cleared, the original sensor is defective. (In case of an internal
defect, troubleshooting is impossible as an assembly. Replace whole assembly.)

40-674 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4162]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Check that system operating lamp is not illuminated, and then turn the battery
disconnect switch to OFF position.
3. Disconnect connector R52, and connect T-adapter to female side.
4. Turn the battery disconnect switch to ON position.
3 High battery voltage
5. Turn starting switch to ON position.
Between R52 (female) (1) and (4) 22 to 30 V
Voltage Between R52 (female) (2) and (4) 22 to 30 V
Between R52 (female) (3) and (4) 22 to 30 V
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-675
FAILURE CODE [CA4162] 40 TROUBLESHOOTING

Circuit diagram related to KDOC/KDPF temperature sensor

40-676 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4163]

FAILURE CODE [CA4163] (ALL-K-A9KA-410-50-B)

Action level Failure code KDOC and KDPF Temperature Sensor ECU Over Temperature Error
Failure
L01 CA4163 (Engine controller system)
Detail of fail-
KDOC/KDPF temperature sensor controller temperature high error
ure
Action of
None in particular
controller
• Defective forcible regeneration control
Phenomenon
• All of the KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet tempera-
on machine
ture cannot be detected.
k Be careful not to get burned as the temperature of KDPF and KDOC rises up over 500 °C.
• The KDOC inlet temperature sensor, the KDOC outlet temperature sensor, and the KDPF
outlet temperature sensor are integrated into one sensor controller which provides CAN
communication with the engine controller.
• For replacement of the KDPF temperature sensor, see Disassembly and assembly, “Dis-
Related assembly and assembly of KDPF assembly”.
information NOTICE
For this failure code, after investigating the cause of the problem and completing the re-
pair, perform “Loaded Diagnostics Operation To Confirm Failure Correction” to make
sure that the failure code is cleared. (Repair completion cannot be judged without rais-
ing the exhaust temperature even if this failure code is cleared by turning ON the start-
ing switch)

No. Cause Procedure, measuring location, criteria and remarks

Exhaust gas leakage Check if the temperature sensor controller environmental temperature is extraordi-
1 (high environmental tem- nary high (150 °C or above).
perature)
1. Turn starting switch to OFF position.
2. Replace KDPF temperature sensor.
Defective KDPF temper-
2 3. Turn starting switch to ON position.
ature sensor
If this failure code is cleared, the original sensor is defective. (In case of an internal
defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

REMARK
If this failure code is displayed during “Loaded Diagnostics Operation To Confirm Failure Correction”, return to
troubleshooting.
Check if the repair has been completed with the following procedure:
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to the ON position, and check the failure code is cleared. If this failure code is dis-
played, return to troubleshooting.
3. Start the engine.
4. Run the engine at low idle speed for 10 minutes.
5. Run the engine at high idle speed for 10 minutes.
6. If this failure code is cleared, repair is completed.

HB365LC-3 40-677
FAILURE CODE [CA4163] 40 TROUBLESHOOTING

Circuit diagram related to KDOC/KDPF temperature sensor

40-678 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4164]

FAILURE CODE [CA4164] (ALL-K-AFP0-410-50-B)

Action level Failure code SCR Temperature Sensor ECU Voltage High Error
Failure
L01 CA4164 (Engine controller system)
Detail of fail-
High voltage error is detected in power supply voltage of SCR temperature sensor controller.
ure
• The SCR temperature and SCR outlet temperature are the latest normal value for opera-
Action of tion.
controller • Advances to Inducement strategy.
• AdBlue/DEF injection stops
• Defective detection of SCR temperature and SCR outlet temperature.
Phenomenon
• NOx emission increases because AdBlue/DEF injection is disabled.
on machine
• Engine power deration according to inducement strategy.
k The SCR assembly, sensor fitting piping, and sensor probe become hot (Min. 400 °C). Be
careful not to get burned.
• The SCR temperature sensor and SCR outlet temperature sensor are integrated into one
Related sensor controller which provides CAN communication with the engine controller.
information • For the replacement procedure of the SCR temperature sensor, see “DISASSEMBLY AND
ASSEMBLY”, “REMOVE AND INSTALL SCR TEMPERATURE SENSOR”.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector
2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Check that system operating lamp is not illuminated, and then turn the battery
disconnect switch to OFF position.
3. Disconnect connector R52, and connect T-adapter to female side.
4. Turn the battery disconnect switch to ON position.
2 High battery voltage
5. Turn starting switch to ON position.
Between R52 (female) (1) and (4) 22 to 30 V
Voltage Between R52 (female) (2) and (4) 22 to 30 V
Between R52 (female) (3) and (4) 22 to 30 V
1. Turn starting switch to OFF position.
2. Replace SCR temperature sensor.
Defective SCR tempera-
3 ture sensor (internal de- 3. Turn starting switch to ON position.
fect) If this failure code is cleared, the original SCR temperature sensor is defective. (In
case of an internal defect, troubleshooting is impossible as an assembly. Replace
whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-679
FAILURE CODE [CA4164] 40 TROUBLESHOOTING

Electrical circuit diagram related to SCR temperature sensor

40-680 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4165]

FAILURE CODE [CA4165] (ALL-K-AFP0-410-60-B)

Action level Failure code SCR Temperature Sensor ECU Voltage Low Error
Failure
L01 CA4165 (Engine controller system)
Detail of fail-
Low voltage error is detected in power supply voltage of SCR temperature sensor controller.
ure
• The SCR temperature and SCR outlet temperature are the latest normal value for opera-
Action of tion.
controller • Advances to Inducement strategy.
• AdBlue/DEF injection stops
• Defective detection of SCR temperature and SCR outlet temperature.
Phenomenon
• NOx emission increases because AdBlue/DEF injection is disabled.
on machine
• Engine power deration according to inducement strategy.
k The SCR assembly, sensor fitting piping, and sensor probe become hot (Min. 400 °C). Be
careful not to get burned.
• The SCR temperature sensor and SCR outlet temperature sensor are integrated into one
Related sensor controller which provides CAN communication with the engine controller.
information • For the replacement procedure of the SCR temperature sensor, see “DISASSEMBLY AND
ASSEMBLY”, “REMOVE AND INSTALL SCR TEMPERATURE SENSOR”.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector
2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Check that system operating lamp is not illuminated, and then turn the battery
disconnect switch to OFF position.
3. Disconnect connector R52, and connect T-adapter to female side.
4. Turn the battery disconnect switch to ON position.
2 Low battery voltage
5. Turn starting switch to ON position.
Between R52 (female) (1) and (4) 22 to 30 V
Voltage Between R52 (female) (2) and (4) 22 to 30 V
Between R52 (female) (3) and (4) 22 to 30 V
1. Turn starting switch to OFF position.
2. Replace SCR temperature sensor.
Defective SCR tempera-
3 ture sensor (internal de- 3. Turn starting switch to ON position.
fect) If this failure code is cleared, the original SCR temperature sensor is defective. (In
case of an internal defect, troubleshooting is impossible as an assembly. Replace
whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-681
FAILURE CODE [CA4165] 40 TROUBLESHOOTING

Electrical circuit diagram related to SCR temperature sensor

40-682 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4166]

FAILURE CODE [CA4166] (ALL-K-AFP0-410-70-B)

Action level Failure code SCR Temperature Sensor ECU High Temperature Error
Failure
L01 CA4166 (Engine controller system)

Detail of fail- High temperature error is detected in SCR temperature sensor controller.
ure (Min. 150 °C)
Action of
None in particular
controller
Phenomenon
• Defective detection of SCR temperature and SCR outlet temperature
on machine

k The SCR assembly, sensor fitting piping, and sensor probe become hot (Min. 400 °C). Be
careful not to get burned.
• The SCR temperature sensor and SCR outlet temperature sensor are integrated into one
sensor controller which provides CAN communication with the engine controller.
• For the replacement procedure of the SCR temperature sensor, see “DISASSEMBLY AND
Related ASSEMBLY”, “REMOVE AND INSTALL SCR TEMPERATURE SENSOR”.
information NOTICE
For this failure code, after investigating the cause of the problem and completing the re-
pair, perform “Loaded Diagnostics Operation To Confirm Failure Correction” to make
sure that the failure code is cleared. (Repair completion cannot be judged without rais-
ing the exhaust temperature even if this failure code is cleared by turning ON the start-
ing switch)

No. Cause Procedure, measuring location, criteria and remarks

Exhaust gas leakage Check if the temperature sensor controller environmental temperature is extraordi-
1 (high environmental tem- nary high (150 °C or above).
perature)
1. Turn starting switch to OFF position.
2. Replace SCR temperature sensor.
Defective SCR tempera- 3. Turn starting switch to ON position.
2 ture sensor (internal de-
fect) 4. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If this failure code is cleared, the original sensor is defective. (In case of an internal
defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Confirm Failure Correction

REMARK
If this failure code is displayed during “Loaded Diagnostics Operation To Confirm Failure Correction”, return to
troubleshooting.
Check if the repair has been completed with the following procedure:
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to the ON position, and check the failure code is cleared. If this failure code is dis-
played, return to troubleshooting.
3. Start the engine.
4. Run the engine at low idle speed for 10 minutes.
5. Run the engine at high idle speed for 10 minutes.

HB365LC-3 40-683
FAILURE CODE [CA4166] 40 TROUBLESHOOTING

6. If this failure code is cleared, repair is completed.

40-684 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4168]

FAILURE CODE [CA4168] (ALL-K-AFKL-410-60-B)

Action level Failure code AdBlue/DEF pump heater ON stuck error

Failure
L01 CA4168 (Engine controller system)

Detail of fail- • Pump drive part of AdBlue/DEF heater relay is actuated unnecessarily.
ure • AdBlue/DEF heater relay (pump heater relay part) may be defective.
Action of
None in particular
controller
Phenomenon
AdBlue/DEF pump breaks down.
on machine
• When there is a heat source around AdBlue/DEF pump, this failure code may be dis-
played.
• In this troubleshooting, if the default of 19136 AdBlue/DEF Pump Temperature exceeds
42 °C, “Loaded Diagnostics Operation To Confirm Failure Correction” is disabled, and
therefore, controller cannot determine the completion of repair.
• When ambient temperature is not low, 19309 AdBlue/DEF Pump Heater State is “0” nor-
mally. (1: Thawing, 2: Warming, 3 or 0: OFF)
• On “Pre-defined Monitoring” screen, AdBlue/DEF pump thawing control diagnosis is used.
(The numbers below denote monitoring codes).
Related • Pre-defined Monitoring (22/28) AdBlue/DEF pump thawing control
information 1. 19107 AdBlue/DEF Pump Heater 1 Command
2. 19309 AdBlue/DEF Pump Heater State
3. 19136 AdBlue/DEF Pump Temperature
4. 19304 AdBlue/DEF Pump State
5. 19400 Ambient Temperature
6. 03203 Battery Power Supply
NOTICE
For this failure code, after investigating the cause of the problem and completing the repair,
perform “Loaded Diagnostics Operation to Confirm Failure Correction” to make sure the fail-
ure code is cleared. (Completion of repair cannot be judged simply by turning the starting
switch to ON position.)

No. Cause Procedure, measuring location, criteria and remarks

Defective AdBlue/DEF Perform troubleshooting for failure code [CA3558] or [CA3559] or [CA2976].
1
pump system
Defective AdBlue/DEF Perform troubleshooting for failure codes [CA4155] and [CA4156].
2 pump heater relay sys-
tem
Check for ambient temperature of 10 °C or above (condition under which
AdBlue/DEF pump heater is not working).
1. Turn starting switch to OFF position.
Hot short circuit in wiring
3 2. Disconnect connector MB02, and connect T-adapter to female side.
harness
3. Turn starting switch to ON position.
Voltage Between MB02 (female) (5) and (6) Max. 1 V
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation to Confirm Failure Correction

Check if the repair has been completed with the following procedure:

HB365LC-3 40-685
FAILURE CODE [CA4168] 40 TROUBLESHOOTING

(Make sure this failure code is not displayed after this procedure.)
1. Turn the starting switch to ON position (Do not start the engine).
2. Check if monitoring code 19136 “AdBlue/DEF Pump Temperature” is 42 °C or less and 19107“AdBlue/DEF
Pump Heater 1 Command” is “0” on the “Pre-defined Monitoring” screen.
3. Wait for 10 minutes.
4. If the AdBlue/DEF Pump Temperature rises 12 °C or less after the starting switch is turned to ON, repair will
be completed.
5. After the repair is completed, see “PROCEDURE FOR TESTING AND TROUBLESHOOTING” to clear the
failure code and make sure that the failure code has been cleared from the Abnormality Record screen.
REMARK
If the increase of “AdBlue/DEF Pump Temperature” is 12 °C or more after the starting switch is turned to ON,
return to troubleshooting.

40-686 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4168]

Electrical circuit diagram related to AdBlue/DEF pump heater

HB365LC-3 40-687
FAILURE CODE [CA4169] 40 TROUBLESHOOTING

FAILURE CODE [CA4169] (ALL-K-AFH0-410-00-B)

Action level Failure code AdBlue/DEF pump heater OFF stuck error
Failure
L01 CA4169 (Engine controller system)
Detail of fail-
AdBlue/DEF pump thawing cannot be completed.
ure
Action of
None in particular
controller
Phenomenon • AdBlue/DEF pump thawing is disabled.
on machine • NOx emission increases because AdBlue/DEF injection is disabled at low temperature.
• On Pre-defined Monitoring screen, AdBlue/DEF pump thawing control is used.
• 19309 AdBlue/DEF Pump Heater State, 1: Thawing, 2: Warming, 3 or 0: OFF
(The numbers below denote monitoring codes.)
AdBlue/DEF pump thawing control diagnosis
• Pre-defined Monitoring (22/28) AdBlue/DEF pump thawing control
1. 19107 AdBlue/DEF Pump Heater 1 Command
2. 19309 AdBlue/DEF Pump Heater State
3. 19136 AdBlue/DEF Pump Temperature
4. 19304 AdBlue/DEF Pump State
5. 19400 Ambient Temperature
6. 03203 Battery Power Supply
Related NOTICE
information For this failure code, after investigating the cause of the problem and completing the repair,
perform “Loaded Diagnostics Operation To Confirm Failure Correction”, and determine by
that result if repair is completed.
(Do not determine the completion of repair by clearing of failure code.)
(This failure code is not cleared by simply turning the starting switch to ON position or per-
forming “AdBlue/DEF Pump Heater Relay Drive Test”.)
• When starting switch is turned to ON position, if “AdBlue/DEF Pump Temperature” is
higher than45 °C, controller cannot determine the completion of repair correctly even
if “Loaded Diagnostics Operation To Confirm Failure Correction” is performed. Wait
until AdBlue/DEF pump temperature becomes 45 °C or lower.
• If “AdBlue/DEF Pump Temperature” is 55 °C or higher, “AdBlue/DEF Pump Heater
Relay Drive Test” cannot of “Loaded Diagnostics Operation To Confirm Failure Cor-
rection” be performed.

No. Cause Procedure, measuring location, criteria and remarks

Defective AdBlue/DEF Perform troubleshooting for failure code [CA3558] or [CA3559] or [CA2976].
1
pump system
Defective AdBlue/DEF Perform troubleshooting for failure codes [CA4155] and [CA4156].
2 pump heater relay sys-
tem
1. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
Defective AdBlue/DEF 2. If the AdBlue/DEF pump temperature does not rise by at least 5 °C during
3
pump heater the test, replace the AdBlue/DEF pump.
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation to Confirm Failure Correction

Check if the repair has been completed with the following procedure:

40-688 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4169]

(Make sure this failure code is not displayed after this procedure.)
1. Turn the starting switch to ON position (Do not start the engine).
2. Check if monitoring code 19136 “AdBlue/DEF Pump Temperature” is 45 °C or below (If not, wait until moni-
toring code 19136 “AdBlue/DEF Pump Temperature” falls down to below 45 °C).
3. See “TESTING AND ADJUSTING”, “Service mode” and “Inspection menu (SCR Service Test)” in “SET-
TING AND OPERATION OF MACHINE MONITOR” to perform “AdBlue/DEF Pump Heater Relay Test”.
4. When the increase of monitoring code 19136“AdBlue/DEF Pump Temperature” is 5 °C or more from the
start of testing within 30 minutes, repair is completed.
5. After the repair is completed, see “CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING” to
clear the failure code and make sure that the failure code has been cleared from the “Abnormality Record”
screen.
REMARK
When the increase of “AdBlue/DEF Pump Temperature is not ” 5 °C or more from the start of testing after 30
minutes, return to troubleshooting.

HB365LC-3 40-689
FAILURE CODE [CA4171] 40 TROUBLESHOOTING

FAILURE CODE [CA4171] (ALL-K-AFH0-410-10-B)

Action level Failure code AdBlue/DEF Pump Thawing Error

Failure
L01 CA4171 (Engine controller system)
Detail of fail-
AdBlue/DEF pump thawing is not complete.
ure
Action of
None in particular
controller
Phenomenon • AdBlue/DEF pump is not thawed.
on machine • NOx emission increases because AdBlue/DEF injection is disabled at low temperature.
• 19309 AdBlue/DEF Pump Heater State, 1: Thawing 2: Heating 3 or 0: OFF
(the figures below denote monitoring codes).
Troubleshooting for AdBlue/DEF pump thawing control
19107 AdBlue/DEF Pump Heater Control Command
19309 AdBlue/DEF Pump Heater State
19136 AdBlue/DEF Pump Temperature
19304 AdBlue/DEF Pump State
19400 Ambient Temperature
03203 Battery Power Supply
Related NOTICE
information After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to check if the repair is completed.
(Clearing the failure code does not determine the completion of repair.)
(This failure code is not cleared by starting switch at ON position or “AdBlue/DEF pump
heater relay drive test” only.)
• If “AdBlue/DEF pump temperature ” is 45 °C or higher when starting switch is turned
to ON position, “Loaded Diagnostics Operation To Confirm Failure Correction” can-
not determine if the repair is completed successfully, therefore, wait until
“AdBlue/DEF pump temperature” becomes 45 °C or lower.
• In addition, if “AdBlue/DEF pump temperature” is 55 °C or higher, “AdBlue/DEF
pump heater relay drive test” in “Loaded Diagnostics Operation To Confirm Failure
Correction” is disabled.

No. Cause Procedure, measuring location, criteria and remarks

Defective AdBlue/DEF Perform troubleshooting for failure code [CA3558] or [CA3559] or [CA2976].
1
pump system
Defective AdBlue/DEF Perform troubleshooting for failure codes [CA4155] and [CA4156].
2 pump heater relay sys-
tem
Check if fuse No. 3 in fuse box F02 is blown.
Defective fuse No. 3 in
3 REMARK
fuse box F02
If blown, perform troubleshooting for ground fault in wiring harness.
1. Turn starting switch to OFF position.
Open or short circuit in 2. Disconnect connector R53A, and connect T-adapter to female side.
4
wiring harness
Resistance Between R53A (female) (2) and (12) 4 to 40 Ω

40-690 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4171]

No. Cause Procedure, measuring location, criteria and remarks

1. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
Defective AdBlue/DEF 2. If the AdBlue/DEF pump temperature does not rise by at least 5 °C during
5
pump heater the test, replace the AdBlue/DEF pump.
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
6
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation to Confirm Failure Correction

Check if the repair has been completed with the following procedure:
(Make sure this failure code is not displayed after this procedure.)
1. Turn the starting switch to ON position (Do not start the engine).
2. Check if monitoring code 19136 “AdBlue/DEF Pump Temperature” is 45 °C or below (If not, wait until moni-
toring code 19136 “AdBlue/DEF Pump Temperature” falls down to below 45 °C).
3. See “TESTING AND ADJUSTING”, “Service mode” and “Inspection menu (SCR Service Test)” in “SET-
TING AND OPERATION OF MACHINE MONITOR” to perform “AdBlue/DEF Pump Heater Relay Test”.
4. When the increase of monitoring code 19136“AdBlue/DEF Pump Temperature” is 5 °C or more from the
start of testing within 30 minutes, repair is completed.
5. After the repair is completed, see “CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING” to
clear the failure code and make sure that the failure code has been cleared from the “Abnormality Record”
screen.
REMARK
When the increase of “AdBlue/DEF Pump Temperature is not ” 5 °C or more from the start of testing after 30
minutes, return to troubleshooting.

HB365LC-3 40-691
FAILURE CODE [CA4171] 40 TROUBLESHOOTING

Electrical circuit diagram related to AdBlue/DEF pump heater

40-692 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4249]

FAILURE CODE [CA4249] (ALL-K-AFH0-410-20-B)

Action level Failure code AdBlue/DEF Pump Temperature Sensor 1 In Range Error
Failure
L01 CA4249 (Engine controller system)
Detail of fail-
AdBlue/DEF pump temperature sensor 1 response is poor.
ure
Action of
None in particular
controller
Phenomenon • AdBlue/DEF pump is not thawed.
on machine • NOx emission increases because AdBlue/DEF injection is disabled at low temperature.
• 19309 “AdBlue/DEF Pump Heater State”, 1: Thawing 2: Heating 3 or 0: OFF
(the figures below denote monitoring codes).
Troubleshooting for AdBlue/DEF pump thawing control
19107 AdBlue/DEF Pump Heater Control Command
19309 AdBlue/DEF Pump Heater State
19136 AdBlue/DEF Pump Temperature
19304 AdBlue/DEF Pump State
19400 Ambient Temperature
03203 Battery Power Supply
Related NOTICE
information After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to check if the repair is completed.
(Clearing the failure code does not determine the completion of repair.)
(This failure code is not cleared by starting switch at ON position or “AdBlue/DEF pump
heater relay drive test” only.)
• If “AdBlue/DEF pump temperature” is 45 °C or higher when starting switch is turned
to ON position, “Loaded Diagnostics Operation To Confirm Failure Correction” can-
not determine if the repair is completed successfully, therefore, wait until
“AdBlue/DEF pump temperature” becomes 45 °C or lower.
• In addition, if “AdBlue/DEF pump temperature” is 55 °C or higher, “AdBlue/DEF
pump heater relay drive test” in “Loaded Diagnostics Operation To Confirm Failure
Correction” is disabled.

No. Cause Procedure, measuring location, criteria and remarks

Defective AdBlue/DEF Perform troubleshooting for failure code [CA3558] or [CA3559] or [CA2976].
1
pump system
Defective AdBlue/DEF Perform troubleshooting for failure codes [CA4155] and [CA4156].
2 pump heater relay sys-
tem
1. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
Defective AdBlue/DEF 2. If the AdBlue/DEF pump temperature does not rise by at least 5 °C during
3 pump temperature sen-
the test, replace the AdBlue/DEF pump.
sor
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation to Confirm Failure Correction

Check if the repair has been completed with the following procedure:
(Make sure this failure code is not displayed after this procedure.)

HB365LC-3 40-693
FAILURE CODE [CA4249] 40 TROUBLESHOOTING

1. Turn the starting switch to ON position (Do not start the engine).
2. Check if monitoring code 19136 “AdBlue/DEF Pump Temperature” is 45 °C or below (If not, wait until moni-
toring code 19136 “AdBlue/DEF Pump Temperature” falls down to below 45 °C).
3. See “TESTING AND ADJUSTING”, “Service mode” and “Inspection menu (SCR Service Test)” in “SET-
TING AND OPERATION OF MACHINE MONITOR” to perform “AdBlue/DEF Pump Heater Relay Test”.
4. When the increase of monitoring code 19136“AdBlue/DEF Pump Temperature” is 5 °C or more from the
start of testing within 30 minutes, repair is completed.
5. After the repair is completed, see “CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING” to
clear the failure code and make sure that the failure code has been cleared from the “Abnormality Record”
screen.
REMARK
When the increase of “AdBlue/DEF Pump Temperature is not ” 5 °C or more from the start of testing after 30
minutes, return to troubleshooting.

40-694 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4251]

FAILURE CODE [CA4251] (ALL-K-AFH1-410-B0-B)

Action level Failure code AdBlue/DEF Pump Temperature Sensor 2 In Range Error
Failure
L01 CA4251 (Engine controller system)
Detail of fail-
AdBlue/DEF pump temperature sensor 2 response is poor.
ure
Action of
None in particular
controller
Phenomenon • AdBlue/DEF pump is not thawed
on machine • NOx emission increases because AdBlue/DEF injection is disabled at low temperature.
• 19309 “AdBlue/DEF Pump Heater State”, 1: Thawing 2: Heating 3 or 0: OFF
(the figures below denote monitoring codes).
Troubleshooting for AdBlue/DEF pump thawing control
19107 AdBlue/DEF Pump Heater Control Command
19309 AdBlue/DEF Pump Heater State
19136 AdBlue/DEF Pump Temperature
19304 AdBlue/DEF Pump State
19400 Ambient Temperature
03203 Battery Power Supply
Related NOTICE
information After investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Confirm Failure Correction” to check if the repair is completed.
(Clearing the failure code does not determine the completion of repair.)
(This failure code is not cleared by starting switch at ON position or “AdBlue/DEF pump
heater relay drive test” only.)
• If “AdBlue/DEF pump temperature” is 45 °C or higher when starting switch is turned
to ON position, “Loaded Diagnostics Operation To Confirm Failure Correction” can-
not determine if the repair is completed successfully, therefore, wait until
“AdBlue/DEF pump temperature” becomes 45 °C or lower.
• In addition, if “AdBlue/DEF pump temperature” is 55 °C or higher, “AdBlue/DEF
pump heater relay drive test” in “Loaded Diagnostics Operation To Confirm Failure
Correction” is disabled.

No. Cause Procedure, measuring location, criteria and remarks

Defective AdBlue/DEF Perform troubleshooting for failure code [CA3558] or [CA3559] or [CA2976].
1
pump system
Defective AdBlue/DEF Perform troubleshooting for failure codes [CA4155] and [CA4156].
2 pump heater relay sys-
tem
1. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
Defective AdBlue/DEF 2. If the AdBlue/DEF pump temperature does not rise by at least 5 °C during
3 pump temperature sen-
the test, replace the AdBlue/DEF pump.
sor
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation to Confirm Failure Correction

Check if the repair has been completed with the following procedure:
(Make sure this failure code is not displayed after this procedure.)

HB365LC-3 40-695
FAILURE CODE [CA4251] 40 TROUBLESHOOTING

1. Turn the starting switch to ON position.

2. Check if monitoring code 19136 “AdBlue/DEF Pump Temperature” is 45 °C or below (If not, wait until moni-
toring code 19136 “AdBlue/DEF Pump Temperature” falls down to below 45 °C).
3. See "TESTING AND ADJUSTING", “Special functions of machine monitor”, “Testing”, “SCR Service Test” to
perform “AdBlue/DEF pump heater relay drive test”.
4. Continue the test approximately for 15 minutes.
5. When on the screen displaying "Test State", Test State parameter “10” and “12” are blinking alternately, re-
pair is completed.
6. After the repair is completed, see “CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING” to
clear the failure code and make sure that the failure code has been cleared from the Abnormality Record
screen.
REMARK
If Test State does not change to “12”, return to troubleshooting.

40-696 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4259]

FAILURE CODE [CA4259] (ALL-K-A9KA-410-20-B)

Action level Failure code KDOC and KDPF Temperature Sensor Power Interrupt Error
Failure
L03 CA4259 (Engine controller system)
Detail of fail- KDPF temperature sensor interrupt power failure error (12 open circuits are detected in the power
ure supply line in 60 seconds.)
Normal control
• Default value of the KDOC inlet temperature, KDOC outlet temperature, and the KDPF
outlet temperature (250 °C).
• Engine power deration
Action of
• AdBlue/DEF injection stops
controller
• EGR valve closed.
• Regeneration control stops.
• Fuel dosing stops.
• Advances to Inducement strategy.
• KDOC inlet temperature, KDOC outlet temperature, and KDPF outlet temperature detec-
tion error.
Phenomenon • Defective regeneration control.
on machine • NOx emission increases because AdBlue/DEF injection is disabled.
• KDPF accumulated soot level is high.
• Engine output is reduced based on inducement strategy.
• Mostly, momentary power failure is caused by defective contact and visually check a torn
harness coating and check for defective contact at the connector.
• To detect an incomplete wire breakage, sway the wiring harness as much as possible at
the resistance measurement to check if the resistance can change or not.
• The KDPF temperature sensor consists of the KDOC inlet temperature sensor, the KDOC
outlet temperature sensor, and the KDPF outlet temperature sensor and is integrated into
one sensor controller which provides CAN communication with the engine controller.
Related • Note that sensor power supply relay connector is energized even if starting switch is
information turned to OFF position.
• For replacement of the KDPF temperature sensor, see Disassembly and assembly, “Dis-
assembly and assembly of KDPF assembly”.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine and travel (vibrate the machine).
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note that the engine power deration is not canceled only by the failure
code is cleared).

No. Cause Procedure, measuring location, criteria and remarks

Defective sensor power Perform troubleshooting for failure code [CA1776].
1
supply relay system

HB365LC-3 40-697
FAILURE CODE [CA4259] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery dis-
connect switch to OFF position.
3. Insert T-adapter into connector R52.
Defective sensor power
2 4. Disconnect connector E26.
supply relay
5. Turn battery disconnect switch to ON position.
6. Turn starting switch to ON position.
Voltage Between R52 (8) and (4) Min. 22 V
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connector E26, and connect T-adapter to female side.
3
ness 3. Turn starting switch to ON position.
Voltage Between E26 (female) (4) and (1) Min. 22 V
Defective KDPF temper- If failure code is still displayed after above checks, KDPF temperature sensor may
4 ature sensor (defective be defective. (In case of an internal defect, troubleshooting is impossible as an as-
internal circuit) sembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)
If there is no abnormality in above diagnosis, defective contact of harness is a pos-
6 Defective wiring harness
sibility (Replace harness).

40-698 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4259]

Circuit diagram related to KDPF temperature sensor

HB365LC-3 40-699
FAILURE CODE [CA4261] 40 TROUBLESHOOTING

FAILURE CODE [CA4261] (ALL-K-AFP0-410-90-B)

Action level Failure code SCR Temperature Sensor Power Interrupt Error
Failure
L01 CA4261 (Engine controller system)
Detail of fail- Interrupted power failure error in SCR temperature sensor is detected. (12 open circuits are detect-
ure ed in the power supply line in 60 seconds.)
• Holds the SCR temperature and the SCR outlet temperature using the last normal values.
Action of
• AdBlue/DEF injection stops
controller
• Advances to Inducement strategy.
• SCR temperature and SCR outlet temperature have detection errors.
Phenomenon
• NOx emission increases because AdBlue/DEF injection is disabled.
on machine
• Engine output is reduced based on inducement strategy.
k SCR assembly, the sensor installation piping, and the sensor probe become hot
(Min. 400 °C). Be careful not to get burned.
k Be careful not to get burned by the sensor probe as it is heated by itself even if the
ambient temperature is not high.
• Mostly, momentary power failure is caused by defective contact and visually check a torn
harness coating and check for defective contact at the connector.
• To detect an incomplete wire breakage, sway the wiring harness as much as possible at
Related the resistance measurement to check if the resistance can change or not.
information • The SCR temperature sensor and the SCR outlet temperature sensor are integrated into
one sensor controller which provides CAN communication with the engine controller.
• Note that smart sensor relay connector is energized even if starting switch is turned to
OFF position.
• For replacement of the SCR outlet temperature sensor, see Disassembly and assembly,
“Removal and installation of SCR temperature sensor”.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine and travel (vibrate the machine).

No. Cause Procedure, measuring location, criteria and remarks

Defective sensor power Perform troubleshooting for failure code [CA1776].
1
supply relay system
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn battery dis-
connect switch to OFF position.
Defective sensor power 3. Insert T-adapter into connector R52.
2 supply relay (defective in- 4. Disconnect connector E34.
ternal circuit)
5. Turn battery disconnect switch to ON position.
6. Turn starting switch to ON position.
Voltage Between R52 (9) and (4) Min. 22 V
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connector E34, and connect T-adapter to female side.
3
ness 3. Turn starting switch to ON position.
Voltage Between E34 (female) (4) and (1) Min. 22 V
Defective SCR tempera- If failure code is still displayed after above checks, SCR temperature sensor may
4 ture sensor (internal de- be defective. (In case of an internal defect, troubleshooting is impossible as an as-
fect) sembly. Replace whole assembly.)

40-700 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4261]

No. Cause Procedure, measuring location, criteria and remarks

Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)
If the failure code persists even after replacing the engine controller, defective con-
6 Defective wiring harness
tact of harness is a possibility (Replace harness).

HB365LC-3 40-701
FAILURE CODE [CA4261] 40 TROUBLESHOOTING

Electrical circuit diagram related to SCR temperature sensor

40-702 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4277]

FAILURE CODE [CA4277] (ALL-K-AFG0-410-F0-B)

Action level Failure code AdBlue/DEF quality sensor liquid distinction impossible error
Failure
L01 CA4277 (Engine controller system)
Detail of fail-
AdBlue/DEF sensor cannot measure the quality and that state continues.
ure
Advances to Inducement strategy. (*1)
*1: It corresponds to machines of North America specification which equipped with engines compati-
Action of
ble with EPA and California regulations since 2017.
controller
REMARK
EPA and California regulations can be checked on the nameplate of the engine serial number.
Quality of AdBlue/DEF cannot be measured.
Engine output is reduced based on inducement strategy. (*1)
Phenomenon *1: It corresponds to machines of North America specification which equipped with engines compati-
on machine ble with EPA and California regulations since 2017.
REMARK
EPA and California regulations can be checked on the nameplate of the engine serial number.

HB365LC-3 40-703
FAILURE CODE [CA4277] 40 TROUBLESHOOTING

• If boots are not attached to the AdBlue/DEF tank sensor, install the boots. For details, see
DISASSEMBLY AND ASSEMBLY, “REMOVE AND INSTALL AdBlue/DEF TANK SEN-
SOR”.
• AdBlue/DEF quality sensor is one of AdBlue/DEF tank sensors which are integrated in one
unit with AdBlue/DEF level sensor and AdBlue/DEF temperature sensor. It communicates
with engine controller through CAN communication.
• If AdBlue/DEF quality sensor is Liquid Distinction Impossible state, the last time memory
value of AdBlue/DEF concentration is displayed on the monitor.
• When AdBlue/DEF temperature in tank is 0 °C or lower, the engine controller does not
troubleshoot this failure code. (Failure code is not cleared even after performing machine
operation for clearing the failure code.)
• Check that AdBlue/DEF temperature in tank is 0 °C or higher on Pre-defined Monitoring
screen, and then troubleshoot this failure code.
• When AdBlue/DEF level in tank is 0 %, the engine controller does not troubleshoot this
failure code. (Failure code is not cleared even after performing machine operation for
clearing the failure code.)
• Check that AdBlue/DEF level is 20 % or more on Pre-defined Monitoring screen, and then
Related troubleshoot this failure code.
information • For details of drain method and clean method of AdBlue/DEF tank, see TESTING AND
ADJUSTING, “CLEAN AdBlue/DEF TANK”.
• For AdBlue/DEF level sensor replacement, see DISASSEMBLY AND ASSEMBLY, “RE-
MOVE AND INSTALL AdBlue/DEF TANK SENSOR”.
• On Pre-defined Monitoring screen, AdBlue/DEF level and quality sensor are used. (The
numbers below denote monitoring codes).
• Pre-defined Monitoring (19/23) AdBlue/DEF level, quality sensor
1. 19100 AdBlue/DEF Concentration
2. 19110 AdBlue/DEF Level
3. 19111 AdBlue/DEF Level Corrected
4. 19115 AdBlue/DEF Temperature in Tank
5. 19400 Ambient Temperature
6. 19305 AdBlue/DEF Tank Heating State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. After
investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Clear Failure Code” to make sure the failure code is cleared.
(This failure code is not cleared by simply turning the starting switch to ON position.)

No. Cause Procedure, measuring location, criteria and remarks

1. If failure code [CA1669] or [CA1677] or [CA1678] or [CA1686] or [CA1714]
or [CA1715] or [CA3868] or [CA4277] or [CA4731] or [CA4732] or
Defective AdBlue/DEF [CA4739] or [CA4768] or [CA4769] is displayed, perform troubleshooting
1 these first.
tank sensor system
2. If troubleshooting has been performed, carry out “Loaded Diagnostics Op-
eration To Clear Failure Code” topics.

40-704 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4277]

No. Cause Procedure, measuring location, criteria and remarks

1. Check that the value of AdBlue/DEF level is displayed correctly with moni-
toring function.
REMARK
If AdBlue/DEF is empty and AdBlue/DEF level sensor cannot be sensed, 7 %
is displayed as the AdBlue/DEF level (compensation value).
2 Low AdBlue/DEF amount
2. When AdBlue/DEF is empty, refill AdBlue/DEF.
3. After finishing the work, perform “Loaded Diagnostics Operation To Clear
Failure Code” and the repair is completed.
4. If this failure code is displayed even if AdBlue/DEF level is displayed cor-
rectly, proceed to the next troubleshooting.
1. Drain more than 1 ℓ of AdBlue/DEF to check that it is not contaminated
with foreign material, etc.
2. If the drained AdBlue/DEF is contaminated, drain all of the AdBlue/DEF
and refill with fresh AdBlue/DEF.
Contaminated 3. If it is heavily contaminated with sand, dirt, etc., clean the AdBlue/DEF
3
AdBlue/DEF tank.
4. If the “AdBlue/DEF concentration” is in 29 to 36 % after the work finished,
perform “Loaded Diagnostics Operation To Clear Failure Code”.
5. If the “AdBlue/DEF concentration” is out of the normal range, proceed to
the next troubleshooting.
1. Remove the AdBlue/DEF level sensor so that you can reach the
AdBlue/DEF concentration detection part (end of sensor).
2. Clean up the AdBlue/DEF concentration detection part with dry and clean
cloth, and install the AdBlue/DEF level sensor.
3. If AdBlue/DEF concentration is within the range from 29 to 36 % on "Pre-
defined Monitoring" screen, perform “Loaded Diagnostics Operation to
Clear Failure Code” to complete the repair work.
Foreign matter adhered 4. If AdBlue/DEF concentration is out of the normal range, proceed to the
4 to the sensing part of the next troubleshooting.
AdBlue/DEF tank sensor
REMARK
• If the new AdBlue/DEF has not been added as described in Cause “Conta-
minated AdBlue/DEF”, and if it takes time to remove the sensor, drain the
total amount of AdBlue/DEF, refill with new AdBlue/DEF again, and check
the sensor output.
• For details of removing AdBlue/DEF tank sensor, see DISASSEMBLY AND
ASSEMBLY, “REMOVE AND INSTALL AdBlue/DEF TANK SENSOR
FLANGE ASSEMBLY”.
1. Replace the AdBlue/DEF tank sensor.
2. If the “AdBlue/DEF concentration” displayed on the Pre-defined Monitoring
Defective AdBlue/DEF
screen falls in the range of 29 to 36%, perform “Loaded Diagnostics Oper-
5 tank sensor (internal de-
ation To Clear Failure Code” topics to complete the repair.
fect)
3. If the “AdBlue/DEF concentration” falls outside of this range, proceed to
the next troubleshooting.
1. Replace the engine controller.
Defective engine control- 2.
6 Perform “Loaded Diagnostics Operation To Clear Failure Code”.
ler
3. If this failure code is displayed, perform troubleshooting again.

HB365LC-3 40-705
FAILURE CODE [CA4277] 40 TROUBLESHOOTING

Loaded Diagnostics Operation to Clear Failure Code

Check if the repair has been completed with the following procedure:
(Make sure this failure code is cleared after this procedure.)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position.
3. Wait for 60 minutes. (It is not necessary to start the engine.)
4. If this failure code is cleared, repair is completed.

40-706 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4281]

FAILURE CODE [CA4281] (ALL-K-AFN0-410-80-B)

Action level Failure code SCR NH3 sensor stuck response error
Failure
L01 CA4281 (Engine controller system)
Detail of fail-
Ammonia concentration detected by ammonia sensor does not change quickly.
ure
Action of
Controls AdBlue/DEF injection without using ammonia sensor.
controller
Phenomenon AdBlue/DEF injection becomes inappropriate and the NOx emission may increase, or ammonia may
on machine be discharged.

k SCR assembly, sensor fitting piping, and sensor probe are heated to 400 °C or high-
er. Be careful not to get burn injury.
k As for the sensor probe, be careful not to get burn injury even if the surroundings
are not hot, because sensor itself is heated.
• This is displayed when the data is not obtained by ammonia sensor due to missing of sen-
sor probe on the exhaust pipe, etc.
• This error occurs by clogged AdBlue/DEF injector as well. If failure code [CA3568] or
[CA3582] or [CA4658] is displayed, repair those code first and then perform troubleshoot-
ing.
• When AdBlue/DEF injector is clogged under the outside air temperature at -5 °C or lower,
this error alone may be displayed.
• On “Pre-defined Monitoring” screen, AdBlue/DEF injector diagnosis and engine operation
state diagnosis are used. (The numbers below denote monitoring codes).
• Pre-defined Monitoring (17/28) AdBlue/DEF injector
1. 47200 KDPF 1 Outlet Temperature
Related
2. 19304 AdBlue/DEF Pump State
information 3. 19120 AdBlue/DEF Injection Quantity
4. 19205 SCR NH3 Concentration Corrected
5. 19202 Turbo Outlet NOx Corrected
6. 19209 SCR Outlet NOx Corrected
• Pre-defined Monitoring (16/28) Engine operation state
1. 01002 Engine Speed
2. 18600 Inject Fueling Command
3. 19200 Exhaust Gas Flow Rate
4. 47300 KDOC 1 Inlet Temperature
5. 19300 SCR Temperature
6. 19302 SCR Outlet Temperature
NOTICE
This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. After
investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Clear Failure Code” to make sure the failure code is cleared.
(This failure code is not cleared by simply turning the starting switch to ON position.)

No. Cause Procedure, measuring location, criteria and remarks

Defective AdBlue/DEF in- If failure code [CA3568] or [CA4658] is displayed, perform troubleshooting for the
1
jector system code first.
2 Defective SCR catalyst If failure code [CA3582] is displayed, perform troubleshooting for the code first.

HB365LC-3 40-707
FAILURE CODE [CA4281] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective ammonia sen- 2. Check if the ammonia sensor probe is correctly installed on SCR catalyst and
3 sor is not loose.
(improper installation) 3. After repair is completed, perform “Loaded Diagnostics Operation To Clear
Failure Code”.
1. Check that the “AdBlue/DEF concentration” displayed on the Pre-defined
Monitoring screen is in the normal range (29 to 36 %).
Low AdBlue/DEF con-
4 2. If the “AdBlue/DEF concentration” is out of the normal range, replace the
centration
AdBlue/DEF in the AdBlue/DEF tank, and perform “Loaded Diagnostics
Operation To Clear Failure Code”.
1. Start engine.
2. When SCR temperature is 200 °C or higher on the Pre-defined Monitoring
screen, check for ammonia concentration.
Clogged AdBlue/DEF in- 1) If ammonia concentration indicates approximately 5 to 150(ppm), perform
5 jector “Loaded Diagnostics Operation To Clear Failure Code” because a clogged
AdBlue/DEF injector failure is cleared. (AdBlue/DEF injector is not clogged
(temporarily clogged)
anymore.)
2) If ammonia concentration stays at 0ppm, perform “Testing and adjusting”,
“SPECIAL FUNCTIONS OF MACHINE MONITOR”, “Testing”, “Active Re-
generation for Service”. (Clogged AdBlue/DEF injector)
If the failure code persists after the above checks, the sensor may be defective.
1. Turn starting switch to OFF position.
Defective ammonia sen- 2. Replace the ammonia sensor.
6
sor
3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code is cleared, the original ammonia sensor may be defective.
1. Turn starting switch to OFF position.
2. If this failure code is displayed in above diagnosis, replace an ammonia
Defective ammonia sen- sensor controller.
7
sor controller 3. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code is cleared, the original ammonia sensor controller may be defec-
tive.
If failure code is still displayed after above checks, the turbocharger outlet NOx
sensor may be defective.
(Offset/drift due to sulfur-poisoned turbocharger outlet NOx sensor)
Defective turbocharger 1. Turn starting switch to OFF position.
8
outlet NOx sensor
2. NOx sensor fails, therefore, replace the turbocharger outlet NOx sensor.
3. Turn starting switch to ON position.
4. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If failure code is still displayed after above checks, the intake system may be defec-
tive.
(Offset/drift due to the deteriorated and aged MAF sensor, distorted intake system,
damaged rectifier)
Defective air intake sys- 1. Check for a defective air intake pipe and repair or replace any damaged or
9
tem defective rectifier, if any.
2. Replace mass air flow (MAF) sensor.
3. Turn starting switch to ON position.
4. Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.

40-708 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4281]

No. Cause Procedure, measuring location, criteria and remarks

1. If the failure code persists after the above checks, replace the engine con-
Defective engine control-
troller.
10 2.
ler Perform “Loaded Diagnostics Operation To Confirm Failure Correction”.
If the failure code disappeared, the engine controller may be defective.

Loaded Diagnostics Operation To Clear Failure Code

Check if the repair has been completed with the following procedure.
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Start the engine.
3. Secure a safety condition and run the engine at low idle (with no load) for approximately 1 minute.
4. After finishing the warm-up operation, set the swing lock switch to ON position, working mode to B, and fuel
control dial to MAX position.
5. Perform arm IN relief operation for approximately 30 seconds.
NOTICE
Take care not to overheat the hydraulic oil.
Check that the monitoring code 19300 “SCR Temperature” is 290 °C or higher and the monitoring
code 19202 “Turbo Outlet NOx Corrected” is 120 ppm or more on the Pre-defined Monitoring
screen.
6. Run the engine at high idle with no load for 30 seconds.
NOTICE
Take care not to overheat the hydraulic oil.
Check that the monitoring code 19300 “SCR Temperature” is around 250 °C on the Pre-defined
Monitoring screen.
7. Repeat above steps 5 and 6 up to 20 times.
8. Repeat high idle run under no load for 5 minutes and arm IN relief operation for 3 minutes for 5 times.
9. If this failure code is cleared, repair work is completed.
10. If this failure code is not cleared, return to troubleshooting.
Checklist
Relieve the Arm IN Run the engine at high idle (with no load)
Operation
for 30 seconds for 30 seconds
SCR Temperature
Monitoring screen
ID: 19300
Value to be checked Around 250 °C
1st time
2nd time
3rd time
4th time
5th time
6th time
7th time
8th time
9th time

HB365LC-3 40-709
FAILURE CODE [CA4281] 40 TROUBLESHOOTING

Relieve the Arm IN Run the engine at high idle (with no load)
Operation
for 30 seconds for 30 seconds
SCR Temperature
Monitoring screen
ID: 19300
Value to be checked Around 250 °C
10th time
11th time
12th time
13th time
14th time
15th time
16th time
17th time
18th time
19th time
20th time

Relieve the Arm IN Run the engine at high idle (with no load)
Operation
for 3 min. for 5 min.
SCR Temperature
Monitoring screen
ID: 19300
Value to be checked Min. 290 °C Around 250 °C
1st time
2nd time
3rd time
4th time
5th time

40-710 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4459]

FAILURE CODE [CA4459] (ALL-K-AFKL-410-20-B)

Action level Failure code AdBlue/DEF line heater relay 2 voltage high error
Failure
L01 CA4459 (Engine controller system)
Detail of fail-
High voltage error occurs in AdBlue/DEF line heater relay 2 circuit.
ure
Action of
None in particular
controller
Phenomenon AdBlue/DEF line stops thawing
on machine NOx emission increases because AdBlue/DEF injection is disabled at low temperature.
• AdBlue/DEF line heater relay 2 is driven at AdBlue/DEF supply system thawing/thermal in-
sulation or “AdBlue/DEF Line Heater Relay 2 Test”.
• AdBlue/DEF line heater relay 2 is built in AdBlue/DEF heater relay.
• Troubleshooting of this failure code covers circuits from engine controller through
AdBlue/DEF heater relay to power supply.
Related
• This failure code is detected only when AdBlue/DEF line heater 2 is turned ON.
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start the engine in low temperature (engine room temperature is Max. 12 °C)
or perform AdBlue/DEF line heater 2 test.
(See “service modes” of “SET AND OPERATE MACHINE MONITOR”, and “METHOD
FOR OPERATING TESTING MENU (SCR SERVICE TEST)”.)

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
FORMATION ON TROUBLESHOOTING”, and check them.
2. Start the engine in low temperature (engine room temperature of 12 °C or
Defective wiring harness
1 lower) or perform “AdBlue/DEF Line Heater Relay 2 Test”. For details, see
connector
SET AND OPERATE MACHINE MONITOR, “SERVICE MODE” and
“METHOD FOR SETTING WITH TESTING MENU (SCR SERVICE
TEST)”.
If this failure code is displayed, the wiring harness connector is defective.
1. Turn the starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector R53A, and connect T-adapter to female side.
Hot short circuit in wiring
2 4. Turn the battery disconnect switch to ON position.
harness
5. Turn the starting switch to ON position (with connector R53A disconnect-
ed).
Voltage Between R53A (female) (11) and (12) Max. 3 V

HB365LC-3 40-711
FAILURE CODE [CA4459] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn the bat-
tery disconnect switch OFF.
3. Disconnect connector R53A and R53B, and replace AdBlue/DEF heater
relay.
Defective AdBlue/DEF
3 4. Turn the battery disconnect switch ON.
heater relay
5. Perform the “AdBlue/DEF line heater relay 2 test”by staring the engine in
low ambient temperature (12 °C or below), or by referring “SERVICE
MODES” of setting and operating machine monitor, “METHOD FOR OP-
ERATING TESTING MENU (SCR SERVICE TEST)”.
If this failure code is cleared, the original AdBlue/DEF heater relay is defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

40-712 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4459]

Circuit diagram related to AdBlue/DEF line heater

HB365LC-3 40-713
FAILURE CODE [CA4461] 40 TROUBLESHOOTING

FAILURE CODE [CA4461] (ALL-K-AFKL-410-30-B)

Action level Failure code AdBlue/DEF line heater relay 2 voltage low error
Failure
L01 CA4461 (Engine controller system)
Detail of fail-
A low voltage error occurs in AdBlue/DEF line heater relay 2 circuit.
ure
Action of
Advances to Inducement strategy.
controller
• AdBlue/DEF line stops thawing.
Phenomenon
• NOx emission increases.
on machine
• Engine output is reduced based on inducement strategy.
• AdBlue/DEF line heater relay 2 is driven at AdBlue/DEF supply system thawing/thermal in-
sulation or “AdBlue/DEF line heater relay 2 test”.
• AdBlue/DEF line heater relay 2 is integrated in the AdBlue/DEF heater relay.
• Troubleshooting of this failure code covers circuits from engine controller through
Related AdBlue/DEF heater relay to power supply.
information • This failure code is detected only when the AdBlue/DEF line heater relay 2 is turned OFF.
• This failure code is displayed if connector R53A is removed when AdBlue/DEF line heater
2 is turned OFF.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “c: Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
Check if fuse No. 4 in fuse box F02 is blown.
Defective fuse No. 4 in
2 REMARK
fuse box F02
If blown, perform troubleshooting for ground fault in wiring harness.
1. Turn the starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
Open circuit in wiring har- 3. Disconnect connector R53B, and connect T-adapter to female side.
3 ness (sensor relay power
4. Turn the battery disconnect switch to ON position.
supply side)
5. Turn the starting switch to ON position.
Voltage Between ground and R53B (female) (1) or (2) Min. 22 V
If no failure is found by above checks, this check is not required.
1. Turn the starting switch to OFF position.
Open circuit in wiring har- 2. Turn the battery disconnect switch to OFF position.
4 ness (line heater relay
drive signal side) 3. Disconnect the connectors J2 and R53A, and connect the T-adapter to
each female side.
Resistance Between J2 (female) (7) and R53A (female) (11) Max. 10 Ω

40-714 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4461]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
Ground fault in wiring
3. Disconnect the connectors J2 and R53A, and connect the T-adapter to ei-
5 harness (contact with
ground circuit) ther female side.
Between ground and J2 (female) (7) or R53A (female)
Resistance Min. 100 kΩ
(11)
1. Starting switch: OFF
2. Turn the battery disconnect switch to OFF position.
Short circuit in wiring har- 3. Disconnect connectors ECM J2 and R53A, and connect T-adapter to fe-
6
ness male side of ECM J2.
Between ECM J2 (female) (7) and each pin other than No continui-
Continuity
pin (7) ty
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn the bat-
tery disconnect switch OFF.
Defective AdBlue/DEF 3. Disconnect connector R53A and R53B, and replace AdBlue/DEF heater
7 relay.
heater relay
4. Turn the battery disconnect switch ON.
5. Turn starting switch to ON position.
If this failure code is cleared, the original AdBlue/DEF heater relay is defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
8
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-715
FAILURE CODE [CA4461] 40 TROUBLESHOOTING

Circuit diagram related to AdBlue/DEF line heater

40-716 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4658]

FAILURE CODE [CA4658] (ALL-K-AFJ0-410-00-B)

Action level Failure code AdBlue/DEF injection flow rate decrease.

Failure
- CA4658 (Engine controller system)
Detail of fail-
AdBlue/DEF injector or AdBlue/DEF pressure hose is clogged.
ure
Action of
• None in particular
controller
Phenomenon
• NOx emission increases because AdBlue/DEF injection is disabled.
on machine

HB365LC-3 40-717
FAILURE CODE [CA4658] 40 TROUBLESHOOTING

k AdBlue/DEF injector part is heated to 400 °C or higher. Be careful not to get burn injury.
• This failure code is displayed together with failure codes whose possible cause is clogging
of AdBlue/DEF injector or AdBlue/DEF hose. This is the failure code to identify the failure
place, and need not to be treated individually.
• This failure code is displayed for the purpose of monitoring for cause identification of the
failure codes [CA3151] and [CA3543]. It is not necessary to troubleshoot and replace parts
when this failure code is displayed alone.
• Even if cause of failure is eliminated, it takes time to detect that the cause has been elimi-
nated, so the failure code may be displayed continuously, but no action is required.
• Engine controller does not display this failure code while AdBlue/DEF supply system is un-
der thawing control. (It cannot judge because AdBlue/DEF injection is disabled.)
• Start the engine, wait for 3 minutes, and then check that the number showing 4 conditions
below is other than 1 (Thawing). (You cannot troubleshoot this failure until thawing is com-
pleted.)
• The state of each heater is 1: Thawing control, 2: Warming, 3 or 0: OFF.
On the monitoring code screen, input following number directly to check the value.
19305 AdBlue/DEF Tank Heating State
19306 AdBlue/DEF Line Heater 1 State
19307 AdBlue/DEF Line Heater 2 State
Related
19309 AdBlue/DEF Pump Heater State
information
• On Pre-defined Monitoring screen, AdBlue/DEF injector diagnosis and AdBlue/DEF pump
diagnosis are used. (The numbers below denote monitoring codes).
• Pre-defined Monitoring (17/28) AdBlue/DEF injector
1. 47200 KDPF 1 Outlet Temperature
2. 19304 AdBlue/DEF Pump State
3. 19120 AdBlue/DEF Injection Quantity
4. 19205 SCR NH3 Concentration Corrected
5. 19202 Turbo Outlet NOx Corrected
6. 19209 SCR Outlet NOx Corrected
• Pre-defined Monitoring (18/28) AdBlue/DEF pump
1. 19120 AdBlue/DEF Injection Quantity
2. 19108 AdBlue/DEF Pump Pressure
3. 19109 AdBlue/DEF Pump Pressure Sensor Voltage
4. 19304 AdBlue/DEF Pump State
5. 19136 AdBlue/DEF Pump Temperature
6. 19114 AdBlue/DEF Reverting Valve Cmd
NOTICE
This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. After
investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Clear Failure Code” to make sure the failure code is cleared.
(This failure code is not cleared by simply turning the starting switch to ON position.)

No. Cause Procedure, measuring location, criteria and remarks

1. Start the engine, run it with low idle.
2. At approximately 2 minutes after the starting of the engine, check that
19108 AdBlue/DEF pump pressure is kept around 900 kPa.
Reset of judgment condi- 3. Check that 19120 AdBlue/DEF Injection Quantity is “0”.
1
tions If it is still injected (the injection quantity is not “0”), wait for the injection to
stop. (It takes Max. 30 minutes to stop AdBlue/DEF. )
4. Wait 3 minutes after AdBlue/DEF Injection Quantity becomes “0”.
5. Performing “Loaded Diagnostics Operation To Clear Failure Code”.

40-718 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4658]

No. Cause Procedure, measuring location, criteria and remarks

Defective AdBlue/DEF If failure code [CA3558] or [CA3559] or [CA3571] or [CA3572] is displayed on the
2
pump system abnormality record screen, perform troubleshooting these first.
Defective AdBlue/DEF in- If failure code [CA3567] is displayed on the abnormality record screen, perform
3
jector system troubleshooting these first.
See “TESTING AND ADJUSTING”, “SERVICE MODE” and “METHOD FOR SET-
TING WITH TESTING MENU (SCR SERVICE TEST)” in “SETTING AND OPERA-
TION OF MACHINE MONITOR” to perform “AdBlue/DEF Injector Rate Test”.
Case 1: AdBlue/DEF injection stops
The AdBlue/DEF injector or the AdBlue/DEF pressure hose may be clogged. Pro-
ceed to cause 5 to determine the cause of the failure.
Failure of the Case 2: AdBlue/DEF injection continues for more than 2 seconds without stoppage
4
AdBlue/DEF injector 1. The AdBlue/DEF injector is stuck open. Replace with a new one.
2. To remove the accumulated deposits of AdBlue/DEF in SCR, see “SET-
TING AND OPERATION OF MACHINE MONITOR” of “SERVICE MODE”,
and “METHOD FOR SETTING WITH TESTING MENU (SCR SERVICE
TEST)” to perform “Active Regeneration for Service” for 3 times (Refer-
ence: Approximately 2 hours is required in total (40 minutes per opera-
tion))
1. Prepare a container at the injector to receive drained AdBlue/DEF.
2. Remove the hose at AdBlue/DEF injector to allow AdBlue/DEF to drain.
3. See “TESTING AND ADJUSTING”, “SERVICE MODE” of “SETTING AND OP-
ERATION OF MACHINE MONITOR”, “METHOD FOR SETTING WITH TEST-
ING MENU (SCR SERVICE TEST)” to perform an “AdBlue/DEF Pump Pres-
sure Up Test”.
4. If AdBlue/DEF flows out from the AdBlue/DEF pressure hose while the AdBl-
Clogged AdBlue/DEF ue/DEF pump pressure does not reach 900 kPa, there is no clogging in the
5
pressure hose AdBlue/DEF pressure hose.
5. The AdBlue/DEF injector is clogged. Replace it.
6. If the AdBlue/DEF pump pressure stays at 900 kPa, there is a clogging in the
AdBlue/DEF pressure hose. Clean or replace the AdBlue/DEF hose.
REMARK
Failure code [CA1682] may be displayed if the pressure does not rise within 3
minutes while performing the “AdBlue/DEF Pump Pressure Up Test”.
If failure code is still displayed after above checks, the AdBlue/DEF injector may
Clogged AdBlue/DEF in-
have been temporarily clogged but is now normal.
6 jector
Perform “Loaded Diagnostics Operation To Clear Failure Code”. If this failure code
(temporarily clogged)
is cleared, repair is completed.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
7
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation To Clear Failure Code

Check if the repair has been completed with the following procedure.
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Start the engine, and perform the warm-up operation.
3. Set the working mode to B.
4. Check that the monitoring code 19108 “AdBlue/DEF Pump Pressure” is around 900 kPa.
5. Turn the fuel control dial to MAX position, and run the engine at high idle speed with no load for 30 sec-
onds.
6. Turn the fuel control dial to MAX position, and perform the work equipment relief operation for 30 seconds.

HB365LC-3 40-719
FAILURE CODE [CA4658] 40 TROUBLESHOOTING

7. Repeat above steps 5 and 6 up to 20 times.

8. If this failure code is cleared (if this failure code is not displayed), the repair work is completed.
9. If this failure code is not cleared, return to troubleshooting.

40-720 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4731]

FAILURE CODE [CA4731] (ALL-K-AFG0-410-70-B)

Action level Failure code AdBlue/DEF Temperature Sensor Transmission Data Error
Failure
L01 CA4731 (Engine controller system)
Detail of fail-
Temperature data sent by AdBlue/DEF sensor is abnormal.
ure
Action of
Advances to Inducement strategy. (EU Specification).
controller
Phenomenon • AdBlue/DEF temperature cannot be measured.
on machine • Engine output is reduced based on inducement strategy. (EU Specification).
• AdBlue/DEF level sensor is one of AdBlue/DEF tank sensors and is integrated with AdBl-
ue/DEF temperature sensor and AdBlue/DEF quality sensor, providing CAN communica-
Related tion with the engine controller.
information • This failure code is displayed unless an approved sensor is installed.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Check the sensor connector for contamination and damage.
2. Turn starting switch to OFF position.
3. Replace the AdBlue/DEF tank sensor.
Defective AdBlue/DEF
2 4. Turn starting switch to ON position.
tank sensor
If this failure code is cleared, any internal parts in the original AdBlue/DEF tank
sensor is defective. (In case of an internal defect, troubleshooting is impossible as
an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-721
FAILURE CODE [CA4732] 40 TROUBLESHOOTING

FAILURE CODE [CA4732] (ALL-K-AFG0-410-80-B)

Action level Failure code AdBlue/DEF Level Sensor Transmission Data Error
Failure
L01 CA4732 (Engine controller system)
Detail of fail-
Level data sent by AdBlue/DEF sensor is abnormal.
ure
Action of
Advances to Inducement strategy. (EU Specification).
controller
Phenomenon • AdBlue/DEF level cannot be measured.
on machine • Engine output is reduced based on inducement strategy. (EU Specification).
• AdBlue/DEF level sensor is one of AdBlue/DEF tank sensors and is integrated with AdBl-
ue/DEF temperature sensor and AdBlue/DEF quality sensor, providing CAN communica-
Related tion with the engine controller.
information • This failure code is displayed unless an approved sensor is installed.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Check the sensor connector for contamination and damage.
2. Turn starting switch to OFF position.
3. Replace the AdBlue/DEF tank sensor.
Defective AdBlue/DEF
2 4. Turn starting switch to ON position.
tank sensor
If this failure code is cleared, any internal parts in the original AdBlue/DEF tank
sensor is defective. (In case of an internal defect, troubleshooting is impossible as
an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

40-722 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4739]

FAILURE CODE [CA4739] (ALL-K-AFG0-410-90-B)

Action level Failure code AdBlue/DEF Level Sensor Internal Circuit Error
Failure
L01 CA4739 (Engine controller system)
Detail of fail-
AdBlue/DEF level sensor is defective (an error is detected in level measurement circuit)
ure
Action of
Advances to Inducement strategy. (EU Specification).
controller
Phenomenon • AdBlue/DEF level cannot be measured.
on machine • Engine output is reduced based on inducement strategy. (EU Specification).
• AdBlue/DEF level sensor is one of AdBlue/DEF tank sensors and is integrated with AdBl-
ue/DEF temperature sensor and AdBlue/DEF quality sensor, providing CAN communica-
tion with the engine controller.
Related
• This failure code is displayed when the engine controller receives information stating the
information level measurement circuit is abnormal.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Check the sensor connector for contamination and damage.
2. Turn starting switch to OFF position.
3. Replace the AdBlue/DEF tank sensor.
Defective AdBlue/DEF
2 4. Turn starting switch to ON position.
tank sensor
If this failure code is cleared, any internal parts in the original AdBlue/DEF tank
sensor is defective. (In case of an internal defect, troubleshooting is impossible as
an assembly. Replace whole assembly.)
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
3
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-723
FAILURE CODE [CA4768] 40 TROUBLESHOOTING

FAILURE CODE [CA4768] (ALL-K-AFG0-410-G0-B)

Action level Failure code Fuel in AdBlue/DEF Tank Error

Failure
L03 CA4768 (Engine controller system)
Detail of fail-
AdBlue/DEF tank is contaminated with diesel fuel.
ure
• Stops AdBlue/DEF injection.
Action of
• Stops AdBlue/DEF pump.
controller
• Engine power deration
Phenomenon • NOx emission increases because AdBlue/DEF injection is disabled.
on machine • Engine power deration.
• If AdBlue/DEF tank temperature is 0 °C or below, the engine controller does not trouble-
shoot this failure code (“Loaded Diagnostics Operation To Clear Failure Code” does not
clear this failure code).
• Make sure that AdBlue/DEF tank temperature is 0 °C or above on the Pre-defined Monitor-
ing screen before troubleshooting this failure code.
• When AdBlue/DEF tank level is 0 %, the engine controller does not troubleshoot this fail-
ure code (“Loaded Diagnostics Operation To Clear Failure Code” does not clear this failure
code).
• Make sure that AdBlue/DEF tank temperature is 20 % or above on the Pre-defined Moni-
toring screen before troubleshooting this failure code.
Related
• For draining and cleaning procedures of AdBlue/DEF tank, see Testing and adjusting,
information “AdBlue/DEF Tank Washing”.
• For the replacement procedure of AdBlue/DEF tank sensor, see Disassembly and assem-
bly, “Disassembly and assembly of AdBlue/DEF tank sensor”.
• Engine power deration is canceled by turning starting switch to OFF position after this fail-
ure code is cleared (note that the engine power deration is not canceled only by the failure
code is cleared).
NOTICE
This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. After
investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Clear Failure Code” to make sure the failure code is cleared.

No. Cause Procedure, measuring location, criteria and remarks

1. If failure code [CA1677] or [CA1678] or [CA1686] or [CA1714] or [CA1715]
or [CA3868] or [CA4731] or [CA4732] or [CA4768] is displayed, perform
Defective AdBlue/DEF troubleshooting these first.
1
tank sensor system
2. If troubleshooting has been performed, carry out “Loaded Diagnostics Op-
eration To Clear Failure Code” topics.
1. Drain total amount of the AdBlue/DEF to check that it is not contaminated
with diesel fuel. (Drain total amount of the AdBlue/DEF, since diesel fuel is
lighter than urea solution.)
AdBlue/DEF tank is con-
2 taminated with diesel 2. If it is contaminated with diesel fuel, clean AdBlue/DEF tank.
fuel. 3. After refill with the new AdBlue/DEF, perform “Loaded Diagnostics Opera-
tion To Clear Failure Code”.
4. If this failure code is displayed, proceed to the next troubleshooting.

40-724 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4768]

No. Cause Procedure, measuring location, criteria and remarks

1. Replace the AdBlue/DEF tank sensor.
2. If the “AdBlue/DEF concentration” displayed on the Pre-defined Monitoring
Defective AdBlue/DEF
screen falls in the range of 29 to 36%, perform “Loaded Diagnostics Oper-
3 tank sensor (internal de-
ation To Clear Failure Code” topics to complete the repair.
fect)
3. If the “AdBlue/DEF concentration” falls outside of this range, proceed to
the next troubleshooting.
1. Replace the engine controller.
Defective engine control- 2.
4 Perform “Loaded Diagnostics Operation To Clear Failure Code”.
ler
3. If this failure code is displayed, perform troubleshooting again.

Loaded Diagnostics Operation to Clear Failure Code

Check if the repair has been completed with the following procedure:
(Make sure this failure code is cleared after this procedure.)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position.
3. Wait for 10 minutes. (Do not start the engine)
4. After the deactivation of this failure code, diesel fuel may remain, so test and replace the SCR system
(pump, hose, etc.).
5. If this failure code is cleared, repair is completed.

HB365LC-3 40-725
FAILURE CODE [CA4769] 40 TROUBLESHOOTING

FAILURE CODE [CA4769] (ALL-K-AFG0-410-H0-B)

Action level Failure code AdBlue/DEF level measurement impossible

Failure
L01 CA4769 (Engine controller system)
Detail of fail-
AdBlue/DEF level sensor cannot measure the AdBlue/DEF level and that state continues.
ure
Action of
Inducement strategy is activated.
controller
• AdBlue/DEF level cannot be measured.
Phenomenon
• Indication of AdBlue/DEF level on the monitor changes.
on machine
• Engine output is reduced based on Inducement strategy.
• This failure code is displayed when AdBlue/DEF tank becomes completely empty.
• Possible causes other than empty AdBlue/DEF tank are sticking of foreign material to
sensing part and defective sensor.
• For this failure code, if the temperature of AdBlue/DEF in tank is 0 °C or lower, the failure
code cannot be cleared.
• On “Pre-defined Monitoring” screen, AdBlue/DEF level and quality sensor are used.
• Pre-defined Monitoring (19/23) AdBlue/DEF level, quality sensor
Related 1. 19100 AdBlue/DEF Concentration
information
2. 19110 AdBlue/DEF Level
3. 19111 AdBlue/DEF Level Corrected
4. 19115 AdBlue/DEF Temperature in Tank
5. 19400 Ambient Temperature
6. 19305 AdBlue/DEF Tank Heating State
NOTICE
This failure code requires“ Loaded Diagnostics Operation To Clear Failure Code”. After
investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Clear Failure Code” to make sure the failure code is cleared.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Check the sight gauge to confirm that there is sufficient amount of
AdBlue/DEF in the AdBlue/DEF tank.
3. If there is no AdBlue/DEF, or AdBlue/DEF level is low.
1) Refill with AdBlue/DEF.
2) Turn starting switch to OFF position.
3) If the value of AdBlue/DEF level is displayed correctly on machine monitor,
perform “Loaded Diagnostics Operation To Clear Failure Code”and repair is
completed.
AdBlue/DEF tank remain- 4) If AdBlue/DEF level is not sensed and the color of AdBlue/DEF icon re-
1
ing amount check mains changed even after AdBlue/DEF has been refilled, proceed to cause
2.
4. If AdBlue/DEF level is normal
1) Turn starting switch to OFF position.
2) If AdBlue/DEF level is not sensed and the color of AdBlue/DEF icon re-
mains changed even after AdBlue/DEF has been refilled, proceed to cause
2.
3) If the value of AdBlue/DEF level is displayed correctly on machine monitor,
perform “Loaded Diagnostics Operation To Clear Failure Code”and repair is
completed.

40-726 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4769]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch OFF, and confirm the following.
1) There is no foreign material such as dirt in AdBlue/DEF tank.
2) There is not a problem in quality and concentration of AdBlue/DEF.
3) There is no foreign material such as dirt attached to AdBlue/DEF sensor.
4) AdBlue/DEF float is not stuck.
2. Repair, or replace to solve if any of these failures are found.
Check inside conditions
2
of AdBlue/DEF tank 3. Turn starting switch to ON position.
4. If the value of AdBlue/DEF level is displayed correctly on machine monitor,
perform “Loaded Diagnostics Operation To Clear Failure Code” and repair
is completed.
5. If AdBlue/DEF level is not sensed and the color of AdBlue/DEF icon re-
mains changed even after performing remedy for these, proceed to cause
3.
• Check the sensor connector for contamination and damage.
• Make sure that DEF tank contains 15 % or more of AdBlue/DEF.
1. Turn starting switch to OFF position.
Defective AdBlue/DEF 2. Replace the AdBlue/DEF tank sensor.
3
tank sensor
3. Turn starting switch to ON position.
4. If the value of AdBlue/DEF level is displayed correctly on machine monitor,
perform “Loaded Diagnostics Operation To Clear Failure Code” and repair is
completed.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

Loaded Diagnostics Operation to Clear Failure Code

Check if the repair has been completed with the following procedure:
(Make sure this failure code is cleared after this procedure.)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position.
3. Display monitoring code 19115 “AdBlue/DEF Temperature in Tank” on “Pre-defined Monitoring” screen.
4. Stand by with the lever and pedal of the machine not operated.
Standby time depends on the initial value of the AdBlue/DEF temperature in tank as follows:
• When the value is 0 °C or below, run the engine and wait for 2 hours after the temperature in tank rises
up to 0 °C or above.
• When the value ranges from 0 to 5 °C, stand by for 60 minutes. (engine may be either started or not.)
• When the value is 5 °C or above, stand by for 30 minutes. (engine may be either started or not.)
5. If this failure code is cleared, repair is completed.

HB365LC-3 40-727
FAILURE CODE [CA4842] 40 TROUBLESHOOTING

FAILURE CODE [CA4842] (ALL-K-AFD0-410-10-B)

Action level Failure code AdBlue/DEF high concentration error

Failure
L01 CA4842 (Engine controller system)
Detail of fail-
AdBlue/DEF concentration is high (40 % or more).
ure
• Inducement strategy is activated. (*1)
• Stops AdBlue/DEF injection. (*1)

Action of
• Stops AdBlue/DEF pump. (*1)
*1: It corresponds to machines of EU, Japan, and North America specification which equipped with
controller
engines compatible with EPA and California regulations since 2017.
REMARK
EPA and California regulations can be checked on the nameplate of the engine serial number.
Engine power derates according to Inducement strategy. (*1)
*1: It corresponds to machines of EU, Japan, and North America specification which equipped with
Phenomenon
engines compatible with EPA and California regulations since 2017.
on machine
REMARK
EPA and California regulations can be checked on the nameplate of the engine serial number.

40-728 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4842]

When machine is operated on slopes or travels on rough ground, top surface of AdBlue/DEF in the
tank fluctuates largely, and the level or concentration of AdBlue/DEF may not be detected correctly.
If AdBlue/DEF level monitor lights up in red or warning for concentration is displayed when machine
is operated on slopes or travels on rough ground, immediately move the machine to level ground,
clear the failure code related to concentration according to step 3 “Contaminated AdBlue/DEF” and
subsequent procedures, and add AdBlue/DEF. If these phenomena occur repeatedly, increase the
AdBlue/DEF in AdBlue/DEF tank.
• When AdBlue/DEF temperature in tank is 0 °C or lower, the engine controller does not
troubleshoot this failure code. (Failure code is not cleared even after performing machine
operation for clearing the failure code.)
• Check that AdBlue/DEF temperature in tank is 0 °C or higher on Pre-defined Monitoring
screen, and then troubleshoot this failure code.
• When AdBlue/DEF level in tank is 0 %, the engine controller does not troubleshoot this
failure code. (Failure code is not cleared even after performing machine operation for
clearing the failure code.)
• Check that AdBlue/DEF level is 20 % or more on Pre-defined Monitoring screen, and then
troubleshoot this failure code.
Related
• For details of drain method and clean method of AdBlue/DEF tank, see TESTING AND
information ADJUSTING, “CLEAN AdBlue/DEF TANK”.
• For AdBlue/DEF level sensor replacement, see DISASSEMBLY AND ASSEMBLY, “RE-
MOVE AND INSTALL AdBlue/DEF LEVEL SENSOR”.
• On “Pre-defined Monitoring” screen, AdBlue/DEF level and quality sensor are used. (The
numbers below denote monitoring codes).
• Pre-defined Monitoring (19/23) AdBlue/DEF level, quality sensor
1. 19100 AdBlue/DEF Concentration
2. 19110 AdBlue/DEF Level
3. 19111 AdBlue/DEF Level Corrected
4. 19115 AdBlue/DEF Temperature in Tank
5. 19400 Ambient Temperature
6. 19305 AdBlue/DEF Tank Heating State
NOTICE
This failure code requires “Loaded Diagnostics Operation To Clear Failure Code”. After
investigating the cause of the problem and completing the repair, perform “Loaded Di-
agnostics Operation To Clear Failure Code” to make sure the failure code is cleared.
(This failure code is not cleared by simply turning the starting switch to ON position.)

No. Cause Procedure, measuring location, criteria and remarks

1. If failure code [CA1669] or [CA1677] or [CA1678] or [CA1686] or [CA1714]
or [CA1715] or [CA3868] or [CA4277] or [CA4731] or [CA4732] or
Defective AdBlue/DEF [CA4739] or [CA4768] or [CA4769] is displayed, perform troubleshooting
1 these first.
tank sensor system
2. If troubleshooting has been performed, carry out “Loaded Diagnostics Op-
eration To Clear Failure Code” topics.

HB365LC-3 40-729
FAILURE CODE [CA4842] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Check that the “AdBlue/DEF concentration” displayed on the Pre-defined
Monitoring screen is in the normal range (29 to 36 %).
2. If the “AdBlue/DEF concentration” is normal, perform “Loaded Diagnostics
Operation To Clear Failure Code”.
3. If the “AdBlue/DEF concentration” falls outside of this range, use a porta-
High AdBlue/DEF con- ble concentration meter to recheck the concentration. If the concentration
2
centration still falls outside of the range of 31.5 to 33.5 %, drain all of the AdBlue/DEF
from the tank and refill with fresh AdBlue/DEF.
4. If the “AdBlue/DEF concentration” is in 29 to 36 % after the work finished,
perform “Loaded Diagnostics Operation To Clear Failure Code”.
5. If the portable concentration meter reading is in the range of 31.5 to
33.5 %, proceed to the next troubleshooting.
1. Drain more than 1 ℓ of AdBlue/DEF to check that it is not contaminated
with foreign material, etc.
2. If the drained AdBlue/DEF is contaminated, drain all of the AdBlue/DEF
and refill with fresh AdBlue/DEF.
Contaminated 3. If it is heavily contaminated with sand, dirt, etc., clean the AdBlue/DEF
3
AdBlue/DEF tank.
4. If the “AdBlue/DEF concentration” is in 29 to 36 % after the work finished,
perform “Loaded Diagnostics Operation To Clear Failure Code”.
5. If the “AdBlue/DEF concentration” is out of the normal range, proceed to
the next troubleshooting.
1. Remove the AdBlue/DEF level sensor so that you can reach the
AdBlue/DEF concentration detection part (end of sensor).
2. Clean up the AdBlue/DEF concentration detection part with dry and clean
cloth, and install the AdBlue/DEF level sensor.
3. If AdBlue/DEF concentration is within the range from 29 to 36 % on "Pre-
defined Monitoring" screen, perform “Loaded Diagnostics Operation to
Clear Failure Code” to complete the repair work.
Foreign matter adhered 4. If AdBlue/DEF concentration is out of the normal range, proceed to the
4 to the sensing part of the next troubleshooting.
AdBlue/DEF tank sensor
REMARK
• If the new AdBlue/DEF has not been added as described in Cause “Conta-
minated AdBlue/DEF”, and if it takes time to remove the sensor, drain the
total amount of AdBlue/DEF, refill with new AdBlue/DEF again, and check
the sensor output.
• For details of removing AdBlue/DEF tank sensor, see DISASSEMBLY AND
ASSEMBLY, “REMOVE AND INSTALL AdBlue/DEF TANK SENSOR
FLANGE ASSEMBLY”.
1. Replace the AdBlue/DEF tank sensor.
2. If the “AdBlue/DEF concentration” displayed on the Pre-defined Monitoring
Defective AdBlue/DEF
screen falls in the range of 29 to 36%, perform “Loaded Diagnostics Oper-
5 tank sensor (internal de-
ation To Clear Failure Code” topics to complete the repair.
fect)
3. If the “AdBlue/DEF concentration” falls outside of this range, proceed to
the next troubleshooting.

40-730 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4842]

No. Cause Procedure, measuring location, criteria and remarks

1. Replace the engine controller.
Defective engine control- 2. If “AdBlue/DEF concentration” ranges from 29 to 36 % on the Trouble-
6
ler shooting Pre-defined Monitoring screen, perform “Loaded Diagnostics Op-
eration To Clear Failure Code” and repair is completed.

Loaded Diagnostics Operation to Clear Failure Code

Check if the repair has been completed with the following procedure:
(Make sure this failure code is cleared after this procedure.)
1. Turn the starting switch to OFF position, and shut down the engine controller.
2. Turn the starting switch to ON position.
3. Display monitoring code 19115 “AdBlue/DEF Temperature in Tank” on “Pre-defined Monitoring” screen.
4. Stand by with the lever and pedal of the machine not operated.
Standby time depends on the initial value of the AdBlue/DEF temperature in tank as follows:
• When the value is 0 °C or below, run the engine and wait for 2 hours after the temperature in tank rises
up to 0 °C or above.
• When the value ranges from 0 to 5 °C, stand by for 60 minutes. (engine may be either started or not.)
• When the value is 5 °C or above, stand by for 30 minutes. (engine may be either started or not.)
5. If this failure code is cleared, repair is completed.

HB365LC-3 40-731
FAILURE CODE [CA4952] 40 TROUBLESHOOTING

FAILURE CODE [CA4952] (ALL-K-AW1Q-410-00-B)

Action level Failure code System Operating Lamp Short Circuit (Engine Controller)
Failure
― CA4952 (Engine controller system)
Detail of fail- Engine controller determines that system operating lamp circuit shorts because voltage of output
ure circuit does not become Low level while engine controller outputs current to system operating lamp.
Action of
Stops driving system operating lamp.
controller
Phenomenon
None in particular
on machine
• Do not turn the battery disconnect switch to OFF position while the system operating lamp
is lit.
• If the battery disconnect switch is turned to OFF position while the system operating lamp
is lit, the memory data stored in each controller may be destroyed.
Related
• Although engine controller is not able to light up system operating lamp, no trouble will re-
information sult unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, wiring harness connector is defective.
1. Starting switch: OFF
2. Remove fuse No. 16 in fuse box F01.
Short circuit in wiring har-
2 3. Disconnect connectors CP02, CK01, CM01, ECM J2, and L19, and con-
ness
nect T-adapter to female side of connector L19.
Resistance Between L19 (female) (1) and (2) Min. 100 kΩ
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector L19, and connect T-adapter to female side.
3
harness 3. Turn starting switch to ON position .
Voltage Between L19 (female) (2) and ground Max. 1 V
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

40-732 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA4952]

Circuit diagram related to system operating lamp

HB365LC-3 40-733
FAILURE CODE [CA5115] 40 TROUBLESHOOTING

FAILURE CODE [CA5115] (ALL-K-AFK5-410-30-B)

Action level Failure code AdBlue/DEF Line Heater 1 Voltage Low Error
Failure
L01 CA5115 (Engine controller system)
Detail of fail- A low voltage error occurs in AdBlue/DEF line heater 1 ( low-temperature pressure, intake and re-
ure turn side) signal circuit.
Action of
None in particular
controller
Phenomenon • AdBlue/DEF line stops thawing.
on machine • NOx emission increases because AdBlue/DEF injection is disabled at low temperature.
• AdBlue/DEF line heater 1 is driven at AdBlue/DEF supply system thawing/thermal insula-
tion or “AdBlue/DEF line heater relay 1 test”.
• AdBlue/DEF line heater 1 is driven by AdBlue/DEF line heater relay 1 inside AdBlue/DEF
heater relay.
Related • This failure code is detected only when the AdBlue/DEF line heater 1 is turned ON.
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start the engine in low temperature (ambient temperature of 5 °C or below) or
see “service modes” of “setting and operating machine monitor”, and “explanation of oper-
ating method of testing menu (SCR service test)” to perform “AdBlue/DEF line heater relay
1 test”.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
FORMATION ON TROUBLESHOOTING”, and check them.
Defective wiring harness 2. Start the engine in low temperature (ambient temperature of 5 °C or lower)
1
connector or perform “AdBlue/DEF Line Heater Relay 1 Test”. For details, see SET
AND OPERATE MACHINE MONITOR, “SERVICE MODE” and “METHOD
FOR SETTING WITH TESTING MENU (SCR SERVICE TEST)”.
If this failure code is cleared, the wiring harness connector is defective.
1. Turn the starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connectors ECM J2, R53A, MB04, MB05 and MB07, and con-
nect T-adapter to each female side.
Between ECM J2 (female) (39) and R53A (female) (8) Max. 10 Ω
Between R53A (female) (12) and ground Max. 10 Ω
Open circuit in wiring har-
2 Between MB04 (female) (1) and R53A (female) (2) Max. 10 Ω
ness
Between MB04 (female) (2) and ground Max. 10 Ω
Resistance
Between MB05 (female) (1) and R53A (female) (6) Max. 10 Ω
Between MB05 (female) (2) and ground Max. 10 Ω
Between MB07 (female) (1) and R53A (female) (5) Max. 10 Ω
Between MB07 (female) (2) and ground Max. 10 Ω

40-734 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA5115]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect the connectors ECM J2, R53A, MB04 and MB05, and connect
the T-adapter to any female side.
Ground fault in wiring Between ground and ECM J2 (female) (39) or R53A
3 Min. 100 kΩ
harness (female) (8)
Between ground and R53A (female) (5) or MB05 (fe-
Resistance Min. 100 kΩ
male) (1)
Between ground and R53A (female) (6) or MB04 (fe-
Min. 100 kΩ
male) (1)
1. Turn starting switch to OFF position.
2. Disconnect connector MB04 and MB05, MB07, and connect T-adapter to
male side.
Between MB04 (male) (1) and (2) 5 to 40 Ω
Defective AdBlue/DEF Between MB05 (male) (1) and (2) 5 to 40 Ω
4
line heater
Between MB07 (male) (1) and (2) 5 to 40 Ω
Resistance
Between ground and MB04 (male) (1) Min. 100 kΩ
Between ground and MB05 (male) (1) Min. 100 kΩ
Between ground and MB07 (male) (1) Min. 100 kΩ
1. Turn the starting switch to OFF position.
Defective supply voltage 2. Disconnect the connector R53B, and connect the T-adapter to female side.
5 to AdBlue/DEF line heat-
er Between R53B (female) (1) and ground 20 to 30 V
Resistance
Between R53B (female) (2) and ground 20 to 30 V
1. Starting switch: OFF
2. Disconnect connectors ECM J2 and R53A, and connect T-adapter to fe-
Short circuit in wiring har-
6 male side of ECM J2.
ness
Between ECM J2 (female) (39) and each pin other No continui-
Continuity
than pin (39) ty
1. Turn starting switch to OFF position.
2. Check that system operating lamp does not light up, and then turn the bat-
tery disconnect switch OFF.
Defective AdBlue/DEF 3. Disconnect connector R53A and R53B, and replace AdBlue/DEF heater
7 relay.
heater relay
4. Turn the battery disconnect switch ON.
5. Turn starting switch to ON position.
If this failure code is cleared, the original AdBlue/DEF heater relay is defective.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
8
ler an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-735
FAILURE CODE [CA5115] 40 TROUBLESHOOTING

Circuit diagram related to AdBlue/DEF line heater

40-736 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA5179]

FAILURE CODE [CA5179] (ALL-K-AFKH-410-00-B)

Action level Failure code Engine Room Temperature Sensor High Error
Failure
L01 CA5179 (Engine controller system)
Detail of fail-
A high voltage error occurs in signal circuit of engine room temperature sensor.
ure
Action of
Run the engine by using the default value of the engine room temperature (25 °C).
controller
Phenomenon • AdBlue/DEF line stops thawing.
on machine • NOx emission may increase because AdBlue/DEF line stops thawing.
• This failure code is displayed when the engine room temperature sensor connector is re-
Related moved.
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, the wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector P66 and connect socket to male side.
REMARK
If a resistance value of the engine room temperature sensor ranges from 280 Ω to
382 kΩ, the engine room temperature sensor is considered to be normal.
291 to
-40 °C
382 kΩ
85 to
-20 °C
Defective engine room 109 kΩ
2
temperature sensor
0 °C 29 to 36 kΩ
7.3 to
Between `P66 (male) (A) 30 °C
Resistance 8.8 kΩ
and (B)
2.3 to
60 °C
2.7 kΩ
860 to
90 °C
970 Ω
280 to
130 °C
320 Ω
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J2, and connect T-adapter to female side.
REMARK
Open or short circuit in
3 Use an engine room temperature sensor resistance characteristics table for
wiring harness
check on cause 2 as a resistance value.
280 Ω to
Resistance Between ECM J2 (female) (65) and (32)
382 kΩ

HB365LC-3 40-737
FAILURE CODE [CA5179] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Insert T-adapter into connector ECM J2.
4
harness 3. Turn starting switch to ON position.
Voltage Between ECM J2 (65) and (32) Max. 4.96 V
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)

CIRCUIT DIAGRAM (ENGINE ROOM TEMPERATURE SENSOR)

40-738 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA5181]

FAILURE CODE [CA5181] (ALL-K-AFKH-410-10-B)

Action level Failure code Engine room temperature sensor low error
Failure
L01 CA5181 (Engine controller system)
Detail of fail-
A low voltage error occurs in signal circuit of engine room temperature sensor.
ure
Action of
Run the engine by using the default value of the engine room temperature (25 °C).
controller
Phenomenon • AdBlue/DEF line stops thawing.
on machine • NOx emission may increase because AdBlue/DEF line stops thawing.
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. See descriptions of wiring harness and connectors in “Electrical equip-
ment” in “CHECKS BEFORE TROUBLESHOOTING” of “RELATED IN-
Defective wiring harness FORMATION ON TROUBLESHOOTING”, and check it.
1
connector 2. Turn starting switch to ON position.
If this failure code is cleared, the wiring harness connector is defective.
1. Turn starting switch to OFF position.
2. Disconnect connector P66 and connect socket to male side.
REMARK
If a resistance value of the engine room temperature sensor ranges from 280 Ω to
382 kΩ, the engine room temperature sensor is considered to be normal.
291 to
-40 °C
382 kΩ
85 to
-20 °C
109 kΩ
Defective engine room 0 °C 29 to 36 kΩ
2
temperature sensor
7.3 to
Between `P66 (male) (A) 30 °C
8.8 kΩ
and (B)
Resistance 2.3 to
60 °C
2.7 kΩ
860 to
90 °C
970 Ω
280 to
130 °C
320 Ω
Between P66 (male) (B)
General Min. 100 kΩ
and ground
1. Turn starting switch to OFF position.
2. Disconnect connector ECM J2, and connect T-adapter to female side.
REMARK
Short circuit in wiring har-
3 Use an engine room temperature sensor resistance characteristics table for
ness
check on cause 2 as a resistance value.
280 Ω to
Resistance Between ECM J2 (female) (56) and (32)
382 kΩ

HB365LC-3 40-739
FAILURE CODE [CA5181] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors ECM J2 and P66, and connect T-adapter to female
4
harness side of ECM J2.
Resistance Between ECM J2 (female) (56) and ground Min. 100 kΩ
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
5
ler an internal defect, troubleshooting cannot be performed.)

CIRCUIT DIAGRAM (ENGINE ROOM TEMPERATURE SENSOR)

40-740 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [CA5383]

FAILURE CODE [CA5383] (ALL-K-A9H3-410-00-B)

Action level Failure code Ash Accumulation High Error

Failure
— CA5383 (Engine controller system)
Detail of fail-
Ash accumulation in KDPF is high and ash accumulated in KDPF needs to be cleaned.
ure
Action of
None in particular
controller
Phenomenon
KCSF may be damaged.
on machine

k KDPF becomes hot (Min. 500 °C). Be careful not to get burned.
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
(Code: 47300 (°C))
• Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
• Ash accumulation in KDPF is high and ash accumulated in KDPF needs to be cleaned.
• The KDPF temperature sensor consists of the KDOC inlet temperature sensor, the KDOC
outlet temperature sensor, and the KDPF outlet temperature sensor and is integrated into
one sensor controller which provides CAN communication with the engine controller.
• As to procedure for accessing KDPF temperature sensor, see “50 Disassembly and as-
sembly”, “Removal and installation of KDPF assembly”.
• After turning starting switch to OFF position, engine controller performs AdBlue/DEF purg-
ing (for Max. 6 minutes) and then stops. To restart engine, wait until system operating
lamp goes off after turning starting switch to OFF position, and then turn starting switch to
Related ON position.
information • See Testing and adjusting, “service modes” of “setting and operating machine monitor”
and “setting method of testing menu (ash in soot accumulation correction)” to check ash
accumulation.
• This failure code is displayed when ash accumulation reaches the upper limit of its allowa-
ble amount.
• When the ash accumulation reaches the upper limit, KDPF is experiencing very high pres-
sure loss and ash cleaning is required.
• For resetting KDPF cleaning and KDPF change, see Testing and adjusting, “service
modes” of “setting and operating machine monitor” and “setting method of testing menu
(KDPF memory reset)”.
• This failure code is cleared on the user screen of the machine monitor but is displayed on
“Abnormality Record”screen and in service mode of the machine monitor and KOMTRAX.
NOTICE
• When this failure code is displayed, troubleshoot causes 1 and 2, then make sure to
perform ash cleaning in cause 3.
• After ash cleaning, reset KDPF cleaning and KDPF change.
• Otherwise, KCSF may be damaged.

No. Cause Procedure, measuring location, criteria and remarks

Defective KDPF differen- If failure code [CA1879] or [CA1881] or [CA1883] is displayed, perform trouble-
1
tial pressure sensor shooting for [CA1879] or [CA1881] or [CA1883] first.

HB365LC-3 40-741
FAILURE CODE [CA5383] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Defective KDPF (KDOC, Perform troubleshooting for 1 through 11 in “Active regeneration is executed fre-
2
or KCSF) quently” in S mode.

NOTICE
• Be sure to perform:
1. Remove KDPF and flush ash accumulated in KDPF (see Related informa-
tion).
Excessive ash accumula-
3 2. Turn starting switch to ON position.
tion
3. Perform Reset after KDPF cleaning (see Related information).
4. Perform Reset after KDPF change (see Related information).
5. Make sure that ash accumulation is 0 on the monitor (see Related informa-
tion).
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

40-742 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [D110KB]

FAILURE CODE [D110KB] (ALL-K-AKA1-410-00-B)

Action level Failure code Battery Relay Output Short Circuit

Failure
L01 D110KB (Pump controller system)
Detail of fail-
Abnormal current flows when outputting 24 V to battery relay primary circuit (coil side).
ure
Stops 24 V output to battery relay primary circuit (coil side).
Action of
Even if cause of failure disappears, machine does not become normal until starting switch is turned
controller
to OFF position.
Phenomenon
Each controller may fail in writing of data into its ROM (non-volatile memory).
on machine
• As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
be measured at pump controller connector.
Related • Output (ON/OFF) to battery relay can be checked with monitoring function. (Code: 03700
information Controller output 1)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch from ON to OFF position.

No. Cause Procedure, measuring location, criteria and remarks

1 Defective battery relay
Ground fault in wiring
2
harness
3 Defective pump controller
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the battery relay terminals R01 and R02.
Continuity Between battery relay terminals R01 and R02 Continuity
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connector CP02, and connect the T-adapter to female side.
4. Disconnect the connectors, terminals, and fuses of all the devices which
branch out from connector CP02 (108).
Between ground and either CP02 (female) (108) or
Resistance Min. 1 MΩ
battery relay terminal R02
If no failure is found by above checks, pump controller is defective. (Since this is an
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-743
FAILURE CODE [D110KB] 40 TROUBLESHOOTING

Circuit diagram related to battery relay

40-744 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [D19JKZ]

FAILURE CODE [D19JKZ] (ALL-K-AKC2-410-01-B)

Action level Failure code Personal Code Relay Open Circuit or Short Circuit
Failure
L03 D19JKZ (Machine monitor system)
Detail of fail-
Open error or short circuit occurs in primary (coil) circuit of personal code relay.
ure
None in particular (when open error occurred)
Stops driving personal code relay (when short circuit occurred).
Action of ma-
chine monitor If cause of failure disappears, machine becomes normal by itself (when open error occurred).
Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position (when short circuit occurred).
Phenomenon
on machine
• This failure code is displayed only when engine lock function is enabled.
• After repairing, check if the failure code is cleared by the following procedure.
Related Procedure: Turn starting switch to ON position (when open circuit occurred). Failure code
information cannot be reproduced on the machine (when short circuit occurred).
• Troubleshooting for this failure code covers circuits from fuse No. 3 in fuse box F01
through primary (coil) circuit of personal code relay R07 to machine monitor.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
1 Defective fuse 3. Remove the fuse No.3 in fuse box F01. Check visually if it is not burnt out.
4. When it is not burnt out, check if it is blown out by continuity test.
• When it is burnt out, check the wiring harness for ground fault.
• When it is not burnt out but it has no continuity, replace the fuse.
1. Turn the starting switch to OFF position.
Defective personal code 2. Disconnect the connector R07, and connect the T-adapter to male side.
2
relay
200 to
Resistance Between R07 (male) (1) and (2)
600 Ω
1. Turn the starting switch to OFF position.
2. Remove the fuse No.3 in fuse box F01
Open circuit in wiring har- 3. Disconnect the connectors CM01 and R07, and connect the T-adapter to
3 each female side.
ness
Between F01-3 and R07 (female) (1) Max. 1 Ω
Resistance
Between R07 (female) (2) and CM01 (female) (6) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CM01 and R07, and connect the T-adapter to
either female side.
Ground fault in wiring 3. Disconnect the connectors, terminals, and fuses of all the devices which
4 branch out from connector R07 (1).
harness
Between ground and either F01-3 or R07 (female) (1) Min. 1 MΩ
Resistance Between ground and either R07 (female) (2) or CM01
Min. 1 MΩ
(female) (6)

HB365LC-3 40-745
FAILURE CODE [D19JKZ] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Remove the fuse No.3 in fuse box F01
Short circuit in wiring har- 3. Disconnect the connectors CM01 and R07, and connect the T-adapter to
5
ness female side of CM01.
Between CM01 (female) (6) pin and each pin other No continui-
Continuity
than (6) ty
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
6
tor an internal defect, troubleshooting cannot be performed.)

40-746 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [D19JKZ]

Circuit diagram related to personal code relay

HB365LC-3 40-747
FAILURE CODE [D811MC] 40 TROUBLESHOOTING

FAILURE CODE [D811MC] (ALL-K-Q220-410-00-B)

Action level Failure code

Failure KOMTRAX Malfunction (KOMTRAX system)
- D811MC
Details of
KOMTRAX Error
failure
Action of
None in particular
controller
Phenomenon
KOMTRAX system does not operate normally.
on machine
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective KOMTRAX ter- KOMTRAX terminal is defective. (Since this is an internal defect, troubleshooting
1
minal cannot be performed.)

40-748 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [D862KA]

FAILURE CODE [D862KA] (ALL-K-Q280-410-00-B)

Action level Failure code GPS Antenna Open Circuit

Failure
- D862KA (KOMTRAX system)
Details of
Open circuit occurs in GPS antenna circuit.
failure
Action of • None in particular
controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
GPS positioning system does not work.
on machine
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective GPS antenna GPS antenna may be defective, or antenna cable may have open or short circuit,
1
or antenna cable or poor contact at antenna cable connection (GPS).

Configuration diagram of GPS system

HB365LC-3 40-749
FAILURE CODE [D8ALKA] 40 TROUBLESHOOTING

FAILURE CODE [D8ALKA] (ALL-K-Q260-410-00-B)

Action level Failure code System Operating Lamp Open Circuit (KOMTRAX)
Failure
- D8ALKA (KOMTRAX system)
KOMTRAX terminal has detected an open circuit because the output line voltage of system operat-
Detail of fail-
ing lamp is approximately 5 V and below while the KOMTRAX terminal does not output the voltage
ure
for approximately 3 seconds after the starting switch is turned to ON position.
• Stops driving system operating lamp.
Action of
• Even if cause of failure is eliminated, machine does not become normal until starting
controller
switch is turned to OFF position.
Phenomenon
None in particular
on machine
• Do not turn the battery disconnect switch to OFF position while the system operating lamp
is lit.
• If the battery disconnect switch is turned to OFF position while the system operating lamp
is lit, the memory data stored in each controller may be destroyed.
• Although KOMTRAX terminal is not able to light up system operating lamp, no trouble will
Related result unless battery disconnect switch is turned to OFF position.
information • When controller lights up system operating lamp, output circuit voltage is at low level.
• Since no controller drives system operating lamp for approximately 3 seconds after start-
ing switch is turned to ON position, open circuit can be detected.
• After completion of repair, check that the failure code is cleared by the following proce-
dure.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.16 in fuse box F01. Check visually if it is not burnt
1 Defective fuse out.
4. When it is not burnt out, check if it is blown out by continuity test.
• When it is burnt out, check the wiring harness for ground fault.
• When it is not burnt out but it has no continuity, replace the fuse.
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.16 in fuse box F01
Open circuit in wiring har-
2
ness 4. Disconnect the connectors CK01 and L19, and connect the T-adapter to
each female side.
Between F01-16 and L19 (female) (1) Max. 1 Ω
Resistance
Between CK01 (female) (15) and L19 (female) (2) Max. 1 Ω

40-750 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [D8ALKA]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
Ground fault in wiring 3.
3 Disconnect the connector L19, and connect the T-adapter to female side.
harness
4. Disconnect the connectors, terminals, and fuses of all the devices which
branch out from connector L19 (1).
Resistance Between ground and either L19 (female) (1) or F01-16 Min. 1 MΩ
Defective KOMTRAX ter- If no failure is found by above checks, KOMTRAX terminal is defective. (Since this
4
minal is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to system operating lamp

HB365LC-3 40-751
FAILURE CODE [D8ALKB] 40 TROUBLESHOOTING

FAILURE CODE [D8ALKB] (ALL-K-Q260-410-10-B)

Action level Failure code System Operating Lamp Short Circuit (KOMTRAX)
Failure
- D8ALKB (KOMTRAX system)
Detail of fail- KOMTRAX terminal has detected a short circuit because voltage of output circuit does not become
ure low level while KOMTRAX terminal outputs current to system operating lamp.
• Stops driving the system operating lamp.
Action of
• Even if cause of failure is eliminated, machine does not become normal until starting
controller
switch is turned to OFF position.
Phenomenon
None in particular
on machine
• Do not turn the battery disconnect switch to OFF position while the system operating lamp
is lit.
• If the battery disconnect switch is turned to OFF position while the system operating lamp
is lit, the memory data stored in each controller may be destroyed.
Related • Although KOMTRAX terminal is not able to light up system operating lamp, no trouble will
information result unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.
• After completion of repair, check that the failure code is cleared by the following proce-
dure.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector L19, and connect the T-adapter to female side.
1
harness 3. Turn the starting switch to ON position.
Voltage Between L19 (female) (2) and ground Max. 1 V
Defective KOMTRAX ter- If no failure is found by above checks, KOMTRAX terminal is defective. (Since this
2
minal is an internal defect, troubleshooting cannot be performed.)

40-752 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [D8ALKB]

Circuit diagram related to system operating lamp

HB365LC-3 40-753
FAILURE CODE [D8AQKR] 40 TROUBLESHOOTING

FAILURE CODE [D8AQKR] (ALL-K-Q258-410-00-B)

Action level Failure code CAN 2 defective communication (KOMTRAX) (Detected by machine
Failure monitor)
- D8AQKR (Machine monitor system)
Detail of fail-
Machine monitor does not recognize KOMTRAX over CAN communication-2 line (KOMNET/c).
ure
Action of ma-
None
chine monitor
Phenomenon
None
on machine
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.
• ACC signal of starting switch is the command to start CAN communication for each con-
troller.
• 5 different failure codes, [D8AQKR], [DA2QKR], [DAFQKR], [DB2QKR], and [GA2QKR]
are used for defective CAN communication by CAN 2 when it is detected by machine
monitor. When all of these 5 failure codes are displayed, ground fault, short circuit or hot
Related short circuit in wiring harness (CAN communication circuit) can be suspected.
information
REMARK
If air conditioner is controlled, there is no possibility of ground fault, short circuit, or hot
short circuit occurring in wiring harness (CAN communication line).
• Since each controller and machine monitor are connected directly to battery, they are sup-
plied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is turned off, and then turn the battery
disconnect switch to OFF position.
3. Disconnect connector CK02, and connect T-adapter to female side.
Defective KOMTRAX ter-
4. Turn the battery disconnect switch to ON position.
1 minal power supply cir-
cuit REMARK
If there is no failure, troubleshooting for No. 2 is not required.
Between CK02 (female) (6) and (1) 20 to 30 V*
Voltage
Between CK02 (female) (7) and (2) 20 to 30 V*
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.17 in fuse box F01
Open circuit in wiring har- 4. Disconnect the connector CK02, and connect the T-adapter to female side.
2
ness
Between CK02 (female) (6) and F01-17 Max. 1 Ω
Between CK02 (female) (7) and F01-17 Max. 1 Ω
Resistance
Between CK02 (female) (1) and ground Max. 1 Ω
Between CK02 (female) (2) and ground Max. 1 Ω

40-754 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [D8AQKR]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connector CK02, and connect the T-adapter to female side.
4. Turn the battery disconnect switch to ON position.
Defective KOMTRAX ter-
3
minal ACC signal circuit 5. Turn the starting switch to ON position.
REMARK
If there is no failure, troubleshooting for No. 2 is not required.
Between CK02 (female) (3) and (1) 20 to 30 V
Voltage
Between CK02 (female) (3) and (2) 20 to 30 V
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No. 14 in fuse box F01.
Open circuit in wiring har-
4 4. Disconnect the connector CK02, and connect the T-adapter to female side.
ness
Between CK02 (female) (3) and F01-14 Max. 1 Ω
Resistance Between CK02 (female) (1) and ground Max. 1 Ω
Between CK02 (female) (2) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect connectors CM02 and K02, and connect T-adapter to each
Defective CAN 2 termi- male side.
5
nating resistor
Between CM02 (male) (7) and (9) 120 ± 12 Ω
Resistance
Between K02 (male) (A) and (B) 120 ± 12 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors CM02, CK01, and K02, and connect the T-
Open circuit in wiring har- adapter to each female side.
6 ness (CAN 2 communi- Between CK01 (female) (10) and CM02 (female) (7) Max. 1 Ω
cation line)
Between CK01 (female) (10) and CM02 (female) (8) Max. 1 Ω
Resistance Between CK01 (female) (11) and CM02 (female) (9) Max. 1 Ω
Between CK01 (female) (10) and K02 (female) (A) Max. 1 Ω
Between CK01 (female) (11) and K02 (female) (B) Max. 1 Ω

HB365LC-3 40-755
FAILURE CODE [D8AQKR] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors CK01 and CM02, and connect the T-adapter to
Ground fault in wiring either female side.
7 harness (CAN 2 commu- 4. Disconnect the connectors, terminals, and fuses of all the devices which
nication line) branch out from connector CK01 (10) and (11).
Between ground and any of CK01 (female) (10), CM02
Min. 1 MΩ
(female) (7), and (8)
Resistance
Between ground and either CK01 (female) (11) or
Min. 1 MΩ
CM02 (female) (9)
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Insert T-adapter into connector K02.
4. Turn the battery disconnect switch to ON position.
Hot short circuit in wiring
8 harness (CAN 2 commu- 5. Turn the starting switch to ON position.
nication line) REMARK
Voltage of CANH and CANL is 2.5 ± 1 V including during communication, so regard
wiring harness as normal if measured voltage is 1 to 4 V.
Between K02(A) and ground 1 to 4 V
Voltage
Between K02(B) and ground 1 to 4 V
Defective KOMTRAX ter- If no failure is found by above checks, KOMTRAX terminal is defective. (Since this
9
minal is an internal defect, troubleshooting cannot be performed.)
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
10
tor an internal defect, troubleshooting cannot be performed.)

40-756 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [D8AQKR]

CIRCUIT DIAGRAM (CAN2 COMMUNICATION)

HB365LC-3 40-757
FAILURE CODE [D8AQKR] 40 TROUBLESHOOTING

Circuit diagram related to KOMTRAX power souce

40-758 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DA20MC]

FAILURE CODE [DA20MC] (ALL-K-C3V1-410-00-B)

Action level Failure code Pump Controller Malfunction

Failure
― DA20MC (Pump controller system)
Detail of fail-
Malfunction of pump controller operation
ure
Action of
controller
Phenomenon
The work equipment, traveling, and turning operations cannot be performed normally.
on machine
Related • After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Pump controller is defective. (Since this is an internal defect, troubleshooting can-
1 Defective pump controller
not be performed.)

HB365LC-3 40-759
FAILURE CODE [DA22KK] 40 TROUBLESHOOTING

FAILURE CODE [DA22KK] (ALL-K-C3VS-410-00-B)

Action level Failure code Pump Controller Solenoid Power Voltage Low Error
Failure
L03 DA22KK (Pump controller system)
Detail of fail-
Power supply voltage of controller for driving solenoids is below 20 V.
ure
Stops detection of failures (open circuit and short circuit) in all solenoid systems while this failure
Action of
code is active.
controller
If cause of failure disappears, machine becomes normal by itself.
Phenomenon No solenoid valve is energized properly, so machine does not work properly.
on machine (Work equipment, swing, and travel systems do not work.)
• If failure code [D110KB] is displayed, perform troubleshooting these first.

Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
be measured at pump controller connector.
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1 Defective battery
2 Defective fusible link
3 Defective fuse
Open circuit in wiring har-
4 female side of CP02 and male side of F04.
ness
Check battery voltage and specific gravity of battery electrolyte.
Battery Voltage (1 battery) Min. 12 V
Battery Voltage (2 batteries in series) Min. 24 V
Specific gravity of battery electrolyte Min. 1.26
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove fusible link F04. Check visually if it is not burnt out.
4. When it is not burnt out, check if it is blown out by continuity test.
• When it is burnt out, check the wiring harness for ground fault.
• When it is not burnt out but it has no continuity, replace the fusible link.
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.2 in fuse box F01. Check visually if it is not burnt out.
4. When it is not burnt out, check if it is blown out by continuity test.
• When it is burnt out, check the wiring harness for ground fault.
• When it is not burnt out but it has no continuity, replace the fuse.
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors CP02 and F04, and connect the T-adapter to
Between CP02 (female) (116) and F04 (male) (2) Max. 1 Ω
Resistance Between CP02 (female) (118) and F04 (male) (2) Max. 1 Ω
Between CP02 (female) (121) and F04 (male) (2) Max. 1 Ω

40-760 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DA22KK]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors CP02 and F04, and connect the T-adapter to
Ground fault in wiring female side of CP02 and male side of F04.
5
harness 4. Disconnect the connectors, terminals, and fuses of all the devices which
branch out from connector CP02 (116), (118) and (121).
Between ground and any of CP02 (female) (116),
Min. 1 MΩ
Resistance (118), (121), and F01-2
Between ground and either F01-1A or F04 (male) (2) Min. 1 MΩ
If no failure is found by above checks, pump controller is defective. (Since this is an
6 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-761
FAILURE CODE [DA22KK] 40 TROUBLESHOOTING

Circuit diagram related to pump controller solenoid power supply

40-762 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DA25KP]

FAILURE CODE [DA25KP] (ALL-K-C3V5-410-00-B)

Action level Failure code 5 V Sensor 1 Power Voltage Low Error

Failure
― DA25KP (Pump controller system)
Detail of fail-
Voltage of 5 V sensor power supply output 1 circuit is below 2.5 V or above 6.0 V.
ure
Stops output of power from 5 V sensor power supply output 1.
Action of
Even if cause of failure disappears, machine does not become normal until starting switch is turned
controller
to OFF position.
Signal of pressure sensor is not input properly.
The error code for the pressure sensor is displayed as well.
Phenomenon
Travel and work equipment speeds are slow.
on machine
Automatic travel speed selector function does not work (pump pressure sensor system).
Auto-decelerator function remains activated or fine control performance of work equipment is poor.
Related • After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1 Defective 5 V sensor
Ground fault in wiring
2 3.
harness
Hot short circuit in wiring
3
harness
4 Defective pump controller
1. Turn the starting switch to OFF position.
2. Disconnect the following connectors one by one in order, and turn the
starting switch to ON position each time.
3. If this failure code is not displayed, the disconnected device is defective.
Repeat steps 1 to 3 until it is confirmed that there is no device causing fail-
ure.
REMARK
Since connector is disconnected, other failure codes are also displayed. Ignore all
of displayed failure codes other than this one.
Travel forward left pressure sensor P09
Travel reverse left pressure sensor P10
Connector Travel forward right pressure sensor P11
Travel reverse right pressure sensor P12
Fan clutch speed sensor V13
1. Turn the starting switch to OFF position.
2. Disconnect the connector CP01 and connect the T-adapter to female side.
Disconnect the connectors, terminals, and fuses of all the devices which
branch out from connector CP01 (6).
Resistance Between CP01 (female) (6) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors P09 through P12 and V13, and connect the T-
adapter to female side of P09.
3. Turn the starting switch to ON position (with connector disconnected).
Voltage Between P09 (female) (3) and (1) 4.5 to 5.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-763
FAILURE CODE [DA25KP] 40 TROUBLESHOOTING

Circuit diagram related to pump controller 5V sensor power supply

40-764 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DA26KP]

FAILURE CODE [DA26KP] (ALL-K-C3V6-410-00-B)

Action level Failure code 5 V Sensor 2 Power Voltage Low Error

Failure
- DA26KP (Pump controller system)
Detail of fail-
Voltage of 5 V sensor power supply output 2 circuit is 2.5 V or less or 6.0 V or more.
ure
Stops output of power from 5 V sensor power supply output 2.
Action of
Even if cause of failure is eliminated, machine does not become normal until the starting switch is
controller
turned to OFF position once.
• Signal of pressure sensor is not input properly.
• Failure code of pressure sensor is displayed at the same time.
Phenomenon • Travel and work equipment speeds are slow.
on machine • Automatic gear shift function of travel does not work.
• Auto-decelerator function remains activated, and fine control performance of work equip-
ment is poor.
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the following connectors one by one in order, and turn the
starting switch to ON position each time.
3. If this failure code is not displayed, the disconnected device is defective.
Repeat steps 1 to 3 until it is confirmed that there is no device causing fail-
ure.
REMARK
Since connector is disconnected, other failure codes are also displayed. Ignore all
of displayed failure codes other than this one.
Bucket CURL pressure sensor P01
Boom LOWER pressure sensor P02
Swing (LEFT) pressure sensor P03
1 Defective 5 V sensor
Arm IN pressure sensor P04
Bucket DUMP pressure sensor P05
Boom RAISE pressure sensor P06
Connector Swing (RIGHT) pressure sensor P07
Arm OUT pressure sensor P08
Front pump pressure sensor P25
Rear pump pressure sensor P26
Front pump swash plate sensor P27
Rear pump swash plate sensor P28
Service pressure sensor (if equipped) P49

HB365LC-3 40-765
FAILURE CODE [DA26KP] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector CP01, and connect the T-adapter to female side.
Ground fault in wiring
2 3. Disconnect the connectors, terminals, and fuses of all the devices which
harness
branch out from connector CP01 (63).
Resistance Between CP01 (female) (63) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector P01, and connect the T-adapter to female side.
3
harness 3. Turn the starting switch to ON position.
Voltage Between P01 (female) (3) and (1) 4.5 to 5.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

40-766 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DA26KP]

Circuit diagram related to pump controller 5V sensor power supply

HB365LC-3 40-767
FAILURE CODE [DA29KQ] 40 TROUBLESHOOTING

FAILURE CODE [DA29KQ] (ALL-K-Q1GB-410-00-B)

Action level Failure code Model Selection Signal Mismatch (Pump Controller)
Failure
L01 DA29KQ (Pump controller system)
Detail of fail-
Model code signal for model which is not registered in controller is input.
ure
Controls machine by regarding machine as default model (PC400 standard specification machine).
Action of
Even if cause of failure disappears, machine does not become normal until starting switch is turned
controller
to OFF position.
Phenomenon
No problem appears if machine is PC400 standard specification machine.
on machine
• Part number of pump controller assembly can be checked with monitoring function. (Code:
20229 assembly part number (pump controller))
• Signal state (ON/OFF) of model selection signal can be checked with monitoring function.
(Code: 02201 switch input 2)
REMARK
Related For standard specification, the followings are correct:
information Model selection signal 1: ON
Model selection signal 2: ON
Model selection signal 3: ON
Model selection signal 4: OFF
Model selection signal 5: ON
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Turn the starting switch to ON position, and perform troubleshooting (with monitor-
ing).
Monitoring code: 02201 switch input 2
Model selection 1 ON
Defective machine model
1 Model selection 2 ON
code signal
Normal dis-
Model selection 3 ON
play
Model selection 4 OFF
Model selection 5 ON
1. Turn the starting switch to OFF position.
2. Disconnect the connector S30, and connect the T-adapter to female side.
Between S30 (female) (1) and (8) Max. 1 Ω
Defective model selec-
2 Between S30 (female) (1) and (2) Max. 1 Ω
tion connector
Resistance Between S30 (female) (2) and (3) Max. 1 Ω
Between S30 (female) (3) and (4) Min. 1 MΩ
Between S30 (female) (7) and (8) Max. 1 Ω

40-768 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DA29KQ]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and S30, and connect the T-adapter to
female side of CP01 and male side of S30.
Between CP01 (female) (21) and S30 (male) (3) Max. 1 Ω
Open circuit in wiring har-
3
ness Between CP01 (female) (40) and S30 (male) (2) Max. 1 Ω
Resistance Between CP01 (female) (58) and S30 (male) (7) Max. 1 Ω
Between CP01 (female) (59) and S30 (male) (1) Max. 1 Ω
Between S30 (female) (8) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and S30, and connect the T-adapter to
Ground fault in wiring
4 female side of CP01 and male side of S30.
harness
Between ground and either CP01 (female) (77) or S30
Resistance Min. 1 MΩ
(male) (4)
1. Turn the starting switch to OFF position.
Short circuit in wiring har- 2. Disconnect the connectors CP01 and S30, and connect the T-adapter to
5
ness male side of S30.
Resistance Between S30 (male) (3) and each pin other than (3) Min. 1 MΩ
Nonconformity pump Check if the part number of replaced pump controller is correct.
6
controller
If no failure is found by above checks, pump controller is defective. (Since this is an
7 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to machine model setting system

HB365LC-3 40-769
FAILURE CODE [DA2LKA] 40 TROUBLESHOOTING

FAILURE CODE [DA2LKA] (ALL-K-C3X6-410-00-B)

Action level Failure code System Operating Lamp Open Circuit (Pump Controller)
Failure
― DA2LKA (Pump controller system)
Pump controller determines that system operating lamp circuit is open because voltage of output
Detail of fail-
circuit remains at approximately 5 V or below for approximately 3 seconds after starting switch is
ure
turned to ON position, during which pump controller outputs no current to system operating lamp.
Action of
None in particular
controller
Phenomenon
None in particular
on machine
• Do not turn the battery disconnect switch to OFF position while the system operating lamp
is lit.
• If the battery disconnect switch is turned to OFF position while the system operating lamp
is lit, the memory data stored in each controller may be destroyed.
• Pump controller is not able to light up system operating lamp.
Related • After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.
• Although work equipment controller is not able to light up system operating lamp, no trou-
ble will result unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.
• Since no controller drives system operating lamp for approximately 3 seconds after start-
ing switch is turned to ON position, open circuit can be detected.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.16 in fuse box F01. Check visually if it is not burnt
1 Defective fuse out.
4. When it is not burnt out, check if it is blown out by continuity test.
• When it is burnt out, check the wiring harness for ground fault.
• When it is not burnt out but it has no continuity, replace the fuse.
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
Ground fault in wiring 3.
2 Disconnect the connector L19, and connect the T-adapter to female side.
harness
4. Disconnect the connectors, terminals, and fuses of all the devices which
branch out from connector L19 (1).
Resistance Between ground and either L19 (female) (1) or F01-16 Min. 1 MΩ

40-770 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DA2LKA]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.16 in fuse box F01
Open circuit in wiring har-
3
ness 4. Disconnect the connectors CP02, and L19, and connect the T-adapter to
each female side.
Between F01-16 and L19 (female) (1) Max. 1 Ω
Resistance
Between CP02 (female) (100) and L19 (female) (2) Max. 1 Ω
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to system operating lamp

HB365LC-3 40-771
FAILURE CODE [DA2LKB] 40 TROUBLESHOOTING

FAILURE CODE [DA2LKB] (ALL-K-C3X6-410-10-B)

Action level Failure code System Operating Lamp Short Circuit (Pump Controller)
Failure
― DA2LKB (Pump controller system)
Detail of fail- Pump controller determines that system operating lamp circuit shorts because voltage of output cir-
ure cuit does not become Low level while pump controller outputs current to system operating lamp.
Action of
None in particular
controller
Phenomenon
None in particular
on machine
• Do not turn the battery disconnect switch to OFF position while the system operating lamp
is lit.
• If the battery disconnect switch is turned to OFF position while the system operating lamp
is lit, the memory data stored in each controller may be destroyed.
Related • Pump controller is not able to light up system operating lamp.
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• Although work equipment controller is not able to light up system operating lamp, no trou-
ble will result unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector L19, and connect the T-adapter to female side.
1
harness 3. Turn the starting switch to ON position.
Voltage Between L19 (female) (2) and ground Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an
2 Defective pump controller
internal defect, troubleshooting cannot be performed).

40-772 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DA2LKB]

Circuit diagram related to system operating lamp

HB365LC-3 40-773
FAILURE CODE [DA2QKR] 40 TROUBLESHOOTING

FAILURE CODE [DA2QKR] (ALL-K-C3XA-410-00-B)

Action level Failure code Controller area network 2 defective communication (Pump controller)
Failure
L03 DA2QKR (Machine monitor system)
Detail of fail- Machine monitor does not recognize pump controller through CAN communication 2 line
ure (KOMNET/c).
Action of
Retains information when the failure occurred.
controller

Phenomenon Information to be obtained from pump controller is not displayed and special functions do not work.
Or update of received data is stopped (such as failure codes and monitoring codes sent from the
on machine pump controller).
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.
• ACC signal of starting switch is the command to start CAN communication for each con-
troller.
• 5 different failure codes, [D8AQKR], [DA2QKR], [DAFQKR], [DB2QKR], and [GA2QKR]
are used for defective CAN communication by CAN 2 when it is detected by machine
monitor. When all of these 5 failure codes are displayed, ground fault, short circuit or hot
short circuit in wiring harness (CAN communication circuit) can be suspected.
REMARK
Related If air conditioner is controlled, there is no possibility of ground fault, short circuit, or hot
information short circuit occurring in wiring harness (CAN communication line).
• This can be activated even when power supply to pump controller is turned off.
REMARK
Air conditioner can be controlled even when failure code is displayed on the monitor screen. If
air conditioner is controlled, there is no possibility of ground fault, short circuit, or hot short cir-
cuit occurring in wiring harness (CAN communication line).
• Since each controller and machine monitor are connected directly to battery, they are sup-
plied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connector CP01 and connect the T-adapter to female side.
4. Turn the battery disconnect switch to ON position.
Defective pump controller
1 5. Turn the starting switch to ON position.
power supply circuit
REMARK
If there is no failure, troubleshooting for No. 2 is not required.
Between CP01 (female) (1) and (2) 20 to 30 V
Voltage
Between CP01 (female) (4) and (5) 20 to 30 V

40-774 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DA2QKR]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.17 in fuse box F01
Open circuit in wiring har- 4. Disconnect the connector CP01 and connect the T-adapter to female side.
2
ness
Between CP01 (female) (1) and F01-17 Max. 1 Ω
Between CP01 (female) (4) and F01-17 Max. 1 Ω
Resistance
Between CP01 (female) (2) and ground Max. 1 Ω
Between CP01 (female) (5) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connector CP01 and connect the T-adapter to female side.
4. Turn the battery disconnect switch to ON position.
Defective pump controller 5. Turn the starting switch to ON position.
3
ACC signal circuit
REMARK
If there is no failure, troubleshooting for No. 4 is not required.
Between CP01 (female) (24) and (2) 20 to 30 V
Voltage Between CP01 (female) (43) and (5) 20 to 30 V
Between CP01 (female) (80) and (2) 20 to 30 V
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No. 14 in fuse box F01.
4. Disconnect the connector CP01 and connect the T-adapter to female side.
Open circuit in wiring har-
4 Between CP01 (female) (24) and F01-14 Max. 1 Ω
ness
Between CP01 (female) (43) and F01-14 Max. 1 Ω
Resistance Between CP01 (female) (80) and F01-14 Max. 1 Ω
Between CP01 (female) (2) and ground Max. 1 Ω
Between CP01 (female) (5) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect connectors CM02 and K02, and connect T-adapter to each
Defective CAN 2 termi- male side.
5
nating resistor
Between CM02 (male) (7) and (9) 120 ± 12 Ω
Resistance
Between K02 (male) (A) and (B) 120 ± 12 Ω

HB365LC-3 40-775
FAILURE CODE [DA2QKR]
No. Cause
Open circuit in wiring har-
6 ness (CAN 2 communi-
cation line)
Ground fault in wiring
7 harness (CAN 2 commu-
nication line)
Hot short circuit in wiring
8 harness (CAN 2 commu-
nication line)
9 Defective pump controller
Defective machine moni-
10
tor
40-776
40 TROUBLESHOOTING
Procedure, measuring location, criteria and remarks
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors CM02, CP01, and K02, and connect the T-
adapter to each female side.
Between CP01 (female) (45) and CM02 (female) (7) Max. 1 Ω
Between CP01 (female) (45) and CM02 (female) (8) Max. 1 Ω
Resistance Between CP01 (female) (64) and CM02 (female) (9) Max. 1 Ω
Between CP01 (female) (45) and K02 (female) (A) Max. 1 Ω
Between CP01 (female) (64) and K02 (female) (B) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors CM02, CP01, and K02, and connect the T-
adapter to each female side.
Between CP01 (female) (45) and CM02 (female) (7) Max. 1 Ω
Between CP01 (female) (45) and CM02 (female) (8) Max. 1 Ω
Resistance Between CP01 (female) (64) and CM02 (female) (9) Max. 1 Ω
Between CP01 (female) (45) and K02 (female) (A) Max. 1 Ω
Between CP01 (female) (64) and K02 (female) (B) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Insert T-adapter into connector K02.
4. Turn the battery disconnect switch to ON position.
5. Turn the starting switch to ON position.
REMARK
Voltage of CANH and CANL is 2.5 ± 1 V including during communication, so regard
wiring harness as normal if measured voltage is 1 to 4 V.
Between K02(A) and ground 1 to 4 V
Voltage
Between K02(B) and ground 1 to 4 V
If no failure is found by above checks, pump controller is defective. (Since this is an
internal defect, troubleshooting cannot be performed).
If no failure is found by above checks, machine monitor is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)
HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DA2QKR]

CIRCUIT DIAGRAM (CAN2 COMMUNICATION)

HB365LC-3 40-777
FAILURE CODE [DA2QKR] 40 TROUBLESHOOTING

Circuit diagram related to pump controller power souce

40-778 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DA2RKR]

FAILURE CODE [DA2RKR] (ALL-K-C3X9-410-00-B)

Action level Failure code CAN 1 defective communication (Pump controller)

Failure
L04 DA2RKR (Machine monitor system)
Detail of fail- Machine monitor does not recognize pump controller through CAN communication 1 line
ure (KOMNET/r).
• Retains current working mode.
Action of • Retains current selection of auto-deceleration.
controller • Retains current setting (Hi/Lo) of travel speed.
• Retains information when the failure occurred.
• Information to be obtained from pump controller is not displayed and special functions that
need information do not work. Or update of received data is stopped.
• Pump control is disabled.
Phenomenon
• Hydraulic oil temperature gauge pointer disappears on machine monitor screen.
on machine
• Windshield wiper operation is disabled.
• Washer operation is disabled.
• Flow rate of attachment oil pressure line cannot be controlled.
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.
• ACC signal of starting switch is the command to start CAN communication for each con-
troller.
• 3 different failure codes, [DA2RKR], [DB2RKR], and [GA2RKR] are used for defective
CAN communication by CAN 1 when it is detected by machine monitor. When these 3 fail-
ure codes are displayed, ground fault, short circuit or hot short circuit in wiring harness
Related
(CAN communication circuit) can be suspected.
information
• CAN1 terminating resister is located in machine monitor on operator's cab side and con-
nector “C23” is located on engine side (CAN communication-1 circuit (KOMNET/r) is not
provided. It is output from connector “ECM J2”).
• Since each controller and machine monitor are connected directly to battery, they are sup-
plied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connector CP01 and connect the T-adapter to female side.
4. Turn the battery disconnect switch to ON position.
Defective pump controller
1 5. Turn the starting switch to ON position.
power supply circuit
REMARK
If there is no failure, troubleshooting for No. 2 is not required.
Between CP01 (female) (1) and (2) 20 to 30 V
Voltage
Between CP01 (female) (4) and (5) 20 to 30 V

HB365LC-3 40-779
FAILURE CODE [DA2RKR] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.17 in fuse box F01
Open circuit in wiring har- 4. Disconnect the connector CP01 and connect the T-adapter to female side.
2
ness
Between CP01 (female) (1) and F01-17 Max. 1 Ω
Between CP01 (female) (4) and F01-17 Max. 1 Ω
Resistance
Between CP01 (female) (2) and ground Max. 1 Ω
Between CP01 (female) (5) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connector CP01 and connect the T-adapter to female side.
4. Turn the battery disconnect switch to ON position.
Defective pump controller 5. Turn the starting switch to ON position.
3
ACC signal circuit
REMARK
If there is no failure, troubleshooting for No. 4 is not required.
Between CP01 (female) (24) and (2) 20 to 30 V
Voltage Between CP01 (female) (43) and (5) 20 to 30 V
Between CP01 (female) (80) and (2) 20 to 30 V
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No. 14 in fuse box F01.
4. Disconnect the connector CP01 and connect the T-adapter to female side.
Open circuit in wiring har-
4 Between CP01 (female) (24) and F01-14 Max. 1 Ω
ness
Between CP01 (female) (43) and F01-14 Max. 1 Ω
Resistance Between CP01 (female) (80) and F01-14 Max. 1 Ω
Between CP01 (female) (2) and ground Max. 1 Ω
Between CP01 (female) (5) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors C23 and CM02, and connect the T-adapter to
Defective CAN 1 termi- each male side.
5
nating resistor
Between CM02 (male) (10) and (12) 120 ± 12 Ω
Resistance
Between C23 (male) (A) and (B) 120 ± 12 Ω

40-780 HB365LC-3
40 TROUBLESHOOTING
No. Cause
Open circuit in wiring har-
6 ness (CAN 1 communi-
cation line)
Ground fault in wiring
7 harness (CAN 1 commu-
nication line)
Hot short circuit in wiring
8 harness (CAN 1 commu-
nication line)
9 Defective pump controller
Defective machine moni-
10
tor
HB365LC-3
FAILURE CODE [DA2RKR]
Procedure, measuring location, criteria and remarks
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors CM02, CP01, and C23, and connect the T-
adapter to each female side.
Between CP01 (female) (7) and CM02 (female) (10) Max. 1 Ω
Between CP01 (female) (7) and CM02 (female) (11) Max. 1 Ω
Resistance Between CP01 (female) (26) and CM02 (female) (12) Max. 1 Ω
Between CP01 (female) (7) and C23 (female) (A) Max. 1 Ω
Between CP01 (female) (26) and C23 (female) (B) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors CP01 and CM02, and connect the T-adapter to
either female side.
4. Disconnect the connectors, terminals, and fuses of all the devices which
branch out from connector CP01 (7) and (26).
Between ground and any of CP01 (female) (7), CM02
Min. 1 MΩ
(female) (10), and (11)
Resistance
Between ground and either CP01 (female) (26) or
Min. 1 MΩ
CM02 (female) (12)
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Insert the T-adapter into connector C23.
4. Turn the battery disconnect switch to ON position.
5. Turn the starting switch to ON position.
REMARK
Voltage of CANH and CANL is 2.5 ± 1 V including during communication, so regard
wiring harness as normal if measured voltage is 1 to 4 V.
Between ground and C23 (A) 1 to 4 V
Voltage
Between ground and C23 (B) 1 to 4 V
If no failure is found by above checks, pump controller is defective. (Since this is an
internal defect, troubleshooting cannot be performed).
If no failure is found by above checks, machine monitor is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)
40-781
FAILURE CODE [DA2RKR] 40 TROUBLESHOOTING

Circuit diagram related to CAN communication 1

40-782 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DA2RKR]

Circuit diagram related to pump controller power souce

HB365LC-3 40-783
FAILURE CODE [DAF0KM] 40 TROUBLESHOOTING

FAILURE CODE [DAF0KM] (ALL-K-K900-410-01-B)

Action level Failure code Inconsistency of KomVision setting

Failure
L03 DAF0KM (Machine monitor system)
Detail of fail-
In KomVision-mounted machine model, With/Without KomVision is set to Without.
ure
Action of
Operates according to settings without KomVision.
controller
Phenomenon
Single camera image is not displayed normally.
on machine
Related • After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position and display a Bird's Eye View

No. Cause Procedure, measuring location, criteria and remarks

Select with of With/Without KomVision.
Setting mistake of With/
1 See testing and adjusting“KomVision RELATED DEVICES”, and check that the set-
Without KomVision
ting is done correctly.

40-784 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DAF0MB]

FAILURE CODE [DAF0MB] (ALL-K-Q170-410-00-B)

Action level Failure code Monitor ROM Abnormality

Failure
- DAF0MB (Machine monitor system)
Detail of fail-
Machine monitor program is rewritten (program error).
ure
Action of Even if cause of failure is eliminated, machine does not become normal until starting switch is
controller turned to OFF position.

Phenomenon • Machine monitor display is unreliable.

on machine • It can neither transmit the data to controllers nor receive the data from them.
Related After completion of repair, check if the failure code is cleared by the following procedure.
information Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- Machine monitor is defective. (Since this is an internal defect, troubleshooting can-
1
tor not be performed.)

HB365LC-3 40-785
FAILURE CODE [DAF0MC] 40 TROUBLESHOOTING

FAILURE CODE [DAF0MC] (ALL-K-Q170-410-10-B)

Action level Failure code Monitor Malfunction

Failure
- DAF0MC (Machine monitor system)
Detail of fail-
Malfunction of machine monitor
ure
Action of Even if cause of failure is eliminated, machine does not become normal until starting switch is
controller turned to OFF position.

Phenomenon • Machine monitor display is unreliable.

on machine • It can neither transmit the data to controllers nor receive the data from them.
Related After completion of repair, check if the failure code is cleared by the following procedure.
information Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- Machine monitor is defective. (Since this is an internal defect, troubleshooting can-
1
tor not be performed.)

40-786 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DAF8KB]

FAILURE CODE [DAF8KB] (ALL-K-Q163-410-00-B)

Action level Failure code

Failure Camera Power Supply Short Circuit (Machine monitor system)
L03 DAF8KB
Detail of fail- Output power supply voltage (rating: 8 V) from machine monitor to camera is 10 V and above when
ure no current is outputted.
• Stops output power supply voltage to camera.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon
Camera image is not displayed on machine monitor.
on machine
Related After repair is completed, check if the failure code is cleared by the following procedure.
information Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector A41.
1 Defective camera 3. Turn the starting switch to ON position.
If failure code is not displayed after disconnecting camera to perform operation of
reproducing procedure, camera has internal defect.
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CM04 and A41, and connect the T-adapter to
either CM04 (female) or A41 (male).
Ground fault in wiring
2 3. Disconnect the connectors, terminals, and fuses of all the devices which
harness
branch out from connector CM04 (1).
Between ground and either CM04 (female) (1) or A41
Resistance Min. 1 MΩ
(male) (1)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector A41, and connect the T-adapter to male side.
3
harness 3. Turn the starting switch to ON position.
Voltage Between A41 (male) (1) and (4) Max. 9 V
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
4
tor an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-787
FAILURE CODE [DAF8KB] 40 TROUBLESHOOTING

Circuit diagram related to camera power supply

40-788 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DAF9KQ]

FAILURE CODE [DAF9KQ] (ALL-K-Q1GM-410-00-B)

Action level Failure code Model Selection Signal Mismatch (Monitor)

Failure
L03 DAF9KQ (Machine monitor system)

Detail of fail- Machine model registered in machine monitor and pump controller differs.
ure (Machine monitor or pump controller of wrong part number is installed for replacement.)
Action of
controller
Phenomenon
Machine does not operate normally.
on machine
• Assembly part number of pump controller program can be checked with monitoring func-
tion. (Code: 20229)
Related • Assembly part number of machine monitor program can be checked with monitoring func-
information tion. (Code: 20227)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Nonconformity machine Check if the part number of replaced machine monitor is correct.
1
monitor
Turn the starting switch to ON position, and perform troubleshooting (with monitor-
ing).
Monitoring code: 02201 switch input 2
Model selection 1 ON
Defective machine model
2 Model selection 2 ON
code signal
Normal dis-
Model selection 3 ON
play
Model selection 4 OFF
Model selection 5 ON
Nonconformity pump Check if the part number of replaced pump controller is correct.
3
controller

HB365LC-3 40-789
FAILURE CODE [DAFGMC] 40 TROUBLESHOOTING

FAILURE CODE [DAFGMC] (ALL-K-Q290-410-00-B)

Action level Failure code GPS Module Malfunction

Failure
- DAFGMC (KOMTRAX system)
Details of No position data is sent from GPS module (inside of machine monitor) to KOMTRAX communica-
failure tion modem more than 50 seconds since the startup of KOMTRAX.

Action of • None in particular

controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
None in particular
on machine
After repairing, check if the failure code is cleared by the following procedure.
Related
Procedure: Turn starting switch to ON position. (Wait for more than 50 seconds after the switch is
information
turned ON.)

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- GPS module of machine monitor is defective. (Since this is an internal defect, trou-
1
tor bleshooting cannot be performed.)

40-790 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DAFLKA]

FAILURE CODE [DAFLKA] (ALL-K-Q1B2-410-00-B)

Action level Failure code System Operating Lamp Open Circuit (Monitor)
Failure
- DAFLKA (Machine monitor system)
Machine monitor has detected an open circuit because the output line voltage of system operating
Detail of fail-
lamp is approximately 5 V and below while the machine monitor does not output the voltage for ap-
ure
proximately 3 seconds after the starting switch is turned to ON position.
• Stops driving system operating lamp.
Action of
• Even if cause of failure is eliminated, machine does not become normal until starting
controller
switch is turned to OFF position.
Phenomenon
None in particular
on machine
• Do not turn the battery disconnect switch to OFF position while the system operating lamp
is lit.
• If the battery disconnect switch is turned to OFF position while the system operating lamp
is lit, the memory data stored in each controller may be destroyed.
• You cannot make system operating lamp light up from machine monitor.

Related • Although machine monitor is not able to light up system operating lamp, no trouble will re-
sult unless battery disconnect switch is turned to OFF position.
information
• When controller lights up system operating lamp, output circuit voltage is at low level.
• Since no controller drives system operating lamp for approximately 3 seconds after start-
ing switch is turned to ON position, open circuit can be detected.
• After completion of repair, check that the failure code is cleared by the following proce-
dure.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.16 in fuse box F01. Check visually if it is not burnt
1 Defective fuse out.
4. When it is not burnt out, check if it is blown out by continuity test.
• When it is burnt out, check the wiring harness for ground fault.
• When it is not burnt out but it has no continuity, replace the fuse.
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.16 in fuse box F01
Open circuit in wiring har-
2
ness 4. Disconnect the connectors CM01 and L19, and connect the T-adapter to
each female side.
Between F01-16 and L19 (female) (1) Max. 1 Ω
Resistance
Between CM01 (female) (8) and L19 (female) (2) Max. 1 Ω

HB365LC-3 40-791
FAILURE CODE [DAFLKA] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
Ground fault in wiring 3.
3 Disconnect the connector L19, and connect the T-adapter to female side.
harness
4. Disconnect the connectors, terminals, and fuses of all the devices which
branch out from connector L19 (1).
Resistance Between ground and either L19 (female) (1) or F01-16 Min. 1 MΩ
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
4
tor an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to system operating lamp

40-792 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DAFLKB]

FAILURE CODE [DAFLKB] (ALL-K-Q1B2-410-10-B)

Action level Failure code System Operating Lamp Short Circuit (Monitor)
Failure
- DAFLKB (Machine monitor system)
Detail of fail- Machine monitor has detected a short circuit because voltage of output circuit does not become low
ure level while machine monitor outputs current to system operating lamp.
• Turns driving the system operating lamp to OFF.
Action of
• Even if cause of failure is eliminated, machine does not become normal until starting
controller
switch is turned to OFF position.
Phenomenon
None in particular
on machine
• Do not turn the battery disconnect switch to OFF position while the system operating lamp
is lit.
• If the battery disconnect switch is turned to OFF position while the system operating lamp
is lit, the memory data stored in each controller may be destroyed.
• You cannot make system operating lamp light up from machine monitor.
Related
• Although machine monitor is not able to light up system operating lamp, no trouble will re-
information
sult unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.
• After completion of repair, check that the failure code is cleared by the following proce-
dure.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector L19, and connect the T-adapter to female side.
1
harness 3. Turn the starting switch to ON position.
Voltage Between L19 (female) (2) and ground Max. 1 V
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
2
tor an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-793
FAILURE CODE [DAFLKB] 40 TROUBLESHOOTING

Circuit diagram related to system operating lamp

40-794 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DAFQKR]

FAILURE CODE [DAFQKR] (ALL-K-Q182-410-00-B)

Action level Failure code CAN 2 Defective Communication (Monitor)

Failure
- DAFQKR (KOMTRAX system)
Detail of fail-
KOMTRAX terminal does not recognize machine monitor through CAN communication 2 line.
ure
Action of
None in particular
controller
Phenomenon
KOMTRAX system may not function normally.
on machine
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.
• Start of CAN communication is recognized by each controller when ACC signal of starting
switch is received.
• Failure code is transmitted to and displayed on machine monitor by CAN communication.
Related Accordingly, if CAN communication with machine monitor fails, failure code [DAFQKR] is
information not displayed on machine monitor and it can be observed only through KOMTRAX sys-
tem.
• Since each controller and machine monitor are connected directly to battery, they are sup-
plied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connector CM01 and connect the T-adapter to female side.
Defective machine moni- 4. Turn the battery disconnect switch to ON position.
1
tor power supply circuit
REMARK
If there is no failure, troubleshooting for No. 2 is not required.
Between CM01 (female) (1) and (3) 20 to 30 V
Voltage
Between CM01 (female) (2) and (4) 20 to 30 V
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.17 in fuse box F01
Open circuit in wiring har- 4. Disconnect the connector CM01 and connect the T-adapter to female side.
2
ness
Between CM01 (female) (1) and F01-17 Max. 1 Ω
Between CM01 (female) (2) and F01-17 Max. 1 Ω
Resistance
Between CM01 (female) (3) and ground Max. 1 Ω
Between CM01 (female) (4) and ground Max. 1 Ω

HB365LC-3 40-795
FAILURE CODE [DAFQKR] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connector CM01 and connect the T-adapter to female side.
4. Turn the battery disconnect switch to ON position.
Defective machine moni-
3 5. Turn the starting switch to ON position.
tor ACC signal circuit
REMARK
If there is no failure, troubleshooting for No. 4 is not required.
Between CM01 (female) (10) and (3) 20 to 30 V
Voltage
Between CM01 (female) (10) and (4) 20 to 30 V
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No. 14 in fuse box F01.
Open circuit in wiring har-
4 4. Disconnect the connector CM01 and connect the T-adapter to female side.
ness
Between CM01 (female) (10) and F01-14 Max. 1 Ω
Resistance Between CM01 (female) (3) and ground Max. 1 Ω
Between CM01 (female) (4) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect connectors CM02 and K02, and connect T-adapter to each
Defective CAN 2 termi- male side.
5
nating resistor
Between CM02 (male) (7) and (9) 120 ± 12 Ω
Resistance
Between K02 (male) (A) and (B) 120 ± 12 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
Open circuit in wiring har- 3. Disconnect the connectors CM02 and K02, and connect the T-adapter to
6 ness (CAN 2 communi- each female side.
cation line)
Between CM02 (female) (7) and K02 (female) (A) Max. 1 Ω
Resistance Between CM02 (female) (8) and K02 (female) (A) Max. 1 Ω
Between CM02 (female) (9) and K02 (female) (B) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connector CM02, and connect the T-adapter to female
Ground fault in wiring side.
7 harness (CAN 2 commu-
4. Disconnect the connectors, terminals, and fuses of all the devices which
nication line)
branch out from connector CM02 (7), (8), and (9).
Between ground and each of CM02 (female) (7) and
Min. 1 MΩ
Resistance (8)
Between CM02 (female) (9) and ground Min. 1 MΩ

40-796 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DAFQKR]

No. Cause Procedure, measuring location, criteria and remarks

Hot short circuit in wiring
8 harness (CAN 2 commu-
nication line)
Defective machine moni-
9
tor
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Insert T-adapter into connector K02.
4. Turn the battery disconnect switch to ON position.
5. Turn the starting switch to ON position.
REMARK
Voltage of CANH and CANL is 2.5 ± 1 V including during communication, so regard
wiring harness as normal if measured voltage is 1 to 4 V.
Between K02(A) and ground 1 to 4 V
Voltage
Between K02(B) and ground 1 to 4 V
If no failure is found by above checks, machine monitor is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)

CIRCUIT DIAGRAM (CAN2 COMMUNICATION)

HB365LC-3 40-797
FAILURE CODE [DAFQKR] 40 TROUBLESHOOTING

Circuit diagram related to monitor controller power supply

40-798 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DAZ9KQ]

FAILURE CODE [DAZ9KQ] (ALL-K-K5G8-410-00-B)

Action level Failure code Model Selection Signal Mismatch (Air conditioner)
Failure
- DAZ9KQ (Machine monitor system)
Details of Model in machine monitor program is different from that in air conditioner controller program (re-
failure placed machine monitor or air conditioner controller is wrong in part No.)

Action of
controller
Phenomenon
Machine does not operate normally.
on machine
• Model code specified by air conditioner controller program cannot be checked with moni-
toring function.
• Air conditioner control data (model and series) of machine monitor can be checked with
monitoring function (Code: 55200).
Related
• Control data of air conditioner controller (model and series names) can be checked with
information
monitoring function (Code: 55201). (If control data is 01 (indicating hydraulic excavator), it
is correct.)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Turn the starting switch to ON position, and perform troubleshooting (with monitor-
ing).
Monitoring code: 02201 switch input 2
Model selection 1 ON
Defective machine model
1 Model selection 2 ON
code signal
Normal dis-
Model selection 3 ON
play
Model selection 4 OFF
Model selection 5 ON
Nonconformity machine Check if the part number of replaced machine monitor is correct.
2
monitor
Nonconformity air condi- Check if the part number of replaced air conditioner controller is correct.
3
tioner controller

HB365LC-3 40-799
FAILURE CODE [DAZQKR] 40 TROUBLESHOOTING

FAILURE CODE [DAZQKR] (ALL-K-K5G9-410-00-B)

Action level Failure code CAN 2 defective communication (Air conditioner)

Failure
L01 DAZQKR (Machine monitor system)
Detail of fail- In CAN communication 2 line (KOMNET/c), machine monitor cannot recognize air conditioner con-
ure troller.
Action of
Retains information when the failure occurred.
controller
Information obtained from engine controller is not displayed.
Phenomenon (Such as failure codes and monitoring codes sent from the engine controller)
on machine Air conditioner cannot be controlled (air does not blow out).
Air conditioner operation screen of machine monitor is not displayed properly.
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.
• ACC signal of starting switch is the command to start CAN communication for each con-
troller.
• 5 different failure codes, [D8AQKR], [DA2QKR], [DAFQKR], [DB2QKR], and [GA2QKR]
are used for defective CAN communication by CAN 2 when it is detected by machine
monitor. When all of these 5 failure codes are displayed, ground fault, short circuit or hot
Related short circuit in wiring harness (CAN communication circuit) can be suspected.
information
REMARK
If air conditioner is controlled, there is no possibility of ground fault, short circuit, or hot
short circuit occurring in wiring harness (CAN communication line).
• Since each controller and machine monitor are connected directly to battery, they are sup-
plied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connector AC02, and connect the T-adapter to female side.
Defective air conditioner
4. Turn the battery disconnect switch to ON position.
1 controller power supply
circuit 5. Turn the starting switch to ON position.
REMARK
If there is no failure, troubleshooting for No. 2 is not required.
Voltage Between AC02 (female) (3) and (1) 20 to 30 V
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
Open circuit in wiring har- 3. Remove the fuse No.19 in fuse box F01
2
ness
4. Disconnect the connector AC02, and connect the T-adapter to female side.
Between AC02 (female) (3) and F01-19 Max. 1 Ω
Resistance
Between AC02 (female) (1) and ground Max. 1 Ω

40-800 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DAZQKR]

No. Cause Procedure, measuring location, criteria and remarks

Open circuit in wiring har- 3.
3
ness
4.
Defective CAN 2 termi-
4
nating resistor
Open circuit in wiring har-
5 ness (CAN 2 communi-
cation line)
Ground fault in wiring
6 harness (CAN 2 commu-
nication line)
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
Remove the fuse No. 13 in fuse box F01.
Disconnect the connector AC02, and connect the T-adapter to female side.
Between AC02 (female) (4) and F01-13 Max. 1 Ω
Resistance
Between AC02 (female) (1) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect connectors CM02 and K02, and connect T-adapter to each
male side.
Between CM02 (male) (7) and (9) 120 ± 12 Ω
Resistance
Between K02 (male) (A) and (B) 120 ± 12 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors CM02, AC01, and K02, and connect the T-
adapter to each female side.
Between AC01 (female) (2) and CM02 (female) (7) Max. 1 Ω
Between AC01 (female) (2) and CM02 (female) (8) Max. 1 Ω
Resistance Between AC01 (female) (1) and CM02 (female) (9) Max. 1 Ω
Between AC01 (female) (1) and K02 (female) (B) Max. 1 Ω
Between AC01 (female) (2) and K02 (female) (A) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors AC01 and CM02, and connect the T-adapter to
either female side.
4. Disconnect the connectors, terminals, and fuses of all the devices which
branch out from connector AC01 (1) and (2).
Between ground and any of AC01 (female) (2), CM02
Min. 1 MΩ
(female) (7), and (8)
Resistance
Between ground and either AC01 (female) (1) or CM02
Min. 1 MΩ
(female) (9)

HB365LC-3 40-801
FAILURE CODE [DAZQKR] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Insert T-adapter into connector K02.
4. Turn the battery disconnect switch to ON position.
Hot short circuit in wiring
7 harness (CAN 2 commu- 5. Turn the starting switch to ON position.
nication line) REMARK
Voltage of CANH and CANL is 2.5 ± 1 V including during communication, so regard
wiring harness as normal if measured voltage is 1 to 4 V.
Between K02(A) and ground 1 to 4 V
Voltage
Between K02(B) and ground 1 to 4 V
Defective air conditioner If no failure is found by above checks, air conditioner controller is defective. (Since
8
controller this is an internal defect, troubleshooting cannot be performed.)
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
9
tor an internal defect, troubleshooting cannot be performed.)

CIRCUIT DIAGRAM (CAN2 COMMUNICATION)

40-802 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DAZQKR]

Circuit diagram related to air conditioner controller power souce

HB365LC-3 40-803
FAILURE CODE [DB2QKR] 40 TROUBLESHOOTING

FAILURE CODE [DB2QKR] (ALL-K-AP72-410-00-B)

Action level Failure code CAN 2 defective communication (Engine controller)

Failure
L03 DB2QKR (Machine monitor system)
Detail of fail-
Machine monitor cannot recognize engine controller over CAN communication-2 line (KOMNET/c).
ure
Action of
Retains information when the failure occurred.
controller
Information to be obtained from engine controller is not displayed and special functions that need
Phenomenon
information do not work. Or update of received data is stopped.
on machine
(Such as failure codes and monitoring codes sent from the engine controller)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.
• ACC signal of starting switch is the command to start CAN communication for each con-
troller.
• If failure code [DB2RKR] is also displayed, engine controller in cause 1 is probably defec-
tive.
• 5 different failure codes, [D8AQKR], [DA2QKR], [DAFQKR], [DB2QKR], and [GA2QKR]
are used for defective CAN communication by CAN 2 when it is detected by machine
monitor. When all of these 5 failure codes are displayed, ground fault, short circuit or hot
Related short circuit in wiring harness (CAN communication circuit) can be suspected.
information REMARK
If air conditioner is controlled, there is no possibility of ground fault, short circuit, or hot
short circuit occurring in wiring harness (CAN communication line).
• Air conditioner can be controlled even when failure code is displayed on the monitor
screen. If air conditioner is controlled, there is no possibility of ground fault, short circuit, or
hot short circuit occurring in wiring harness (CAN communication line).
• Since each controller and machine monitor are connected directly to battery, they are sup-
plied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connector ECM J2, and connect the T-adapter to female
side.
4. Turn the battery disconnect switch to ON position.
Defective engine control- REMARK
1
ler power supply circuit If there is no failure, troubleshooting for No. 2 is not required.
Between ECM J2 (female) (1) and (49) 20 to 30 V
Between ECM J2 (female) (25) and (50) 20 to 30 V
Voltage Between ECM J2 (female) (26) and (51) 20 to 30 V
Between ECM J2 (female) (27) and (52) 20 to 30 V
Between ECM J2 (female) (28) and (73) 20 to 30 V

40-804 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DB2QKR]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No. 18 in fuse box F01.
4. Disconnect the connector ECM J2, and connect the T-adapter to female
side.
Between ECM J2 (female) (1) and F01-18 Max. 1 Ω
Between ECM J2 (female) (25) and F01-18 Max. 1 Ω
Open circuit in wiring har-
2 Between ECM J2 (female) (26) and F01-18 Max. 1 Ω
ness
Between ECM J2 (female) (27) and F01-18 Max. 1 Ω
Between ECM J2 (female) (28) and F01-18 Max. 1 Ω
Resistance
Between ECM J2 (female) (49) and ground Max. 1 Ω
Between ECM J2 (female) (50) and ground Max. 1 Ω
Between ECM J2 (female) (51) and ground Max. 1 Ω
Between ECM J2 (female) (52) and ground Max. 1 Ω
Between ECM J2 (female) (73) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connector ECM J2, and connect the T-adapter to female
side.
4. Turn the battery disconnect switch to ON position.
5. Turn the starting switch to ON position.
Defective engine control-
3 REMARK
ler ACC signal circuit
If there is no failure, troubleshooting for No. 4 is not required.
Between ECM J2 (female) (5) and (49) 20 to 30 V
Between ECM J2 (female) (5) and (50) 20 to 30 V
Voltage Between ECM J2 (female) (5) and (51) 20 to 30 V
Between ECM J2 (female) (5) and (52) 20 to 30 V
Between ECM J2 (female) (5) and (73) 20 to 30 V

HB365LC-3 40-805
FAILURE CODE [DB2QKR]
No. Cause
Open circuit in wiring har-
4 Between ECM J2 (female) (5) and F01-14
ness
Defective CAN 2 termi-
5
nating resistor
Open circuit in wiring har-
6 ness (CAN 2 communi-
cation line)
Ground fault in wiring
7 harness (CAN 2 commu-
nication line)
40-806
40 TROUBLESHOOTING
Procedure, measuring location, criteria and remarks
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No. 14 in fuse box F01.
4. Disconnect the connector ECM J2, and connect the T-adapter to female
side.
Max. 1 Ω
Between ECM J2 (female) (49) and ground Max. 1 Ω
Between ECM J2 (female) (50) and ground Max. 1 Ω
Resistance
Between ECM J2 (female) (51) and ground Max. 1 Ω
Between ECM J2 (female) (52) and ground Max. 1 Ω
Between ECM J2 (female) (73) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect connectors CM02 and K02, and connect T-adapter to each
male side.
Between CM02 (male) (7) and (9) 120 ± 12 Ω
Resistance
Between K02 (male) (A) and (B) 120 ± 12 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors CM02, ECM J2, and K02, and connect the T-
adapter to each female side.
Between ECM J2 (female) (22) and CM02 (female) (7) Max. 1 Ω
Between ECM J2 (female) (22) and CM02 (female) (8) Max. 1 Ω
Resistance Between ECM J2 (female) (46) and CM02 (female) (9) Max. 1 Ω
Between ECM J2 (female) (22) and K02 (female) (A) Max. 1 Ω
Between ECM J2 (female) (46) and K02 (female) (B) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors ECM J2 and CM02, and connect the T-adapter
to either female side.
4. Disconnect the connectors, terminals, and fuses of all the devices which
branch out from connector ECM J2 (22) and (46).
Between ground and any of ECM J2 (female) (22),
Min. 1 MΩ
CM02 (female) (7), and (8)
Resistance
Between ground and either ECM J2 (female) (46) or
Min. 1 MΩ
CM02 (female) (9)
HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DB2QKR]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Insert T-adapter into connector K02.
4. Turn the battery disconnect switch to ON position.
Hot short circuit in wiring
8 harness (CAN 2 commu- 5. Turn the starting switch to ON position.
nication line) REMARK
Voltage of CANH and CANL is 2.5 ± 1 V including during communication, so regard
wiring harness as normal if measured voltage is 1 to 4 V.
Between K02(A) and ground 1 to 4 V
Voltage
Between K02(B) and ground 1 to 4 V
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
9
ler an internal defect, troubleshooting cannot be performed.)
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
10
tor an internal defect, troubleshooting cannot be performed.)

CIRCUIT DIAGRAM (CAN2 COMMUNICATION)

HB365LC-3 40-807
FAILURE CODE [DB2QKR] 40 TROUBLESHOOTING

Circuit diagram related to engine controller power souce

40-808 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DB2RKR]

FAILURE CODE [DB2RKR] (ALL-K-AP71-410-00-B)

Action level Failure code CAN 1 defective communication (Engine controller)

Failure
L03 DB2RKR (Machine monitor system)
Detail of fail- Machine monitor does not recognize engine controller through CAN communication 1 line (KOM-
ure NET/r).
Retains current working mode.
Action of
Retains current selection of auto-deceleration.
controller
Retains information when the failure occurred.
Information to be obtained from engine controller is not displayed and special functions that need
information do not work. Or update of received data is stopped.
Phenomenon Engine is uncontrollable.
on machine Engine speed and coolant temperature are undetectable.
A gauge pointer for engine coolant temperature and hydraulic oil temperature disappears on ma-
chine monitor screen.
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.
• ACC signal of starting switch is the command to start CAN communication for each con-
troller.
• If failure code [DB2QKR] is also displayed, engine controller system in cause 1 is probably
defective.
• 3 different failure codes, [DA2RKR], [DB2RKR], and [GA2RKR] are used for defective
Related CAN communication by CAN 1 when it is detected by machine monitor. When these 3 fail-
ure codes are displayed, ground fault, short circuit or hot short circuit in wiring harness
information (CAN communication circuit) can be suspected.
• CAN1 terminating resister is located in machine monitor on operator's cab side and con-
nector “C23” is located on engine side (CAN communication-1 circuit (KOMNET/r) is not
provided. It is output from connector “ECM J2”).
• Since each controller and machine monitor are connected directly to battery, they are sup-
plied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connector ECM J2, and connect the T-adapter to female
side.
4. Turn the battery disconnect switch to ON position.
Defective engine control- REMARK
1
ler power supply circuit If there is no failure, troubleshooting for No. 2 is not required.
Between ECM J2 (female) (1) and (49) 20 to 30 V
Between ECM J2 (female) (25) and (50) 20 to 30 V
Voltage Between ECM J2 (female) (26) and (51) 20 to 30 V
Between ECM J2 (female) (27) and (52) 20 to 30 V
Between ECM J2 (female) (28) and (73) 20 to 30 V

HB365LC-3 40-809
FAILURE CODE [DB2RKR] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No. 18 in fuse box F01.
4. Disconnect the connector ECM J2, and connect the T-adapter to female
side.
Between ECM J2 (female) (1) and F01-18 Max. 1 Ω
Between ECM J2 (female) (25) and F01-18 Max. 1 Ω
Open circuit in wiring har-
2 Between ECM J2 (female) (26) and F01-18 Max. 1 Ω
ness
Between ECM J2 (female) (27) and F01-18 Max. 1 Ω
Between ECM J2 (female) (28) and F01-18 Max. 1 Ω
Resistance
Between ECM J2 (female) (49) and ground Max. 1 Ω
Between ECM J2 (female) (50) and ground Max. 1 Ω
Between ECM J2 (female) (51) and ground Max. 1 Ω
Between ECM J2 (female) (52) and ground Max. 1 Ω
Between ECM J2 (female) (73) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connector ECM J2, and connect the T-adapter to female
side.
4. Turn the battery disconnect switch to ON position.
5. Turn the starting switch to ON position.
Defective engine control-
3 REMARK
ler ACC signal circuit
If there is no failure, troubleshooting for No. 4 is not required.
Between ECM J2 (female) (5) and (49) 20 to 30 V
Between ECM J2 (female) (5) and (50) 20 to 30 V
Voltage Between ECM J2 (female) (5) and (51) 20 to 30 V
Between ECM J2 (female) (5) and (52) 20 to 30 V
Between ECM J2 (female) (5) and (73) 20 to 30 V

40-810 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DB2RKR]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No. 14 in fuse box F01.
4. Disconnect the connector ECM J2, and connect the T-adapter to female
side.
Open circuit in wiring har-
4 Between ECM J2 (female) (5) and F01-14 Max. 1 Ω
ness
Between ECM J2 (female) (49) and ground Max. 1 Ω
Between ECM J2 (female) (50) and ground Max. 1 Ω
Resistance
Between ECM J2 (female) (51) and ground Max. 1 Ω
Between ECM J2 (female) (52) and ground Max. 1 Ω
Between ECM J2 (female) (73) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors C23 and CM02, and connect the T-adapter to
Defective CAN 1 termi- each male side.
5
nating resistor
Between CM02 (male) (10) and (12) 120 ± 12 Ω
Resistance
Between C23 (male) (A) and (B) 120 ± 12 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors CM02, ECM J1, and C23, and connect the T-
adapter to each female side.

Open circuit in wiring har- Between ECM J1 (female) (70) and CM02 (female)
Max. 1 Ω
6 ness (CAN 1 communi- (10)
cation line) Between ECM J1 (female) (70) and CM02 (female)
Max. 1 Ω
(11)
Resistance
Between ECM J1 (female) (94) and CM02 (female)
Max. 1 Ω
(12)
Between ECM J1 (female) (70) and C23 (female) (A) Max. 1 Ω
Between ECM J1 (female) (94) and C23 (female) (B) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors ECM J1 and CM02, and connect the T-adapter
Ground fault in wiring to either female side.
7 harness (CAN 1 commu- 4. Disconnect the connectors, terminals, and fuses of all the devices which
nication line) branch out from connector ECM J1 (70) and (94).
Between ground and any of ECM J1 (female) (70),
Min. 1 MΩ
CM02 (female) (10), and (11)
Resistance
Between ground and either ECM J1 (female) (94) or
Min. 1 MΩ
CM02 (female) (12)

HB365LC-3 40-811
FAILURE CODE [DB2RKR] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Insert the T-adapter into connector C23.
4. Turn the battery disconnect switch to ON position.
Hot short circuit in wiring
8 harness (CAN 1 commu- 5. Turn the starting switch to ON position.
nication line) REMARK
Voltage of CANH and CANL is 2.5 ± 1 V including during communication, so regard
wiring harness as normal if measured voltage is 1 to 4 V.
Between ground and C23 (A) 1 to 4 V
Voltage
Between ground and C23 (B) 1 to 4 V
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
9
ler an internal defect, troubleshooting cannot be performed.)
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
10
tor an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to CAN communication 1

40-812 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DB2RKR]

Circuit diagram related to engine controller power souce

HB365LC-3 40-813
FAILURE CODE [DBP0KM] 40 TROUBLESHOOTING

FAILURE CODE [DBP0KM] (ALL-K-K900-410-00-B)

Action level Failure code KomVision Setting Error

Failure
L01 DBP0KM (KomVision controller system)
Detail of fail-
There is an error or an incomplete item in the KomVision controller setting.
ure
Action of
Stops the image output of KomVision
controller
Phenomenon
Display area of KomVision is displayed in black.
on machine

Related • After completion of repair, check that the failure code is cleared by the following proce-
dure.
information Procedure: Turn the starting switch to ON position and display a Bird's Eye View

No. Cause Procedure, measuring location, criteria and remarks

Incomplete KomVision See testing and adjusting“ADJUST KomVision RELATED ITEMS”, and check that
1
Setting the setting is done correctly.

40-814 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DBP0KT]

FAILURE CODE [DBP0KT] (ALL-K-K910-410-00-B)

Action level Failure code KomVision Controller Abnormality

Failure
L01 DBP0KT (KomVision controller system)
Detail of fail-
Abnormal operation of KomVision controller
ure
Action of
Stops the image output of KomVision
controller
Phenomenon
Display area of KomVision is displayed in black.
on machine

Related • After completion of repair, check that the failure code is cleared by the following proce-
dure.
information Procedure: Turn the starting switch to ON position and display a Bird's Eye View

No. Cause Procedure, measuring location, criteria and remarks

Defective KomVision KomVision controller is defective. (Since this is an internal defect, troubleshooting
1
controller cannot be performed.)

HB365LC-3 40-815
FAILURE CODE [DBPQKR] 40 TROUBLESHOOTING

FAILURE CODE [DBPQKR] (ALL-K-0J10-410-00-B)

Action level Failure code CAN 2 defective communication (KomVision)

Failure
L01 DBPQKR (Machine monitor system)
Detail of fail- Machine monitor cannot recognize KomVision controller through CAN communication 2 line (KOM-
ure NET/c).
Action of
None in particular
controller
Phenomenon
Screen operation of KomVision becomes impossible.
on machine
• ACC signal of starting switch is the command to start CAN communication for each con-
troller.
• 5 different failure codes, [D8AQKR], [DA2QKR], [DAFQKR], [DB2QKR], and [GA2QKR]
are used for defective CAN communication by CAN 2 when it is detected by machine
monitor. When all of these 5 failure codes are displayed, ground fault, short circuit or hot
short circuit in wiring harness (CAN communication circuit) can be suspected.
REMARK
If air conditioner is controlled, there is no possibility of ground fault, short circuit, or hot
Related short circuit occurring in wiring harness (CAN communication line).
information • This can be activated even when power supply to KomVision controller is turned off.
• This can be activated if "With KomVision" is selected when setting the machine monitor for
the machine without KomVision specification.
• Since each controller and machine monitor are connected directly to battery, they are sup-
plied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1 Defective fuse
Defective KomVision
2 controller power supply
circuit
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.5 in fuse box F02. Check visually if it is not burnt out.
4. When it is not burnt out, check if it is blown out by continuity test.
• When it is burnt out, check the wiring harness for ground fault.
• When it is not burnt out but it has no continuity, replace the fuse.
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect connector CA02 and connect T-adapter to female side.
4. Turn the battery disconnect switch to ON position.
REMARK
If there is no failure, troubleshooting for No. 2 is not required.
Between CA02 (female) (112) and (104) 20 to 30 V
Voltage
Between CA02 (female) (113) and (105) 20 to 30 V

40-816 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DBPQKR]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No. 5 in fuse box F02.
Open circuit in wiring har- 4. Disconnect the connector CA02, and connect the T-adapter to female side.
3
ness
Between CA02 (female) (112) and F02 -5 Max. 1 Ω
Between CA02 (female) (113) and F02 -5 Max. 1 Ω
Resistance
Between CA02 (female) (104) and ground Max. 1 Ω
Between CA02 (female) (105) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect connector CA02, and connect T-adapter to female side.
Defective KomVision 4. Turn the battery disconnect switch to ON position.
4 controller ACC signal cir- 5. Turn the starting switch to ON position.
cuit
REMARK
If there is no failure, troubleshooting for No. 4 is not required.
Between CA02 (female) (96) and (104) 20 to 30 V*
Voltage
Between CA02 (female) (97) and (105) 20 to 30 V*
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.14 in fuse box F01.
Open circuit in wiring har- 4. Disconnect the connector CA02, and connect the T-adapter to female side.
5
ness
Between CA02 (female) (96) and F01 -14 Max. 1 Ω
Between CA02 (female) (97) and F01 -14 Max. 1 Ω
Resistance
Between CA02 (female) (104) and ground Max. 1 Ω
Between CA02 (female) (105) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect connectors CM02 and K02, and connect T-adapter to each
Defective CAN 2 termi- male side.
6
nating resistor
Between CM02 (male) (7) and (9) 120 ± 12 Ω
Resistance
Between K02 (male) (A) and (B) 120 ± 12 Ω

HB365LC-3 40-817
FAILURE CODE [DBPQKR] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Open circuit in wiring har-
7 ness (CAN 2 communi-
cation line)
Ground fault in wiring
8 harness (CAN 2 commu-
nication line)
Hot short circuit in wiring
9 harness (CAN 2 commu-
nication line)
Defective KomVision
10
controller
Defective machine moni-
11
tor
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect connectors CA02, CK01, and K02, and connect T-adapter to
each female side.
Between CA02 (female) (110) and CM02 (female) (7) Max. 1 Ω
Between CA02 (female) (110) and CM02 (female) (8) Max. 1 Ω
Resistance Between CA02 (female) (111) and CM02 (female) (9) Max. 1 Ω
Between CA02 (female) (110) and K02 (female) (A) Max. 1 Ω
Between CA02 (female) (111) and K02 (female) (B) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect connectors CA02, and CM02, and connect T-adapter to either
female side.
4. Disconnect connector, terminal, and fuse of all the devices which branch out
connector CA02 (110) , and (111).
Between ground and any of CA02 (female) (110) ,
Min. 1 MΩ
CM02 (female) (7), and (8)
Resistance
Between ground and either of CA02 (female) (111) and
Min. 1 MΩ
CM02 (female) (9)
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Insert T-adapter into connector K02.
4. Turn the battery disconnect switch to ON position.
5. Turn the starting switch to ON position.
REMARK
Voltage of CANH and CANL is 2.5 ± 1 V including during communication, so regard
wiring harness as normal if measured voltage is 1 to 4 V.
Between K02(A) and ground 1 to 4 V
Voltage
Between K02(B) and ground 1 to 4 V
If no failure is found by above checks, KomVision controller is defective. (Since this
is an internal defect, troubleshooting cannot be performed).
If no failure is found by above checks, machine monitor is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)

40-818 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DBPQKR]

CIRCUIT DIAGRAM (CAN2 COMMUNICATION)

HB365LC-3 40-819
FAILURE CODE [DBPQKR] 40 TROUBLESHOOTING

Circuit diagram related to KomVision controller power supply

40-820 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DDNRKA]

FAILURE CODE [DDNRKA] (ALL-K-PX11-410-20-B)

Action level Failure code Work Equipment Lever Lock Switch Open Circuit
Failure
L03 DDNRKA (Pump controller system)

• No current flows on the PPC lock lever relay side when the work equipment lock lever is in
Detail of fail- RELEASE position, so the open circuit is detected.
ure • No current flows on the controller side when the work equipment lock lever is in LOCK po-
sition, so the open circuit is detected.
Action of • None in particular (Lock lever automatic lock control may operate wrongly.)
controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
• Starting motor does not start.
on machine
• Condition of lock lever can be checked with monitoring function. (Code: 02203)
Lock lever (start side) ON: Lock/OFF: Free
Related Lock lever 2 (solenoid side) ON: Lock/OFF: Free
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position and lock and unlock work equipment lock
lever.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
1 Defective fuse 3. Remove the fuse No.3 in fuse box F01. Check visually if it is not burnt out.
4. When it is not burnt out, check if it is blown out by continuity test.
• When it is burnt out, check the wiring harness for ground fault.
• When it is not burnt out but it has no continuity, replace the fuse.
1. Turn the starting switch to OFF position.
2. Disconnect the connector S14, and connect the T-adapter to female side.
3. Operate the lock lever to perform troubleshooting.
Defective work equip- Lock lever: LOCK Min. 1 MΩ
2 Between S14 (female) (1)
ment lever lock switch
and (2) Lock lever: FREE Max. 1 Ω
Resistance
Between S14 (female) (1) Lock lever: LOCK Max. 1 Ω
and (3) Lock lever: FREE Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Remove the fuse No.3 in fuse box F01
Open circuit in wiring har- 3. Disconnect the connectors CP01 and S14, and connect the T-adapter to
3 female side of CP01 and male side of S14.
ness
Between S14 (male) (1) and F01-3 Max. 1 Ω
Resistance
Between S14 (male) (2) and CP01 (female) (78) Max. 1 Ω

HB365LC-3 40-821
FAILURE CODE [DDNRKA] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and S14, and connect the T-adapter to
either CP01 (female) or S14 (male).
Ground fault in wiring 3. Disconnect the connectors, terminals, and fuses of all the devices which
4 branch out from connector S14 (1) and (2).
harness
Between ground and either S14 (male) (1) or F01-3 Min. 1 MΩ
Resistance Between ground and either S14 (male) (2) or CP01 (fe-
Min. 1 MΩ
male) (78)
If no failure is found by above checks, pump controller is defective. (Since this is an
5 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to PPC lock switch

40-822 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DDNRKY]

FAILURE CODE [DDNRKY] (ALL-K-PX11-410-10-B)

Action level Failure code Work Equipment Lever Lock Switch Short Circuit
Failure
L03 DDNRKY (Pump controller system)

• PPC lock signal voltage of circuit on controller side is 5.2 V or higher when work equip-
Detail of fail- ment lock lever is in RELEASE position.
ure • Signal voltage of circuit on PPC lock lever relay side is 5.2 V or higher when work equip-
ment lock lever is in LOCK position.
Action of • Stops PPC lock relay output.
controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
None of work equipment, swing or travel works.
on machine
• Condition of lock lever can be checked with monitoring function. (Code: 02203)
Lock lever (start side) ON: Lock/OFF: Free
Related Lock lever 2 (solenoid side) ON: Lock/OFF: Free
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position and lock and unlock work equipment lock
lever.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector S14, and connect the T-adapter to female side.
3. Operate the lock lever to perform troubleshooting.
Defective work equip- Lock lever: LOCK Min. 1 MΩ
1 Between S14 (female) (1)
ment lever lock switch
and (2) Lock lever: FREE Max. 1 Ω
Resistance
Between S14 (female) (1) Lock lever: LOCK Max. 1 Ω
and (3) Lock lever: FREE Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connector S14, and connect the T-adapter to male side.
Hot short circuit in wiring 3. Turn the starting switch to ON position.
2
harness
Between S14 (male) (2) and ground Max. 1 V
Voltage
Between S14 (male) (3) and ground Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an
3 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-823
FAILURE CODE [DDNRKY] 40 TROUBLESHOOTING

Circuit diagram related to PPC lock switch

40-824 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DDNS00]

FAILURE CODE [DDNS00] (ALL-K-PX11-410-00-B)

Action level Failure code Lock Lever Auto Lock Release Switch Operation
Failure
- DDNS00 (pump controller system)
Details of Lock lever automatic lock release switch operation is detected when lock lever is locked automati-
failure cally.

Action of • None in particular

controller • Lock lever automatic lock does not operate.
Phenomenon • Lock lever automatic lock function does not operate.
on machine • Automatic lock release switch monitor is displayed in red on machine monitor.
• Connectors CP01 and S25 do not provide T-adapter for measuring voltage, and use con-
Related nector D03 for troubleshooting.
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position and set PPC lock lever to FREE position.

No. Cause Procedure, measuring location, criteria and remarks

Defective lock lever auto-
1
matic lock cancel switch
Hot short circuit in wiring
2
harness
3 Defective pump controller
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01, D03, R48, and H16, and connect the T-
adapter to female side of D03 and R48.
Between D03 (female) (7) Switch: Released Max. 1 Ω
Resistance
and R48 (female) (3) Switch: Normal Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Insert the T-adapter into connector D03.
3. Turn the starting switch to ON position.
Voltage Between D03 (7) and ground Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-825
FAILURE CODE [DDNS00] 40 TROUBLESHOOTING

Circuit diagram related to PPC lock switch

40-826 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DGH2KA]

FAILURE CODE [DGH2KA] (ALL-K-L2A0-410-20-B)

Action level Failure code Hydraulic Oil Temperature Sensor Open Circuit
Failure
L01 DGH2KA (Pump controller system)
Detail of fail- Signal voltage of hydraulic oil temperature sensor circuit is approximately 5 V or above, so open cir-
ure cuit is detected.
Action of
If cause of failure disappears, machine becomes normal by itself.
controller
Phenomenon While hydraulic oil temperature is rising normally, it does not rise from the top end of white range
on machine (bottom end of green range).

• Signal voltage from the hydraulic oil temperature sensor can be checked with monitoring
Related function. (Code: 04402: Hydraulic Oil Temp Sensor Volt)
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector P22, and connect the T-adapter to male side.
38.1 to
Oil temperature 25 °C
47.8 kΩ
31.0 to
Oil temperature 30 °C
40.0 kΩ
Between P22 (male) (2)
Defective hydraulic oil and (1) (Thermal charac- 6.1 to
1 Oil temperature 80 °C
temperature sensor teristics of oil temperature 7.0 kΩ
Resistance sensor)
4.6 to
Oil temperature 90 °C
5.2 kΩ
3.6 to
Oil temperature 100 °C
4.0 kΩ
Between ground and P22 Oil temperature: Whole
Min. 1 MΩ
(male) (2) or (1) range
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P22, and connect the T-adapter to
Open circuit in wiring har- each female side.
2
ness
Between CP01 (female) (28) and P22 (female) (2) Max. 1 Ω
Resistance
Between CP01 (female) (46) and P22 (female) (1) Max. 1 Ω
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector P22, and connect the T-adapter to female side.
3
harness 3. Turn the starting switch to ON position.
Voltage Between P22 (female) (2) and (1) Approx. 5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-827
FAILURE CODE [DGH2KA] 40 TROUBLESHOOTING

Circuit diagram related to hydraulic oil temperature sensor

40-828 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DGH2KB]

FAILURE CODE [DGH2KB] (ALL-K-L2A0-410-30-B)

Action level Failure code Hydraulic Oil Temperature Sensor Ground Fault
Failure
L01 DGH2KB (Pump controller system)
Detail of fail-
Controller detects ground fault in Hydraulic Oil Temperature Sensor.
ure
Action of
If cause of failure disappears, machine becomes normal by itself.
controller
Phenomenon
Hydraulic oil temperature gauge is equivalent to 50 °C.
on machine
• Signal voltage from the hydraulic oil temperature sensor can be checked with monitoring
Related function. (Code: 04402: Hydraulic Oil Temp Sensor Volt)
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector P22, and connect the T-adapter to male side.
38.1 to
Oil temperature 25 °C
47.8 kΩ
31.0 to
Oil temperature 30 °C
40.0 kΩ
Between P22 (male) (2)
Defective hydraulic oil and (1) (Thermal charac- 6.1 to
1 Oil temperature 80 °C
temperature sensor teristics of oil temperature 7.0 kΩ
Resistance sensor)
4.6 to
Oil temperature 90 °C
5.2 kΩ
3.6 to
Oil temperature 100 °C
4.0 kΩ
Between ground and P22 Oil temperature: Whole
Min. 1 MΩ
(male) (2) or (1) range
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P22, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP01 (female) (28) or P22
Resistance Min. 1 MΩ
(female) (2)
If no failure is found by above checks, pump controller is defective. (Since this is an
3 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-829
FAILURE CODE [DGH2KB] 40 TROUBLESHOOTING

Circuit diagram related to hydraulic oil temperature sensor

40-830 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHA4KA]

FAILURE CODE [DHA4KA] (ALL-K-A966-410-10-B)

Action level Failure code Air Cleaner Clogging Sensor Open Circuit
Failure
L01 DHA4KA (Machine monitor system)
Detail of fail-
Controller detects open circuit in Air Cleaner Clogging Sensor.
ure
Action of
Displays system state monitor on machine monitor in yellow.
controller
Phenomenon
If machine is used as it is, engine may be damaged.
on machine
• Input state (ON/OFF) from air cleaner clogging switch can be checked with monitoring
function. (Code: 04501 “Monitor input 2”)
Related
• After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position.
• Air cleaner suction resistance: Max.-3,430 Pa {-350 mmH2O}

No. Cause Procedure, measuring location, criteria and remarks

Air cleaner may be clogged. Check it for clogging and then clean or replace if clog-
1 Clogging of air cleaner
ged.
1. Turn the starting switch to OFF position.
2. Disconnect the connector P23, and connect the T-adapter to male side.
3. Start the engine.
REMARK
Air cleaner suction resistance value
Defective air cleaner
2 *1: -3430 Pa Max. {-350 mmH2O}
clogging sensor
*2: -7470±490 Pa {-762±50 mmH2O}
When air cleaner: is nor-
Max. 1 Ω
Between P23 (male) (1) mal *1
Resistance
and (2) When air cleaner is clog-
Min. 1 MΩ
ged *2
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CM02 and P23, and connect the T-adapter to
Open circuit in wiring har- each female side.
3
ness
Between CM02 (female) (4) and P23 (female) (1) Max. 1 Ω
Resistance
Between P23 (female) (2) and ground Max. 1 Ω
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
4
tor an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-831
FAILURE CODE [DHA4KA] 40 TROUBLESHOOTING

CIRCUIT DIAGRAM (AIR CLEANER CLOGGING SENSOR)

40-832 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHAAMA]

FAILURE CODE [DHAAMA] (ALL-K-A9HL-410-00-B)

Action level Failure code KDPF Differential Pressure Sensor Frozen

Failure
- DHAAMA (Engine controller system)
Signal voltage from KDPF differential pressure sensor does not show a correct value when ambient
Detail of fail-
temperature is low because of frozen KDPF differential pressure sensor. (Signal voltage is within
ure
“normal” or “operating” range.)
Action of
• Normal operation
controller
Phenomenon
No
on machine

k Since KDOC and KDPF are heated to Min. 500 °C or above, be careful not to get burn in-
jury.
• The cause of this failure code is solved after freeze is solved. Troubleshooting is not nec-
essary.
• If the ambient temperature is not at freezing point of the sensor when this failure code is
displayed on abnormality record, identify the cause according to the following procedures.
• KDPF differential pressure sensor and KDPF outlet pressure sensor are provided as a
unit.
• Signal voltage from KDPF differential pressure sensor can be checked by monitoring func-
tion. (Code: 47101 (V))
• Differential pressure in KDPF differential pressure sensor can be checked by monitoring
function. (Code: 47100 (kPa))
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
Related
(Code: 47300 (°C))

information • Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
• The KDOC inlet temperature sensor, KDOC outlet temperature sensor, and KDPF outlet
temperature sensor are integrated into one sensor controller which provides CAN commu-
nication with the engine controller.
• For details of access to KDPF differential pressure sensor, wiring harness and tube, see
"Chapter 50 DISASSEMBLY AND ASSEMBLY, “REMOVE AND INSTALL KDPF ASSEM-
BLY” and “DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY”.
• After turning starting switch to OFF position, engine controller performs AdBlue/DEF purge
(for Max. 6 minutes) and then stops. To restart engine, wait until system operating lamp
goes off after turning starting switch to OFF position, and then turn starting switch to ON
position.
• Mass air flow sensor and intake air temperature sensor are provided as a unit.

No. Cause Procedure, measuring location, criteria and remarks

1. Remove KDPF differential pressure sensor tube.
2. Clean and unclog KDPF differential pressure sensor tube.
Defective KDPF differen-
1 3. Check KDPF differential pressure sensor tube for cracks and damage.
tial pressure sensor tube
4. Install KDPF differential pressure sensor tube with both tube ends con-
nected securely.
Defective ambient tem- Check the installation of the ambient temperature sensor. If there is a defective in-
2 perature sensor installa- stallation, install it again correctly.
tion

HB365LC-3 40-833
FAILURE CODE [DHAAMA] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Defective mass air flow Check the installation of the mass air flow and temperature sensor. If there is a de-
3
and temperature sensor fective installation, install it again correctly.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

40-834 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHACMA]

FAILURE CODE [DHACMA] (ALL-K-A9HL-410-10-B)

Action level Failure code KDPF Outlet Pressure Sensor Frozen

Failure
- DHACMA (Engine controller system)
Signal voltage from KDPF differential pressure sensor does not show a correct value when ambient
Detail of fail-
temperature is low because of frozen KDPF differential pressure sensor. (Signal voltage is within
ure
"normal" or "operating" range.)
Action of
Normal operation
controller
Phenomenon
No
on machine

k Since KDOC and KDPF are heated to Min. 500 °C or above, be careful not to get burn in-
jury.
• The cause of this failure code is solved after freeze is solved. Troubleshooting is not nec-
essary.
• If the ambient temperature is not freezing point when this failure code is displayed on ab-
normality record, identify the cause according to the following procedures.
• KDPF differential pressure sensor and KDPF outlet pressure sensor are provided as a
unit.
• Signal voltage from KDPF outlet pressure sensor can be checked with monitoring function.
(Code: 47001 (V))
• Pressure detected by KDPF outlet pressure sensor can be checked with monitoring func-
tion. (Code: 47000 (kPa))
• Temperature in KDOC inlet temperature sensor can be checked by monitoring function.
Related
(Code: 47300 (°C))

information • Temperature in KDOC outlet temperature sensor can be checked by monitoring function.
(Code: 47400 (°C))
• Temperature in KDPF outlet temperature sensor can be checked by monitoring function.
(Code: 47200 (°C))
• For details of access to KDPF differential pressure sensor, wiring harness and tube, see
"Chapter 50 DISASSEMBLY AND ASSEMBLY, “REMOVE AND INSTALL KDPF ASSEM-
BLY” and “DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY”.
• The KDOC inlet temperature sensor, KDOC outlet temperature sensor, and KDPF outlet
temperature sensor are integrated into one sensor controller which provides CAN commu-
nication with the engine controller.
• After turning starting switch to OFF position, engine controller performs AdBlue/DEF purge
(for Max. 6 minutes) and then stops. To restart engine, wait until system operating lamp
goes off after turning starting switch to OFF position, and then turn starting switch to ON
position.
• Mass air flow sensor and intake air temperature sensor are provided as a unit.

No. Cause Procedure, measuring location, criteria and remarks

1. Remove KDPF differential pressure sensor tube.
2. Clean and unclog KDPF differential pressure sensor tube.
Defective KDPF differen-
1 3. Check KDPF differential pressure sensor tube for cracks and damage.
tial pressure sensor tube
4. Install KDPF differential pressure sensor tube with both tube ends con-
nected securely.
Defective ambient tem- Check the installation of the ambient temperature sensor. If there is a defective in-
2 perature sensor installa- stallation, install it again correctly.
tion

HB365LC-3 40-835
FAILURE CODE [DHACMA] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Defective mass air flow Check the installation of the mass air flow and temperature sensor. If there is a de-
3
and temperature sensor fective installation, install it again correctly.
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

40-836 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHPAMA]

FAILURE CODE [DHPAMA] (ALL-K-C3W2-410-00-B)

Action level Failure code Front Pump Pressure Sensor Defective Function
Failure
L01 DHPAMA (Pump controller system)
Detail of fail-
Signal voltage of front pump pressure sensor circuit is 0.3 V or less or 4.5 V or above.
ure
Action of Controls machine by regarding front pump pressure as 0 MPa.
controller If cause of failure disappears, machine becomes normal by itself.
Phenomenon Travel automatic transmission function does not work.
on machine Straight travel becomes poor or it is hard to steer.

REMARK
If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will break. Accordingly, take extreme care when checking.

Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
be measured at pump controller connector.
information
• Front pump pressure can be checked with monitoring function.
(Code: 01100 Front pump pressure)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position or start engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Defective front pump 2. Insert the T-adapter into connector P25.
1
pressure sensor 3. Turn the starting switch to ON position.
Voltage Between P25 (2) and (1) 0.5 to 4.5 V
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P25, and connect the T-adapter to
each female side.
Open circuit in wiring har-
2
ness Between CP01 (female) (63) and P25 (female) (3) Max. 1 Ω
Resistance Between CP01 (female) (11) and P25 (female) (2) Max. 1 Ω
Between CP01 (female) (46) and P25 (female) (1) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P25, and connect the T-adapter to
Ground fault in wiring
3 either female side.
harness
Between ground and either CP01 (female) (11) or P25
Resistance Min. 1 MΩ
(female) (2)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector P25, and connect the T-adapter to female side.
4
harness 3. Turn the starting switch to ON position.
Voltage Between P25 (female) (2) and (1) Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an
5 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-837
FAILURE CODE [DHPAMA] 40 TROUBLESHOOTING

Circuit diagram related to front pump pressure sensor

40-838 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHPBMA]

FAILURE CODE [DHPBMA] (ALL-K-C3W3-410-00-B)

Action level Failure code Rear Pump Pressure Sensor Defective Function
Failure
L01 DHPBMA (Pump controller system)
Detail of fail-
Signal voltage of rear pump pressure sensor circuit is 0.3 V or less or 4.5 V or above.
ure
Action of Controls machine by regarding rear pump pressure as 0 MPa.
controller If cause of failure disappears, machine becomes normal by itself.
Phenomenon Travel automatic transmission function does not work.
on machine Straight travel becomes poor or it is hard to steer.

REMARK
If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will break. Accordingly, take extreme care when checking.

Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
be measured at pump controller connector.
information
• Rear pump pressure can be checked with monitoring function.
(Code: 01101 Rear pump pressure)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position or start engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Defective rear pump 2. Insert the T-adapter into connector P26.
1
pressure sensor 3. Turn the starting switch to ON position.
Voltage Between P26 (2) and (1) 0.5 to 4.5 V
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P26, and connect the T-adapter to
each female side.
Open circuit in wiring har-
2
ness Between CP01 (female) (63) and P26 (female) (3) Max. 1 Ω
Resistance Between CP01 (female) (30) and P26 (female) (2) Max. 1 Ω
Between CP01 (female) (46) and P26 (female) (1) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P26, and connect the T-adapter to
Ground fault in wiring
3 either female side.
harness
Between ground and either CP01 (female) (30) or P26
Resistance Min. 1 MΩ
(female) (2)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector P26, and connect the T-adapter to female side.
4
harness 3. Turn the starting switch to ON position.
Voltage Between P26 (female) (2) and (1) Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an
5 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-839
FAILURE CODE [DHPBMA] 40 TROUBLESHOOTING

Circuit diagram related to rear pump pressure sensor

40-840 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHS3MA]

FAILURE CODE [DHS3MA] (ALL-K-L9U8-410-00-B)

Action level Failure code Arm IN PPC Pressure Sensor Defective Function
Failure
L01 DHS3MA (Pump controller system)
Detail of fail-
Signal voltage of arm IN PPC pressure sensor circuit is 0.3 V or less or 4.5 V or above.
ure
Action of Controls machine by regarding arm IN PPC pressure as 0 MPa.
controller If cause of failure disappears, machine becomes normal by itself.
Phenomenon Auto-deceleration function cannot be reset.
on machine Poor operability of arm IN

REMARK
If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will break. Accordingly, take extreme care when checking.

Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
be measured at pump controller connector.
information
• Arm IN PPC pressure can be checked with monitoring function.
(Code: 07200 Arm IN PPC pressure)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position or start engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P04, and connect the T-adapter to
each female side.
Open circuit in wiring har-
1
ness Between CP01 (female) (63) and P04 (female) (3) Max. 1 Ω
Resistance Between CP01 (female) (14) and P04 (female) (2) Max. 1 Ω
Between CP01 (female) (46) and P04 (female) (1) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P04, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP01 (female) (14) or P04
Resistance Min. 1 MΩ
(female) (2)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector P04, and connect the T-adapter to female side.
3
harness 3. Turn the starting switch to ON position.
Voltage Between P04 (female) (2) and (1) Max. 1 V
1. Turn the starting switch to OFF position.
Defective arm IN PPC 2. Insert the T-adapter into connector P04.
4
pressure sensor 3. Turn the starting switch to ON position.
Voltage Between P04 (2) and (1) 0.5 to 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
5 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-841
FAILURE CODE [DHS3MA] 40 TROUBLESHOOTING

Circuit diagram related to arm IN PPC pressure sensor

40-842 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHS4MA]

FAILURE CODE [DHS4MA] (ALL-K-LEN5-410-00-B)

Action level Failure code Bucket CURL PPC Pressure Sensor Defective Function
Failure
L01 DHS4MA (Pump controller system)
Detail of fail-
Signal voltage of bucket CURL PPC pressure sensor circuit is 0.3 V or less or 4.5 V or above.
ure
Action of Controls machine by regarding bucket CURL PPC pressure as 0 MPa.
controller If cause of failure disappears, machine becomes normal by itself.
Phenomenon Auto-deceleration function cannot be reset.
on machine Poor operability of bucket CURL

REMARK
If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will break. Accordingly, take extreme care when checking.

Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
be measured at pump controller connector.
information
• Bucket CURL PPC pressure can be checked with monitoring function.
(Code: 07300 Bucket CURL PPC pressure)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position or start engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P01, and connect the T-adapter to
each female side.
Open circuit in wiring har-
1
ness Between CP01 (female) (63) and P01 (female) (3) Max. 1 Ω
Resistance Between CP01 (female) (69) and P01 (female) (2) Max. 1 Ω
Between CP01 (female) (46) and P01 (female) (1) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P01, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP01 (female) (69) or P01
Resistance Min. 1 MΩ
(female) (2)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector P01, and connect the T-adapter to female side.
3
harness 3. Turn the starting switch to ON position.
Voltage Between P01 (female) (2) and (1) Max. 1 V
1. Turn the starting switch to OFF position.
Bucket CURL PPC pres- 2. Insert the T-adapter into connector P01.
4
sure sensor 3. Turn the starting switch to ON position.
Voltage Between P01 (2) and (1) 0.5 to 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
5 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-843
FAILURE CODE [DHS4MA] 40 TROUBLESHOOTING

Circuit diagram related to bucket CURL PPC pressure sensor

40-844 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHS8MA]

FAILURE CODE [DHS8MA] (ALL-K-L6WF-410-00-B)

Action level Failure code Boom RAISE PPC Pressure Sensor Defective Function
Failure
L01 DHS8MA (Pump controller system)
Detail of fail-
Signal voltage of boom RAISE PPC pressure sensor circuit is 0.3 V or less or 4.5 V or above.
ure
Action of Controls machine by regarding boom RAISE PPC pressure as 0 MPa.
controller If cause of failure disappears, machine becomes normal by itself.
Phenomenon Auto-deceleration function cannot be reset.
on machine Poor operability of boom RAISE operation

REMARK
If 5 V circuit (3) and ground circuit (1) of pressure sensor are connected inversely, pressure sensor
will break. Accordingly, take extreme care when checking.

Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
be measured at pump controller connector.
information
• Boom RAISE PPC pressure can be checked with monitoring function.
(Code: 07400 Boom RAISE PPC pressure)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position or start engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P06, and connect the T-adapter to
each female side.
Open circuit in wiring har-
1
ness Between CP01 (female) (63) and P06 (female) (3) Max. 1 Ω
Resistance Between CP01 (female) (32) and P06 (female) (2) Max. 1 Ω
Between CP01 (female) (46) and P06 (female) (1) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P06, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP01 (female) (32) or P06
Resistance Min. 1 MΩ
(female) (2)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector P06, and connect the T-adapter to female side.
3
harness 3. Turn the starting switch to ON position.
Voltage Between P06 (female) (2) and (1) Max. 1 V
1. Turn the starting switch to OFF position.
Defective boom RAISE 2. Insert the T-adapter into connector P06.
4
PPC pressure sensor 3. Turn the starting switch to ON position.
Voltage Between P06 (2) and (1) 0.5 to 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
5 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-845
FAILURE CODE [DHS8MA] 40 TROUBLESHOOTING

Circuit diagram related to boom RAISE PPC pressure sensor

40-846 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHS9MA]

FAILURE CODE [DHS9MA] (ALL-K-L6WL-410-00-B)

Action level Failure code Boom LOWER PPC pressure sensor malfunction
Failure
L01 DHS9MA (Pump controller system)
Detail of fail-
Signal voltage of boom LOWER pressure sensor circuit is 0.3 V or less or 4.5 V or more.
ure
Action of • Controls machine by regarding boom LOWER PPC pressure as 0 MPa.
controller • If cause of failure is eliminated, machine becomes normal by itself.
• Auto-deceleration function cannot be reset.
Phenomenon
• Poor operability of boom LOWER
on machine
• Low-speed matching is disabled.

REMARK
If 5 V circuit (3) and GND circuit (1) of pressure sensor are connected inversely, pressure sensor will
break. Accordingly, take extreme care when checking.
Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
information be measured at pump controller connector.
• Boom LOWER PPC pressure can be checked with monitoring function. (Code: 07500)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P02, and connect the T-adapter to
each female side.
Open circuit in wiring har-
1
ness Between CP01 (female) (63) and P02 (female) (3) Max. 1 Ω
Resistance Between CP01 (female) (13) and P02 (female) (2) Max. 1 Ω
Between CP01 (female) (46) and P02 (female) (1) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P02, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP01 (female) (13) or P02
Resistance Min. 1 MΩ
(female) (2)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector P02, and connect the T-adapter to female side.
3
harness 3. Turn the starting switch to ON position.
Voltage Between P02 (female) (2) and (1) Max. 1 V
1. Turn the starting switch to OFF position.
Defective boom LOWER 2. Insert the T-adapter into connector P02.
4
PPC pressure sensor 3. Turn the starting switch to ON position.
Voltage Between P02 (2) and (1) 0.5 to 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
5 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-847
FAILURE CODE [DHS9MA] 40 TROUBLESHOOTING

Circuit diagram related to boom LOWER PPC pressure sensor

40-848 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHSAKZ]

FAILURE CODE [DHSAKZ] (ALL-K-JA02-410-40-B)

Action level Failure code Swing RIGHT PPC pressure sensor malfunction
Failure
L03 DHSAKZ (Pump controller system)
Detail of fail-
Signal voltage of swing RIGHT PPC pressure sensor circuit is 0.3 V or less or 4.5 V or more.
ure
• Controls the machine by regarding swing RIGHT PPC pressure as 0 MPa.
Action of • Restricts swing speed.
controller • Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Restricts swing speed.
on machine • Low-speed matching and hoist matching are disabled.

REMARK
If 5 V circuit (3) and GND circuit (1) of pressure sensor are connected inversely, pressure sensor will
break. Accordingly, take extreme care when checking.
Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
information be measured at pump controller connector.
• Swing RIGHT PPC pressure can be checked with monitoring function. (Code: 09002)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P07, and connect the T-adapter to
each female side.
Open circuit in wiring har-
1
ness Between CP01 (female) (63) and P07 (female) (3) Max. 1 Ω
Resistance Between CP01 (female) (12) and P07 (female) (2) Max. 1 Ω
Between CP01 (female) (46) and P07 (female) (1) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P07, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP01 (female) (12) or P07
Resistance Min. 1 MΩ
(female) (2)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector P07, and connect the T-adapter to female side.
3
harness 3. Turn the starting switch to ON position.
Voltage Between P07 (female) (2) and (1) Max. 1 V
1. Turn the starting switch to OFF position.
Defective swing RIGHT 2. Insert the T-adapter into connector P07.
4
PPC pressure sensor 3. Turn the starting switch to ON position.
Voltage Between P07 (2) and (1) 0.5 to 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
5 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-849
FAILURE CODE [DHSAKZ] 40 TROUBLESHOOTING

Circuit diagram related to swing RIGHT PPC pressure sensor

40-850 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHSBKZ]

FAILURE CODE [DHSBKZ] (ALL-K-JA03-410-40-B)

Action level Failure code Swing LEFT PPC pressure sensor malfunction
Failure
L03 DHSBKZ (Pump controller system)
Detail of fail-
Signal voltage of swing LEFT PPC pressure sensor circuit is 0.3 V or less or 4.5 V or more.
ure
• Controls the machine by regarding swing LEFT PPC pressure as 0 MPa.
Action of • Restricts swing speed.
controller • Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Restricts swing speed.
on machine • Low-speed matching and hoist matching are disabled.

REMARK
If 5 V circuit (3) and GND circuit (1) of pressure sensor are connected inversely, pressure sensor will
break. Accordingly, take extreme care when checking.
Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
information be measured at pump controller connector.
• Swing LEFT PPC pressure can be checked with monitoring function. (Code: 09001)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P03, and connect the T-adapter to
each female side.
Open circuit in wiring har-
1
ness Between CP01 (female) (63) and P03 (female) (3) Max. 1 Ω
Resistance Between CP01 (female) (31) and P03 (female) (2) Max. 1 Ω
Between CP01 (female) (46) and P03 (female) (1) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P03, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP01 (female) (31) or P03
Resistance Min. 1 MΩ
(female) (2)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector P03, and connect the T-adapter to female side.
3
harness 3. Turn the starting switch to ON position.
Voltage Between P03 (female) (2) and (1) Max. 1 V
1. Turn the starting switch to OFF position.
Defective swing LEFT 2. Insert the T-adapter into connector P03.
4
PPC pressure sensor 3. Turn the starting switch to ON position.
Voltage Between P03 (2) and (1) 0.5 to 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
5 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-851
FAILURE CODE [DHSBKZ] 40 TROUBLESHOOTING

Circuit diagram related to swing LEFT PPC pressure sensor

40-852 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHSCMA]

FAILURE CODE [DHSCMA] (ALL-K-L9UE-410-00-B)

Action level Failure code Arm OUT PPC pressure sensor malfunction
Failure
L01 DHSCMA (Pump controller system)
Detail of fail-
Signal voltage of arm OUT PPC pressure sensor circuit is 0.3 V or less or 4.5 V or more.
ure
Action of • Controls machine by regarding arm OUT PPC pressure as 0 MPa.
controller • If cause of failure is eliminated, machine becomes normal by itself.
• Auto-deceleration function cannot be reset.
Phenomenon
• Operability of arm OUT is poor.
on machine
• Low-speed matching is disabled

REMARK
If 5 V circuit (3) and GND circuit (1) of pressure sensor are connected inversely, pressure sensor will
break. Accordingly, take extreme care when checking.

Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
be measured at pump controller connector.
information
• Arm OUT PPC pressure can be checked with monitoring function. (Code: 07600)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine + Set to arm crane
mode (L).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P08, and connect the T-adapter to
each female side.
Open circuit in wiring har-
1
ness Between CP01 (female) (63) and P08 (female) (3) Max. 1 Ω
Resistance Between CP01 (female) (51) and P08 (female) (2) Max. 1 Ω
Between CP01 (female) (46) and P08 (female) (1) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P08, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP01 (female) (51) or P08
Resistance Min. 1 MΩ
(female) (2)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector P08, and connect the T-adapter to female side.
3
harness 3. Turn the starting switch to ON position.
Voltage Between P08 (female) (2) and (1) Max. 1 V
1. Turn the starting switch to OFF position.
Defective arm OUT PPC 2. Insert the T-adapter into connector P08.
4
pressure sensor 3. Turn the starting switch to ON position.
Voltage Between P08 (2) and (1) 0.5 to 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
5 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-853
FAILURE CODE [DHSCMA] 40 TROUBLESHOOTING

Circuit diagram related to arm OUT PPC pressure sensor

40-854 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHSDMA]

FAILURE CODE [DHSDMA] (ALL-K-LEN6-410-00-B)

Action level Failure code Bucket DUMP PPC pressure sensor malfunction
Failure
L01 DHSDMA (Pump controller system)
Detail of fail-
Signal voltage of bucket DUMP PPC pressure sensor circuit is 0.3 V or less or 4.5 V or more.
ure
Action of • Controls the machine by regarding bucket DUMP PPC pressure as 0 MPa.
controller • If cause of failure is eliminated, machine becomes normal by itself.
• Auto-deceleration function cannot be reset.
Phenomenon
• Operability of bucket DUMP is poor.
on machine
• Low-speed matching is disabled.

REMARK
If 5 V circuit (3) and GND circuit (1) of pressure sensor are connected inversely, pressure sensor will
break. Accordingly, take extreme care when checking.
Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
information be measured at pump controller connector.
• Bucket DUMP PPC pressure can be checked with monitoring function. (Code: 07301)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P05, and connect the T-adapter to
each female side.
Open circuit in wiring har-
1
ness Between CP01 (female) (63) and P05 (female) (3) Max. 1 Ω
Resistance Between CP01 (female) (50) and P05 (female) (2) Max. 1 Ω
Between CP01 (female) (46) and P05 (female) (1) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P05, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP01 (female) (50) or P05
Resistance Min. 1 MΩ
(female) (2)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector P05, and connect the T-adapter to female side.
3
harness 3. Turn the starting switch to ON position.
Voltage Between P05 (female) (2) and (1) Max. 1 V
1. Turn the starting switch to OFF position.
Defective bucket DUMP 2. Insert the T-adapter into connector P05.
4
PPC pressure sensor 3. Turn the starting switch to ON position.
Voltage Between P05 (2) and (1) 0.5 to 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
5 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-855
FAILURE CODE [DHSDMA] 40 TROUBLESHOOTING

Circuit diagram related to bucket DUMP PPC pressure sensor

40-856 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHSFMA]

FAILURE CODE [DHSFMA] (ALL-K-C6V2-410-00-B)

Action level Failure code Travel forward LEFT PPC pressure sensor abnormality
Failure
L01 DHSFMA (Pump controller system)
Detail of fail-
Signal voltage of travel forward LEFT PPC pressure sensor circuit is 0.3 V or less or 4.5 V or more.
ure
Action of • Controls machine by regarding travel forward LEFT PPC pressure sensor as 0 MPa.
controller • If cause of failure is eliminated, machine becomes normal by itself.
• Auto-deceleration function cannot be reset.
Phenomenon
• Poor operability of travel
on machine
• Low-speed matching is disabled.

REMARK
If 5 V circuit (3) and GND circuit (1) of pressure sensor are connected inversely, pressure sensor will
break. Accordingly, take extreme care when checking.

Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
be measured at pump controller connector.
information
• Travel forward LEFT PPC pressure can be checked with monitoring function. (Code:
07102)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P09, and connect the T-adapter to
each female side.
Open circuit in wiring har-
1
ness Between CP01 (female) (6) and P09 (female) (3) Max. 1 Ω
Resistance Between CP01 (female) (34) and P09 (female) (2) Max. 1 Ω
Between CP01 (female) (18) and P09 (female) (1) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P09, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP01 (female) (34) or P09
Resistance Min. 1 MΩ
(female) (2)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector P09, and connect the T-adapter to female side.
3
harness 3. Turn the starting switch to ON position.
Voltage Between P09 (female) (2) and (1) Max. 1 V
1. Turn the starting switch to OFF position.
Defective travel forward 2. Insert the T-adapter into connector P09.
4
left PPC pressure sensor 3. Turn the starting switch to ON position.
Voltage Between P09 (2) and (1) 0.5 to 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
5 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-857
FAILURE CODE [DHSFMA] 40 TROUBLESHOOTING

Circuit diagram related to travel PPC pressure sensor

40-858 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHSGMA]

FAILURE CODE [DHSGMA] (ALL-K-C6V5-410-00-B)

Action level Failure code Travel forward RIGHT PPC pressure sensor malfunction
Failure
L01 DHSGMA (Pump controller system)
Detail of fail- Signal voltage of travel forward RIGHT PPC pressure sensor circuit is 0.3 V or less or 4.5 V or
ure more.
Action of • Controls machine by regarding travel forward RIGHT PPC pressure sensor as 0 MPa.
controller • If cause of failure is eliminated, machine becomes normal by itself.
• Auto-deceleration function cannot be reset.
Phenomenon
• Poor operability of travel
on machine
• Low-speed matching is disabled.

REMARK
If 5 V circuit (3) and GND circuit (1) of pressure sensor are connected inversely, pressure sensor will
break. Accordingly, take extreme care when checking.

Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
be measured at pump controller connector.
information
• Travel forward RIGHT PPC pressure can be checked with monitoring function. (Code:
07103)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P11, and connect the T-adapter to
each female side.
Open circuit in wiring har-
1
ness Between CP01 (female) (6) and P11 (female) (3) Max. 1 Ω
Resistance Between CP01 (female) (72) and P11 (female) (2) Max. 1 Ω
Between CP01 (female) (18) and P11 (female) (1) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P11, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP01 (female) (72) or P11
Resistance Min. 1 MΩ
(female) (2)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector P11 and connect the T-adapter to female side.
3
harness 3. Turn the starting switch to ON position.
Voltage Between P11 (female) (2) and (1) Max. 1 V
1. Turn the starting switch to OFF position.
Defective travel forward 2. Insert the T-adapter into connector P11.
4 right PPC pressure sen-
3. Turn the starting switch to ON position.
sor
Voltage Between P11 (2) and (1) 0.5 to 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
5 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-859
FAILURE CODE [DHSGMA] 40 TROUBLESHOOTING

Circuit diagram related to travel PPC pressure sensor

40-860 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHSHMA]

FAILURE CODE [DHSHMA] (ALL-K-C6V3-410-00-B)

Action level Failure code Travel reverse LEFT PPC pressure sensor malfunction
Failure
L01 DHSHMA (Pump controller system)
Detail of fail-
Signal voltage of travel reverse LEFT PPC pressure sensor circuit is 0.3 V or less or 4.5 V or more.
ure
Action of • Controls machine by regarding travel reverse LEFT PPC pressure sensor as 0 MPa.
controller • If cause of failure is eliminated, machine becomes normal by itself.
• Auto-deceleration function cannot be reset.
Phenomenon
• Poor operability of travel
on machine
• Low-speed matching is disabled.

REMARK
If 5 V circuit (3) and GND circuit (1) of pressure sensor are connected inversely, pressure sensor will
break. Accordingly, take extreme care when checking.

Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
be measured at pump controller connector.
information
• Travel reverse LEFT PPC pressure can be checked with monitoring function. (Code:
07104)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P10, and connect the T-adapter to
each female side.
Open circuit in wiring har-
1
ness Between CP01 (female) (6) and P10 (female) (3) Max. 1 Ω
Resistance Between CP01 (female) (15) and P10 (female) (2) Max. 1 Ω
Between CP01 (female) (18) and P10 (female) (1) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P10, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP01 (female) (15) or P10
Resistance Min. 1 MΩ
(female) (2)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector P10, and connect the T-adapter to female side.
3
harness 3. Turn the starting switch to ON position.
Voltage Between P10 (female) (2) and (1) Max. 1 V
1. Turn the starting switch to OFF position.
Defective travel reverse 2. Insert the T-adapter into connector P10.
4
left PPC pressure sensor 3. Turn the starting switch to ON position.
Voltage Between P10 (2) and (1) 0.5 to 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
5 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-861
FAILURE CODE [DHSHMA] 40 TROUBLESHOOTING

Circuit diagram related to travel PPC pressure sensor

40-862 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHSJMA]

FAILURE CODE [DHSJMA] (ALL-K-C6V7-410-00-B)

Action level Failure code Travel reverse RIGHT PPC pressure sensor malfunction
Failure
L01 DHSJMA (Pump controller system)
Detail of fail- Signal voltage of travel reverse RIGHT PPC pressure sensor circuit is 0.3 V or less or 4.5 V or
ure more.
Action of • Controls machine by regarding travel reverse RIGHT PPC pressure sensor as 0 MPa.
controller • If cause of failure is eliminated, machine becomes normal by itself.
• Auto-deceleration function cannot be reset.
Phenomenon
• Poor operability of travel
on machine
• Low-speed matching is disabled.

REMARK
If 5 V circuit (3) and GND circuit (1) of pressure sensor are connected inversely, pressure sensor will
break. Accordingly, take extreme care when checking.

Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
be measured at pump controller connector.
information
• Travel reverse RIGHT PPC pressure can be checked with monitoring function. (Code:
07105)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P12, and connect the T-adapter to
each female side.
Open circuit in wiring har-
1
ness Between CP01 (female) (6) and P12 (female) (3) Max. 1 Ω
Resistance Between CP01 (female) (53) and P12 (female) (2) Max. 1 Ω
Between CP01 (female) (18) and P12 (female) (1) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P12, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP01 (female) (53) or P12
Resistance Min. 1 MΩ
(female) (2)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector P12, and connect the T-adapter to female side.
3
harness 3. Turn the starting switch to ON position.
Voltage Between P12 (female) (2) and (1) Max. 1 V
1. Turn the starting switch to OFF position.
Defective travel reverse 2. Insert the T-adapter into connector P12.
4 right PPC pressure sen-
3. Turn the starting switch to ON position.
sor
Voltage Between P12 (2) and (1) 0.5 to 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
5 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-863
FAILURE CODE [DHSJMA] 40 TROUBLESHOOTING

Circuit diagram related to travel PPC pressure sensor

40-864 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHVAKZ]

FAILURE CODE [DHVAKZ] (ALL-K-JA02-410-10-B)

Action level Failure code Hybrid swing RIGHT PPC pressure sensor open and short circuit
Failure
L03 DHVAKZ (Hybrid controller system)
Detail of fail- Signal voltage of hybrid swing RIGHT PPC pressure sensor circuit is 0.3 V or less or 4.5 V or
ure more.
• Restricts operation, swing speed according to pump controller swing RIGHT PPC pres-
Action of sure.
controller • Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon
Swing speed, etc. is restricted.
on machine
• If failure code [GAA6KP] is also displayed, perform troubleshooting for that code first.

Related • Voltage of hybrid swing RIGHT PPC pressure sensor can be checked with monitoring
function. (Code: 09007)
information
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and HP06, and connect the T-adapter to
each female side.
Open circuit in wiring har-
1
ness Between HC02 (female) (38) and HP06 (female) (1) Max. 1 Ω
Resistance Between HC02 (female) (9) and HP06 (female) (2) Max. 1 Ω
Between HC02 (female) (25) and HP06 (female) (3) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and HP06, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either HC02 (female) (9) or HP06
Resistance Min. 1 MΩ
(female) (2)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector HP06, and connect the T-adapter to female side.
3
harness 3. Turn the starting switch to ON position.
Voltage Between HP06 (female) (2) and (1) Max. 1 V
1. Turn the starting switch to OFF position.
Defective swing RIGHT 2. Insert T-adapter into the connector HP06.
4 PPC pressure sensor
3. Turn the starting switch to ON position.
(for hybrid)
Voltage Between HP06 (2) and (1) 0.5 to 4.5 V
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
5
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-865
FAILURE CODE [DHVAKZ] 40 TROUBLESHOOTING

Circuit diagram related to swing PPC pressure sensor (hybrid)

40-866 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHVAL8]

FAILURE CODE [DHVAL8] (ALL-K-JA02-410-20-B)

Action level Failure code Hybrid swing RIGHT PPC pressure sensor signal mismatch
Failure
L03 DHVAL8 (Hybrid controller system)
Difference between the values detected by hybrid swing RIGHT PPC pressure sensor and pump
Detail of fail-
controller swing RIGHT PPC pressure sensor is 0.49 MPa 5.0 kg/cm2 or more when motor-genera-
ure
tor is running.
• Selects the minimum values of pump controller swing RIGHT PPC pressure and hybrid
controller swing RIGHT PPC pressure, and controls each swing RIGHT PPC pressure.
Action of
• Restricts swing speed.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon
Swing speed, etc. is restricted.
on machine
• Pressure detected by hybrid swing RIGHT PPC pressure sensor can be checked with
monitoring function. (Code: 09008)
Related • Pressure detected by pump controller swing RIGHT PPC pressure sensor can be checked
information with monitoring function. (Code: 09002)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Defective swing RIGHT 2. Insert T-adapter into the connector HP06.
1 PPC pressure sensor
3. Turn the starting switch to ON position.
(for hybrid)
Voltage Between HP06 (2) and (1) 0.5 to 4.5 V
1. Turn the starting switch to OFF position.
Defective swing RIGHT 2. Insert the T-adapter into connector P07.
2
PPC pressure sensor 3. Turn the starting switch to ON position.
Voltage Between P07 (2) and (1) 0.5 to 4.5 V
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
3
controller) (Since this is an internal defect, troubleshooting cannot be performed.)
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-867
FAILURE CODE [DHVAL8] 40 TROUBLESHOOTING

Circuit diagram related to swing PPC pressure sensor (hybrid)

Circuit diagram related to swing RIGHT PPC pressure sensor

40-868 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHVAMA]

FAILURE CODE [DHVAMA] (ALL-K-JA02-410-30-B)

Action level Failure code Hybrid swing RIGHT PPC sensor malfunction
Failure
L03 DHVAMA (Hybrid controller system)
Detail of fail-
2 failure codes of [DHVAKZ], [DHVAL8], and [DHSAMA] occur.
ure
• Stops controlling swing motor and motor-generator.
• Applies swing parking brake.
Action of • Disables low-speed matching function.
controller • Disables hoist matching function.
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon
Swing cannot be performed.
on machine
• If failure code [GAA6KP] is also displayed, perform troubleshooting for that code first.
• Voltage of hybrid swing RIGHT PPC pressure sensor can be checked with monitoring
function. (Code: 09007)
Related
• Pressure detected by pump controller swing RIGHT PPC pressure sensor can be checked
information
with monitoring function. (Code: 09002)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective circuit related Check if any of failure codes [DHVAKZ], [DHVAL8] and [DHSAMA] are displayed,
1 to swing RIGHT PPC and perform troubleshooting for them.
sensor

HB365LC-3 40-869
FAILURE CODE [DHVBKZ] 40 TROUBLESHOOTING

FAILURE CODE [DHVBKZ] (ALL-K-JA03-410-10-B)

Action level Failure code Hybrid swing LEFT PPC pressure sensor open and short circuit
Failure
L03 DHVBKZ (Hybrid controller system)
Detail of fail-
Signal voltage of hybrid swing LEFT PPC pressure sensor circuit is 0.3 V or less or 4.5 V or more.
ure
• Restricts operation, swing speed according to pump controller swing LEFT PPC pressure.
Action of
• Even if cause of failure is cleared naturally, machine does not become normal until starting
controller
switch is set to OFF position once.
Phenomenon
Swing speed, etc. is restricted.
on machine
• If failure code [GAA6KP] is also displayed, perform troubleshooting for that code first.

Related • Voltage of hybrid swing LEFT PPC pressure sensor can be checked with monitoring func-
tion. (Code: 09006)
information
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and HP04, and connect the T-adapter to
each female side.
Open circuit in wiring har-
1
ness Between HC02 (female) (38) and HP04 (female) (1) Max. 1 Ω
Resistance Between HC02 (female) (19) and HP04 (female) (2) Max. 1 Ω
Between HC02 (female) (25) and HP04 (female) (3) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and HP04, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either HC02 (female) (19) or
Resistance Min. 1 MΩ
HP04 (female) (2)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector HP04, and connect the T-adapter to female side.
3
harness 3. Turn the starting switch to ON position.
Voltage Between HP04 (female) (2) and (1) Max. 1 V
1. Turn the starting switch to OFF position.
Defective swing LEFT 2. Insert T-adapter into the connector HP04.
4 PPC pressure sensor
3. Turn the starting switch to ON position.
(for hybrid)
Voltage Between HP04 (2) and (1) 0.5 to 4.5 V
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
5
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

40-870 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHVBKZ]

Circuit diagram related to swing PPC pressure sensor (hybrid)

HB365LC-3 40-871
FAILURE CODE [DHVBL8] 40 TROUBLESHOOTING

FAILURE CODE [DHVBL8] (ALL-K-JA03-410-20-B)

Action level Failure code Hybrid swing LEFT PPC pressure sensor signal mismatch
Failure
L03 DHVBL8 (Hybrid controller system)
Difference between the values detected by hybrid swing LEFT PPC pressure sensor and pump con-
Detail of fail-
troller swing LEFT PPC pressure sensor is 0.49 MPa 5.0 kg/cm2 or more when motor-generator is
ure
running.
• Selects the minimum values of pump controller swing LEFT PPC pressure and hybrid con-
troller swing LEFT PPC pressure, and controls each swing LEFT PPC pressure.
Action of
• Restricts swing speed.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon
Swing speed, etc. is restricted.
on machine
• Pressure detected by hybrid swing LEFT PPC pressure sensor can be checked with moni-
toring function. (Code: 09009)
Related • Pressure detected by pump controller swing LEFT PPC pressure sensor can be checked
information with monitoring function. (Code: 09001)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Defective swing LEFT 2. Insert T-adapter into the connector HP04.
1 PPC pressure sensor
3. Turn the starting switch to ON position.
(for hybrid)
Voltage Between HP04 (2) and (1) 0.5 to 4.5 V
1. Turn the starting switch to OFF position.
Defective swing LEFT 2. Insert the T-adapter into connector P03.
2
PPC pressure sensor 3. Turn the starting switch to ON position.
Voltage Between P03 (2) and (1) 0.5 to 4.5 V
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
3
controller) (Since this is an internal defect, troubleshooting cannot be performed.)
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

40-872 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DHVBL8]

Circuit diagram related to swing PPC pressure sensor (hybrid)

Circuit diagram related to swing LEFT PPC pressure sensor

HB365LC-3 40-873
FAILURE CODE [DHVBMA] 40 TROUBLESHOOTING

FAILURE CODE [DHVBMA] (ALL-K-JA03-410-30-B)

Action level Failure code Hybrid swing LEFT PPC sensor malfunction
Failure
L03 DHVBMA (Hybrid controller system)
Detail of fail-
2 failure codes of [DHVBKZ], [DHVBL8], and [DHSBMA] occur.
ure
• Stops controlling swing motor and motor-generator.
• Applies swing parking brake.
Action of • Disables low-speed matching function.
controller • Disables hoist matching function.
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon
Swing cannot be performed.
on machine
• If failure code [GAA6KP] is also displayed, perform troubleshooting for that code first.
• Voltage of hybrid swing LEFT PPC pressure sensor can be checked with monitoring func-
tion. (Code: 09006)
Related
• Pressure detected by pump controller swing LEFT PPC pressure sensor can be checked
information
with monitoring function. (Code: 09001)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective circuit related Check if any of failure codes [DHVBKZ], [DHVBL8] and [DHSBMA] are displayed,
1 to swing LEFT PPC sen- and perform troubleshooting for them.
sor

40-874 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DKR0MA]

FAILURE CODE [DKR0MA] (ALL-K-C3W8-410-00-B)

Action level Failure code F pump swash plate sensor malfunction

Failure
L01 DKR0MA (Pump controller system)
Detail of fail-
Signal voltage of F pump swash plate sensor circuit is 0.5 V or less or 4.5 V or more.
ure
Action of • If cause of failure is eliminated, machine becomes normal by itself.
controller • Disables low-speed matching function.
Phenomenon
Low-speed matching is disabled.
on machine

REMARK
If 5 V circuit (A) and GND circuit (B) of swash plate sensor are connected inversely, pressure sensor
will break. Accordingly, take extreme care when checking.

Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
be measured at pump controller connector.
information
• Voltage from front pump swash plate sensor can be checked with monitoring function.
(Code: 01138)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector P27, and connect the T-adapter to male side.
Approx.
Between P27 (male) (A) and (B)
6 kΩ
Defective F pump swash
1 Approx.
plate sensor Between P27 (male) (B) and (C)
Resistance 6 kΩ
Approx.
Between P27 (male) (A) and (C)
170 Ω
Between P27 (male) (C) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P27, and connect the T-adapter to
each female side.
Open circuit in wiring har-
2
ness Between CP01 (female) (63) and P27 (female) (A) Max. 1 Ω
Resistance Between CP01 (female) (49) and P27 (female) (C) Max. 1 Ω
Between CP01 (female) (47) and P27 (female) (B) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P27, and connect the T-adapter to
Ground fault in wiring
3 either female side.
harness
Between ground and either CP01 (female) (49) or P27
Resistance Min. 1 MΩ
(female) (C)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector P27 and connect the T-adapter to female side.
4
harness 3. Turn the starting switch to ON position.
Voltage Between P27 (female) (C) and (B) Max. 1 V

HB365LC-3 40-875
FAILURE CODE [DKR0MA] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, pump controller is defective. (Since this is an
5 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to F and R pump swash plate sensors

40-876 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DKR1MA]

FAILURE CODE [DKR1MA] (ALL-K-C3WA-410-00-B)

Action level Failure code R pump swash plate sensor malfunction

Failure
L01 DKR1MA (Pump controller system)
Detail of fail-
Signal voltage of R pump swash plate sensor circuit is 0.5 V or less or 4.5 V or more.
ure
Action of • Disables low-speed matching function.
controller • If cause of failure is eliminated, machine becomes normal by itself.
Phenomenon
Low-speed matching is disabled.
on machine

REMARK
If 5 V circuit (A) and GND circuit (B) of swash plate sensor are connected inversely, pressure sensor
will break. Accordingly, take extreme care when checking.

Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
be measured at pump controller connector.
information
• Voltage from rear pump swash plate sensor can be checked with monitoring function.
(Code: 01140)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector P28, and connect the T-adapter to male side.
Approx.
Between P28 (male) (A) and (B)
6 kΩ
Defective R pump swash
1 Approx.
plate sensor Between P28 (male) (B) and (C)
Resistance 6 kΩ
Approx.
Between P28 (male) (A) and (C)
170 Ω
Between P28 (male) (C) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P28, and connect the T-adapter to
each female side.
Open circuit in wiring har-
2
ness Between CP01 (female) (63) and P28 (female) (A) Max. 1 Ω
Resistance Between CP01 (female) (68) and P28 (female) (C) Max. 1 Ω
Between CP01 (female) (47) and P28 (female) (B) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01 and P28, and connect the T-adapter to
Ground fault in wiring
3 either female side.
harness
Between ground and either CP01 (female) (68) or P28
Resistance Min. 1 MΩ
(female) (C)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector P28 and connect the T-adapter to female side.
4
harness 3. Turn the starting switch to ON position.
Voltage Between P28 (female) (C) and (B) Max. 1 V

HB365LC-3 40-877
FAILURE CODE [DKR1MA] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by above checks, pump controller is defective. (Since this is an
5 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to F and R pump swash plate sensors

40-878 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DKULKA]

FAILURE CODE [DKULKA] (ALL-K-PX18-410-00-B)

Action level Failure code PPC Lock Relay Open Circuit

Failure
L03 DKULKA (pump controller system)
Detail of fail- Open circuit was detected because no current is carried when outputting 24 V in the primary (coil)
ure circuit of the PPC lock relay.
Action of
If cause of failure disappears, machine becomes normal by itself.
controller
Phenomenon
The work equipment is not operable because PPC remains locked.
on machine
• The troubleshooting for this failure code is performed on the primary side of the relay and
Related not on the secondary side.
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position and set PPC lock lever to FREE position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector R48, and connect the T-adapter to male side.
1 Defective PPC lock relay
200 to
Resistance Between R48 (male) (1) and (2)
600 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and R48, and connect the T-adapter to
Open circuit in wiring har- each female side.
2
ness
Between CP02 (female) (84) and R48 (female) (1) Max. 1 Ω
Resistance
Between R48 (female) (2) and ground Max. 1 Ω
If no failure is found by above checks, pump controller is defective. (Since this is an
3 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-879
FAILURE CODE [DKULKA] 40 TROUBLESHOOTING

Circuit diagram related to PPC lock switch

40-880 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DKULKB]

FAILURE CODE [DKULKB] (ALL-K-PX18-410-10-B)

Action level Failure code PPC Lock Relay Short Circuit

Failure
L03 DKULKB (pump controller system)
Detail of fail- Short circuit was detected because abnormal current is carried when outputting 24 V in the primary
ure (coil) circuit of the PPC lock relay.
• Stops 24 V output to PPC lock relay primary circuit (coil side).
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon
• The work equipment is not operable because PPC remains locked.
on machine
• The troubleshooting for this failure code is performed on the primary side of the relay and
Related not on the secondary side.
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position and set PPC lock lever to FREE position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector R48, and connect the T-adapter to male side.
1 Defective PPC lock relay
200 to
Resistance Between R48 (male) (1) and (2)
600 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and R48, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP02 (female) (84) or R48
Resistance Min. 1 MΩ
(female) (1)
If no failure is found by above checks, pump controller is defective. (Since this is an
3 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-881
FAILURE CODE [DKULKB] 40 TROUBLESHOOTING

Circuit diagram related to PPC lock switch

40-882 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DKULKY]

FAILURE CODE [DKULKY] (ALL-K-PX18-410-20-B)

Action level Failure code PPC Lock Relay Hot Short Circuit
Failure
L03 DKULKY (pump controller system)
Detail of fail- Short circuit was detected because the specified voltage is exceeded when 24 V is not output in the
ure primary (coil) circuit of the PPC lock relay.
• Stops 24 V output to PPC lock relay primary circuit (coil side).
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon
PPC lock is cleared at all times.
on machine
• The troubleshooting for this failure code is performed on the primary side of the relay and
Related not on the secondary side.
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector R48, and connect the T-adapter to female side.
1
harness 3. Turn the starting switch to ON position.
Voltage Between R48 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
2 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to PPC lock switch

HB365LC-3 40-883
FAILURE CODE [DLM5KA] 40 TROUBLESHOOTING

FAILURE CODE [DLM5KA] (ALL-K-ACN5-410-00-B)

Action level Failure code Fan speed sensor open circuit

Failure
L01 DLM5KA (Pump controller system)
Detail of fail- After starting engine, pulse voltage is not input from fan speed sensor to pump controller for more
ure than a certain period of time.
Action of • None in particular
controller • If cause of failure is eliminated, machine becomes normal by itself.
Phenomenon Fan speed is not controlled, thereby it becomes the maximum speed that can rotate by engine
on machine speed.

• If failure code [DA25KP] is also displayed, perform troubleshooting for that code first.
• Fan speed can be checked with monitoring function. (Code: 10007)
Related • Since fan speed sensor output is pulse voltage, it cannot be measured by using multime-
information ter.
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Defective circuit related 2. Disconnect the connector V13, and connect the T-adapter to female side.
1 to fan speed sensor pow-
3. Turn the starting switch to ON position.
er supply
Voltage Between V13 (female) (2) and (5) 4.5 to 5.5 V
1. Turn the starting switch to OFF position.
Defective fan clutch re- 2. Disconnect the connector K12, and connect the T-adapter to male side.
2
sistor
22 kΩ
Resistance Between K12 (1) and (2)
± 220 Ω
1. Start the engine.
2. Check the fan speed on the Self-define Monitoring screen of the machine
Defective fan clutch
3 monitor.
speed sensor
(rotation) Min.
Monitoring code: 10007 (rpm)
Speed 200 rpm
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01, V13, and K12, and connect the T-adapt-
er to each female side.
Between CP01 (female) (6) and V13 (female) (5) Max. 1 Ω
Open circuit in wiring har-
4
ness Between CP01 (female) (38) and V13 (female) (1) Max. 1 Ω
Resistance Between CP01 (female) (38) and K12 (female) (1) Max. 1 Ω
Between CP01 (female) (44) and V13 (female) (2) Max. 1 Ω
Between CP01 (female) (44) and K12 (female) (2) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01, V13 and K12, and connect the T-adapt-
Ground fault in wiring
5 er to any female side.
harness
Between ground and any of CP01 (female) (38), V13
Resistance Min. 1 MΩ
(female) (1), and K12 (female) (1)

40-884 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DLM5KA]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V13 or K12, and connect the T-adapter to fe-
Hot short circuit in wiring male side.
6
harness 3. Turn the starting switch to ON position.
Between V13 (female) (1) and (2) or between K12 (fe-
Voltage Max. 1 V
male) (1) and (2)
If no failure is found by above checks, pump controller is defective. (Since this is an
7 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to fan clutch

HB365LC-3 40-885
FAILURE CODE [DLM5MB] 40 TROUBLESHOOTING

FAILURE CODE [DLM5MB] (ALL-K-ACN5-410-01-B)

Action level Failure code Fan control mismatch

Failure
L01 DLM5MB (Pump controller system)
Detail of fail-
Fan speed indicated by pump controller does not match speed indicated by fan speed sensor.
ure
Action of
None in particular
controller
Phenomenon
Fan rotation does not work normally.
on machine
• If failure codes [DA25KP], [DLM5KA], [DWN5KA], [DWN5KB], or [DWN5KY] is also dis-
played, perform troubleshooting for that code first.
• Fan speed indicated by pump controller can be checked with monitoring function. (Code:
Related
10010)
information
• Fan speed can be checked with monitoring function. (Code: 10007)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Start the engine.

No. Cause Procedure, measuring location, criteria and remarks

For details, see TESTING AND ADJUSTING, and perform “TEST COOLING FAN
1 Fan speed failure
SPEED” to check that there is a deviation of fan speed.
1. Turn the starting switch to OFF position.
Defective fan clutch re- 2. Disconnect the connector K12, and connect the T-adapter to male side.
2
sistor
22 kΩ
Resistance Between K12 (1) and (2)
± 220 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V13, and connect the T-adapter to
Open circuit in wiring har- each female side.
3
ness
Between CP02 (female) (99) and V13 (female) (4) Max. 1 Ω
Resistance
Between CP02 (female) (117) and V13 (female) (3) Max. 1 Ω
1. Turn the starting switch to OFF position.
Defective circuit related 2. Disconnect the connector V13, and connect the T-adapter to female side.
4
to fan clutch solenoid 3. Turn the starting switch to ON position.
Voltage Between V13 (female) (4) and (3) Min. 20 V
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01, V13, and K12, and connect the T-adapt-
er to each female side.
Between CP01 (female) (6) and V13 (female) (5) Max. 1 Ω
Open circuit in wiring har-
5
ness Between CP01 (female) (38) and V13 (female) (1) Max. 1 Ω
Resistance Between CP01 (female) (38) and K12 (female) (1) Max. 1 Ω
Between CP01 (female) (44) and V13 (female) (2) Max. 1 Ω
Between CP01 (female) (44) and K12 (female) (2) Max. 1 Ω

40-886 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DLM5MB]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V13 or K12, and connect the T-adapter to fe-
Hot short circuit in wiring male side.
6
harness 3. Turn the starting switch to ON position.
Between V13 (female) (1) and (2) or between K12 (fe-
Voltage Max. 1 V
male) (1) and (2)
If no failure is found by above checks, fan clutch is defective. (Since this is an inter-
7 Defective fan clutch
nal defect, troubleshooting cannot be performed.)

Circuit diagram related to fan clutch

HB365LC-3 40-887
FAILURE CODE [DR10KA] 40 TROUBLESHOOTING

FAILURE CODE [DR10KA] (ALL-K-K911-410-00-B)

Action level Failure code KomVision Camera Open Circuit

Failure
L01 DR10KA (KomVision controller system)
Detail of fail-
Signal of KomVision camera cannot be detected.
ure
Action of
None in particular
controller
Phenomenon
Display area of the camera and the single camera images are displayed in black.
on machine

Related • After completion of repair, check that the failure code is cleared by the following proce-
dure.
information Procedure: Turn the starting switch to ON position and display a Bird's Eye View

No. Cause Procedure, measuring location, criteria and remarks

1. Identify the camera displayed in black.
2. Turn the starting switch to OFF position.
3. Disconnect the connectors CA01, A45, A76, A77, and A78, and connect
the T-adapter to each female side.
4. Perform troubleshooting for the camera displayed in black.
Between CA01 (female) (6) and A45 (female) (1)
Max. 1 Ω
Rear camera
Between CA01 (female) (24) and A45 (female) (2)
Max. 1 Ω
Rear camera
Between CA01 (female) (43) and A45 (female) (4)
Max. 1 Ω
Rear camera
Between CA01 (female) (25) and A76 (female) (1)
Max. 1 Ω
Front R.H. camera
Between CA01 (female) (23) and A76 (female) (2)
Open circuit in wiring har- Max. 1 Ω
1 Front R.H. camera
ness
Between CA01 (female) (42) and A76 (female) (4)
Max. 1 Ω
Front R.H. camera
Resistance
Between CA01 (female) (44) and A77 (female) (1)
Max. 1 Ω
R.H. camera
Between CA01 (female) (22) and A77 (female) (2)
Max. 1 Ω
R.H. camera
Between CA01 (female) (41) and A77 (female) (4)
Max. 1 Ω
R.H. camera
Between CA01 (female) (63) and A78 (female) (1)
Max. 1 Ω
L.H. camera
Between CA01 (female) (21) and A78 (female) (2)
Max. 1 Ω
L.H. camera
Between CA01 (female) (40) and A78 (female) (4)
Max. 1 Ω
L.H. camera

40-888 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DR10KA]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Replace the camera of the applicable area which can not be displayed im-
2 Defective camera ages.
3. Turn the starting switch to ON position.
If failure code is not displayed, camera has internal defect.
Defective KomVision If no failure is found by above checks, KomVision controller is defective. (Since this
3
controller is an internal defect, troubleshooting cannot be performed).

Circuit diagram related to rear camera

Circuit diagram related to right camera

HB365LC-3 40-889
FAILURE CODE [DR10KA] 40 TROUBLESHOOTING

Circuit diagram related to right front camera

Circuit diagram related to left camera

40-890 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DR21KX]

FAILURE CODE [DR21KX] (ALL-K-Q16B-410-00-B)

Action level Failure code Camera 2 Picture Reverse Drive Input Out of Range
Failure
L01 DR21KX (Machine monitor system)
Detail of fail- Voltage that is different from output voltage of machine monitor occurs in camera 2 picture reverse
ure drive circuit (pin 6 of connector CM04).
Action of
Camera 2 picture is not displayed
controller
Phenomenon
Camera 2 picture is not displayed.
on machine
• Normal image and mirror image if the camera 2 picture reverse output line (6 pins of con-
nector CM04) is 0 V and 8 V (mirror image command is 8 V because the camera power
supply is 8 V).
Related
• Since there may be several connectors A46, check connector A41 to identify the camera
information 2.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors CM04 and A46, and connect the T-adapter to
each female side.
Open circuit in wiring har-
1
ness Between CM04 (female) (6) and A46 (female) (3) Max. 1 Ω
Resistance Between CM04 (female) (5) and A46 (female) (4) Max. 1 Ω
Between CM04 (female) (8) and A46 (female) (4) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CM04 and A46, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CM04 (female) (6) or A46
Resistance Min. 1 MΩ
(female) (3)
1. Turn the starting switch to OFF position.
2. Disconnect the connector A46, and connect the T-adapter to female side.
3. Turn the starting switch to ON position.
Hot short circuit in wiring
3
harness REMARK
Check that normal image setting is selected for camera 2.
Voltage Between A46 (female) (3) and (4) Max. 1 V
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CM04 and A46, and connect the T-adapter to
Short circuit in wiring har-
4 either female side.
ness
Between CM04 (female) (5) and (6), or between A46
Resistance Min. 1 MΩ
(female) (3) and (4)
If no failure is found by above checks, camera 2 is defective. (Since this is an inter-
5 Defective camera 2
nal defect, troubleshooting cannot be performed.)
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
6
tor an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-891
FAILURE CODE [DR21KX] 40 TROUBLESHOOTING

Circuit diagram related to camera

40-892 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DUMBKA]

FAILURE CODE [DUMBKA] (ALL-K-AW1T-410-0A-B)

Action level Failure code Operating Lamp Open Circuit(KomVision)

Failure
L01 DUMBKA (KomVision controller system)
KomVision controller determines that system operating lamp circuit is open because voltage of out-
Detail of fail- put circuit remains at approximately 5 V or below for approximately 3 seconds after starting switch is
ure turned to ON position, during which KomVision controller outputs no current to system operating
lamp.
Action of
None in particular
controller
Phenomenon
None in particular
on machine
• Do not turn the battery disconnect switch to OFF position while the system operating lamp
is lit.
• If the battery disconnect switch is turned to OFF position while the system operating lamp
is lit, the memory data stored in each controller may be destroyed.
• Although KomVision controller is not able to light up system operating lamp, no trouble will
Related
result unless battery disconnect switch is turned to OFF position.
information
• When controller lights up system operating lamp, output circuit voltage is at low level.
• Since no controller drives system operating lamp for approximately 3 seconds after start-
ing switch is turned to ON position, open circuit can be detected.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.16 in fuse box F01. Check visually if it is not burnt
1 Defective fuse out.
4. When it is not burnt out, check if it is blown out by continuity test.
• When it is burnt out, check the wiring harness for ground fault.
• When it is not burnt out but it has no continuity, replace the fuse.
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.16 in fuse box F01.
Open circuit in wiring har-
2
ness 4. Disconnect the connectors CA02 and L19, and connect the T-adapter to
each female side.
Between CA02 (female) (87) and L19 (female) (2) Max. 1 Ω
Resistance
Between L19 (female) (1) and F01 -16 Max. 1 Ω

HB365LC-3 40-893
FAILURE CODE [DUMBKA] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
Ground fault in wiring 3.
3 Disconnect the connector L19, and connect the T-adapter to female side.
harness
4. Disconnect the connectors, terminals, and fuses of all the devices which
branch out from connector L19 (1).
Resistance Between ground and either L19 (female) (1) or F01-16 Min. 1 MΩ
Defective KomVision If no failure is found by above checks, KomVision controller is defective. (Since this
4
controller is an internal defect, troubleshooting cannot be performed).

Circuit diagram related to system operating lamp

40-894 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DUMBKB]

FAILURE CODE [DUMBKB] (ALL-K-AW1T-410-0B-B)

Action level Failure code System Operating Lamp Short Circuit (KomVision)
Failure
L01 DUMBKB (KomVision controller system)
KomVision controller determines that system operating lamp circuit shorts because voltage of out-
Detail of fail-
put circuit does not become Low level while KomVision controller outputs current to system operat-
ure
ing lamp.
Action of
None in particular
controller
Phenomenon
None in particular
on machine
• Do not turn the battery disconnect switch to OFF position while the system operating lamp
is lit.
• If the battery disconnect switch is turned to OFF position while the system operating lamp
is lit, the memory data stored in each controller may be destroyed.
Related
• Although KomVision controller is not able to light up system operating lamp, no trouble will
information result unless battery disconnect switch is turned to OFF position.
• When controller lights up system operating lamp, output circuit voltage is at low level.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector L19, and connect the T-adapter to female side.
1
harness 3. Turn the starting switch to ON position.
Voltage Between L19 (female) (2) and ground Max. 1 V
Defective KomVision If no failure is found by above checks, KomVision controller is defective. (Since this
2
controller is an internal defect, troubleshooting cannot be performed).

HB365LC-3 40-895
FAILURE CODE [DUMBKB] 40 TROUBLESHOOTING

Circuit diagram related to system operating lamp

40-896 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DV20KB]

FAILURE CODE [DV20KB] (ALL-K-Q520-410-20-B)

Action level Failure code Travel Alarm Short Circuit

Failure
L01 DV20KB (Pump controller system)
Detail of fail-
Abnormal current flows when driving the travel alarm circuit.
ure
Stops driving the travel alarm circuit.
Action of
Even if cause of failure disappears, machine does not become normal until starting switch is set to
controller
OFF position.
Phenomenon
Travel alarm does not sound.
on machine
Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
information be measured at pump controller connector.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and M14, and connect the T-adapter to
Ground fault in wiring
1 either female side.
harness
Between ground and either CP02 (female) (107) or
Resistance Min. 1 MΩ
M14 (female) (1)
1. Turn the starting switch to OFF position.
2. Disconnect connector M14, and connect T-adapter to female side.
3. Turn the starting switch to ON position.
4. Operate the travel lever to perform troubleshooting.
NOTICE
2 Defective travel alarm • When travel lever is set to the travel position, voltage is applied usual-
ly to the travel alarm connector before machine starts moving.
• If the following voltage is normal but travel alarm does not sound,
travel alarm is defective.

Between M14 (female) (1) Travel lever: NEUTRAL Max. 1 V

Voltage
and (2) Travel lever: Operated 20 to 30 V
If no failure is found by above checks, pump controller is defective. (Since this is an
3 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-897
FAILURE CODE [DV20KB] 40 TROUBLESHOOTING

Circuit diagram related to travel alarm

40-898 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DW43KA]

FAILURE CODE [DW43KA] (ALL-K-C6T9-410-00-B)

Action level Failure code Travel Speed Solenoid Open Circuit

Failure
L01 DW43KA (Pump controller system)
Detail of fail- No current flows when pump controller drives travel speed selector solenoid, so pump controller de-
ure termines that open circuit exists in travel speed selector solenoid circuit.
Action of None in particular (Since no current flows, solenoid is not energized.)
controller If cause of failure disappears, machine becomes normal by itself.
Phenomenon Machine travels slow in Hi travel speed setting (machine monitor shows Hi setting but the speed is
on machine kept at around Lo).

• Controller's command (ON/OFF) to travel speed selector solenoid can be checked with
monitoring function. (As long as controller's command to solenoid is "ON", sensor state
displayed on monitoring screen is "ON" even if solenoid is not energized due to short cir-
Related
cuit.)
information (Code: 02300 Solenoid 1)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine, set travel speed to Hi, and operate travel lever.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V04, and connect the T-adapter to male side.
Defective travel speed
1
Hi/Lo solenoid Between V04 (male) (1) and (2) 20 to 60 Ω
Resistance
Between V04 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
Defective circuit related 2. Disconnect the connector V04, and connect the T-adapter to female side.
2 to travel speed Hi/Lo sol-
3. Turn the starting switch to ON position.
enoid
Voltage Between V04 (female) (1) and (2) 1 to 4.5 V
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V04, and connect the T-adapter to
each female side.
Open circuit in wiring har- Between CP02 (female) (93) and V04 (female) (1) Max. 1 Ω
3
ness
Between CP02 (female) (115) and V04 (female) (2) Max. 1 Ω
Resistance
Between CP02 (female) (117) and V04 (female) (2) Max. 1 Ω
Between CP02 (female) (120) and V04 (female) (2) Max. 1 Ω
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-899
FAILURE CODE [DW43KA] 40 TROUBLESHOOTING

Circuit diagram related to travel Hi/Lo solenoid

40-900 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DW43KB]

FAILURE CODE [DW43KB] (ALL-K-C6T9-410-10-B)

Action level Failure code Travel Speed Solenoid Short Circuit

Failure
L01 DW43KB (Pump controller system)
Detail of fail- Abnormal current flows when pump controller drives travel speed solenoid, so pump controller de-
ure termines that short circuit exists in travel speed solenoid circuit.
Stops driving travel speed solenoid.
Action of
Even if cause of failure disappears, machine does not become normal until starting switch is turned
controller
to OFF position.
Phenomenon Machine travels slow in Hi travel speed setting (machine monitor shows Hi setting but the speed is
on machine kept at around Lo).

• Controller's command (ON/OFF) to travel speed selector solenoid can be checked with
monitoring function. (As long as controller's command to solenoid is "ON", sensor state
displayed on monitoring screen is "ON" even if solenoid is not energized due to short cir-
Related
cuit.)
information (Code: 02300 Solenoid 1)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine, set travel speed to Hi, and operate travel lever.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V04, and connect the T-adapter to male side.
Defective travel speed
1
Hi/Lo solenoid Between V04 (male) (1) and (2) 20 to 60 Ω
Resistance
Between V04 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V04, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP02 (female) (93) or V04
Resistance Min. 1 MΩ
(female) (1)
If no failure is found by above checks, pump controller is defective. (Since this is an
3 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to travel Hi/Lo solenoid

HB365LC-3 40-901
FAILURE CODE [DW43KY] 40 TROUBLESHOOTING

FAILURE CODE [DW43KY] (ALL-K-C6T9-410-20-B)

Action level Failure code Travel Speed Solenoid Hot Short Circuit
Failure
L01 DW43KY (Pump controller system)
Detail of fail- When controller does not drive travel speed selector solenoid, output terminal voltage of controller is
ure higher than specified value, and hot short circuit is detected.
Action of • None in particular
controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon Machine travels fast in Lo travel speed setting (machine monitor shows Lo setting but the speed is
on machine kept at around Hi).

• Controller's command (ON/OFF) to travel speed selector solenoid can be checked with
monitoring function. (As long as controller's command to solenoid is OFF, sensor state dis-
Related played on monitoring screen is OFF even if solenoid is not energized due to hot short cir-
information cuit.) (Code: 02300)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector V04, and connect the T-adapter to female side.
1
harness 3. Turn the starting switch to ON position.
Voltage Between V04 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
2 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to travel Hi/Lo solenoid

40-902 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DW45KA]

FAILURE CODE [DW45KA] (ALL-K-JA04-410-00-B)

Action level Failure code Swing parking brake solenoid open circuit
Failure
L03 DW45KA (Hybrid controller system)
Detail of fail- When controller drives swing parking brake solenoid, current does not flow, so open circuit is detect-
ure ed.
• None in particular (Since no current flows, solenoid is not energized. Accordingly, swing
Action of
parking brake is still effective.)
controller
• If cause of failure is eliminated, machine becomes normal by itself.
Phenomenon
Swing is not enabled (swing parking brake is not canceled)
on machine
• If no failure is found in solenoid or wiring harness, set swing parking brake cancel switch
to CANCEL position to enable swing operation (swing parking brake is effective if starting
switch is in OFF position).
• Set swing parking brake cancel switch is to CANCEL position during diagnosis. If swing
parking brake solenoid is normal, current flows to it after turning starting switch to ON po-
sition under this condition, and swing parking brake is canceled.
Related • Controller's command (ON/OFF) to swing parking brake solenoid can be checked with
information monitoring function. (As long as controller's command to solenoid is ON, sensor state dis-
played on monitoring screen is ON even if solenoid is not energized due to open circuit.)
(Code: 09700)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.
• Power supply of swing parking brake solenoid is HC01 (8) pin of inverter (hybrid controller)
or No.1 of fuse box F01.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V05, and connect the T-adapter to male side.
Defective swing parking
1
brake solenoid Between V05 (male) (1) and (2) 20 to 60 Ω
Resistance
Between V05 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
Defective circuit related 2. Disconnect the connector V05, and connect the T-adapter to female side.
2 to swing parking brake
3. Turn the starting switch to ON position.
solenoid
Voltage Between V05 (female) (1) and (2) 1 to 4.5 V
1. Turn the starting switch to OFF position.
2. Disconnect the connector S04, and connect the T-adapter to male side.
Defective swing lock Between S04 (male) (3)
3 Switch position: Normal Max. 1 Ω
switch and (4)
Resistance
Between S04 (male) (5)
Switch position: Normal Min. 1 MΩ
and (6)

HB365LC-3 40-903
FAILURE CODE [DW45KA] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Remove the diode arrays D01 and D03, and connect the T-adapter to
each male side.
No continui-
Between D01 (male) (3)(+) and (7)(-)
4 Defective diode array ty
Between D01 (male) (7)(+) and (3)(-) Continuity
Continuity
No continui-
Between D03 (male) (1)(+) and (5)(-)
ty
Between D03 (male) (5)(+) and (1)(-) Continuity
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC01, D01, S04 and V05, and connect the T-
adapter to each female side.
Between HC01 (female) (8) and D01 (female) (7) Max. 1 Ω
Open circuit in wiring har-
5
ness Between D01 (female) (3) and S04 (female) (3) Max. 1 Ω
Resistance Between S04 (female) (4) and V05 (female) (1) Max. 1 Ω
Between HC01 (female) (13) and V05 (female) (2) Max. 1 Ω
Between HC01 (female) (19) and V05 (female) (2) Max. 1 Ω
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
6
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

40-904 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DW45KA]

Circuit diagram related to swing parking brake

HB365LC-3 40-905
FAILURE CODE [DW45KB] 40 TROUBLESHOOTING

FAILURE CODE [DW45KB] (ALL-K-JA04-410-10-B)

Action level Failure code Swing parking brake solenoid short circuit
Failure
L03 DW45KB (Hybrid controller system)
Detail of fail- When controller does not drive swing parking brake solenoid, solenoid output voltage of controller is
ure higher than specified value, and short circuit is detected.
• None in particular (Since no current flows, solenoid is not energized. Accordingly, swing
Action of
parking brake is still effective.)
controller
• If cause of failure is eliminated, machine becomes normal by itself.
Phenomenon
Swing is not enabled (swing parking brake is not canceled)
on machine
• If no failure is found in solenoid or wiring harness, set swing parking brake cancel switch
to CANCEL position to enable swing operation (swing parking brake is effective if starting
switch is in OFF position).
• Set swing parking brake cancel switch is to CANCEL position during diagnosis. If swing
parking brake solenoid is normal, current flows to it after turning starting switch to ON po-
sition under this condition, and swing parking brake is canceled.
Related • Controller's command (ON/OFF) to swing parking brake solenoid can be checked with
information monitoring function. (As long as controller's command to solenoid is ON, sensor state dis-
played on monitoring screen is ON even if solenoid is not energized due to short circuit.)
(Code: 09700)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.
• Power supply of swing parking brake solenoid is HC01 (8) pin of inverter (hybrid controller)
or No.1 of fuse box F01.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V05, and connect the T-adapter to male side.
Defective swing parking
1
brake solenoid Between V05 (male) (1) and (2) 20 to 60 Ω
Resistance
Between V05 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Remove the diode arrays D01 and D03, and connect the T-adapter to
each male side.
No continui-
Between D01 (male) (3)(+) and (7)(-)
2 Defective diode array ty
Between D01 (male) (7)(+) and (3)(-) Continuity
Continuity
No continui-
Between D03 (male) (1)(+) and (5)(-)
ty
Between D03 (male) (5)(+) and (1)(-) Continuity

40-906 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DW45KB]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC01, D01, S04 and V05, and connect the T-
adapter to any female side.
3. Disconnect the connectors, terminals, and fuses of all the devices which
branch out from connector HC01 (8).
Ground fault in wiring
3 Between ground and either HC01 (female) (8) or D01
harness Min. 1 MΩ
(female) (7)
Between ground and either D01 (female) (3) or S04
Resistance Min. 1 MΩ
(female) (3)
Between ground and either S04 (female) (4) or V05
Min. 1 MΩ
(female) (1)
1. Turn the starting switch to OFF position.
2. Remove the fuse No.1 in fuse box F01 and diode D01.
Short circuit in wiring har- 3. Disconnect the connectors HC01 and D01, and connect the T-adapter to
4
ness each female side.
Between D01 (female) (3) and HC01 (female) (13),
Resistance 20 to 60 Ω
(19)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
5
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-907
FAILURE CODE [DW45KB] 40 TROUBLESHOOTING

Circuit diagram related to swing parking brake

40-908 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DW45KK]

FAILURE CODE [DW45KK] (ALL-K-JA04-410-40-B)

Action level Failure code Swing parking brake solenoid valve power supply voltage low
Failure
L03 DW45KK (Hybrid controller system)
Detail of fail- Low power supply voltage in power supply circuit for driving swing parking brake solenoid in inverter
ure (hybrid controller) is detected.
Action of • None in particular (Since no current flows, solenoid is not energized.)
controller • If cause of failure is eliminated, machine becomes normal by itself.
Phenomenon
Swing is not enabled (swing parking brake is not canceled)
on machine
• If failure code [DA22KK] is also displayed, perform troubleshooting for that code first.
• If no failure is found in solenoid or wiring harness, set swing parking brake cancel switch
to CANCEL position to enable swing operation (swing parking brake is not canceled when
Related starting switch is in OFF position).
information • Controller's command (ON/OFF) to swing parking brake solenoid can be checked with
monitoring function (Code: 09700).
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect the connectors HC01 and CP02, and connect the T-adapter to
1
ness each female side.
Resistance Between CP02 (female) (101) and HC01 (female) (21) Max. 1 Ω
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
2
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-909
FAILURE CODE [DW45KK] 40 TROUBLESHOOTING

Circuit diagram related to swing parking brake

40-910 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DW45KY]

FAILURE CODE [DW45KY] (ALL-K-JA04-410-20-B)

Action level Failure code Swing parking brake solenoid hot short circuit
Failure
L03 DW45KY (Hybrid controller system)
Detail of fail- When controller does not drive swing parking brake solenoid, output terminal voltage of controller is
ure higher than specified value, and hot short circuit is detected.
Action of • None in particular
controller • If cause of failure is eliminated, machine becomes normal by itself.
Phenomenon
Swing parking brake does not work.
on machine
• If no failure is found in solenoid or wiring harness, set swing parking brake cancel switch
to CANCEL position to enable swing operation (swing parking brake is effective if starting
switch is in OFF position).
• Set swing lock switch to OFF position, and set swing parking brake cancel switch is to
CANCEL position during diagnosis. If swing parking brake solenoid is normal, current
flows to it after turning starting switch to ON position under this condition, and swing park-
ing brake is canceled.
Related
• Controller's command (ON/OFF) to swing parking brake solenoid can be checked with
information monitoring function. (As long as controller's command to solenoid is OFF, sensor state dis-
played on monitoring screen is OFF even if solenoid is energized due to open short cir-
cuit.) (Code: 09700)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.
• Power supply of swing parking brake solenoid is HC01 (8) pin of inverter (hybrid controller)
or No.1 of fuse box F01.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector V05, and connect the T-adapter to female side.
1
harness 3. Turn the starting switch to ON position.
Voltage Between V05 (female) (1) and (2) Max. 1 V
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
2
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-911
FAILURE CODE [DW45KY] 40 TROUBLESHOOTING

Circuit diagram related to swing parking brake

40-912 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DW4CKY]

FAILURE CODE [DW4CKY] (ALL-K-PX10-410-10-B)

Action level Failure code PPC Lock Solenoid Hot Short Circuit
Failure
L03 DW4CKY (pump controller system)
Details of
Controller detects hot short circuit in PPC lock solenoid.
failure
Action of • None in particular
controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon
Lock cannot be engaged by using lock lever.
on machine
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Start the engine and lock the lock lever.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector V01, and connect the T-adapter to female side.
1
harness 3. Turn the starting switch to ON position.
Voltage Between V01 (female) (1) and (2) Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an
2 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to PPC lock switch

HB365LC-3 40-913
FAILURE CODE [DW91KA] 40 TROUBLESHOOTING

FAILURE CODE [DW91KA] (ALL-K-C6TA-410-00-B)

Action level Failure code Travel Junction Solenoid Open Circuit

Failure
L01 DW91KA (Pump controller system)
Detail of fail- When output to travel junction solenoid is ON, no current flows in the circuit, so the open circuit is
ure detected.
Action of None in particular (Since no current flows, solenoid is not energized.)
controller If cause of failure disappears, machine becomes normal by itself.
Phenomenon
It is hard to steer the machine at travel.
on machine
• Controller's command (ON/OFF) to travel junction solenoid can be checked with monitor-
ing function. (As long as controller's command to solenoid is "ON", sensor state displayed
on monitoring screen is "ON" even if solenoid is not energized due to open circuit.)
Related (Code: 02300 Solenoid 1)
information • Setting the solenoid to OFF interconnects travel junction circuit.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine and operate left/right travel lever for steering.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V03, and connect the T-adapter to male side.
Defective travel junction
1
solenoid Between V03 (male) (1) and (2) 20 to 60 Ω
Resistance
Between V03 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
Defective circuit related 2. Disconnect the connector V03, and connect the T-adapter to female side.
2
to travel junction solenoid 3. Turn the starting switch to ON position.
Voltage Between V03 (female) (1) and (2) 1 to 4.5 V
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V03, and connect the T-adapter to
each female side.
Open circuit in wiring har- Between CP02 (female) (85) and V03 (female) (1) Max. 1 Ω
3
ness
Between CP02 (female) (115) and V03 (female) (2) Max. 1 Ω
Resistance
Between CP02 (female) (117) and V03 (female) (2) Max. 1 Ω
Between CP02 (female) (120) and V03 (female) (2) Max. 1 Ω
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

40-914 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DW91KA]

Circuit diagram related to travel junction valve solenoid

HB365LC-3 40-915
FAILURE CODE [DW91KB] 40 TROUBLESHOOTING

FAILURE CODE [DW91KB] (ALL-K-C6TA-410-10-B)

Action level Failure code Travel Junction Solenoid Short Circuit

Failure
L01 DW91KB (Pump controller system)
Detail of fail-
Controller detects short circuit in travel junction solenoid.
ure
Stops driving travel junction solenoid.
Action of
Even if cause of failure disappears, machine does not become normal until starting switch is turned
controller
to OFF position.
Phenomenon
It is hard to steer the machine at travel.
on machine
• Controller's command (ON/OFF) to travel junction solenoid can be checked with monitor-
ing function. (As long as controller's command to solenoid is "ON", sensor state displayed
on monitoring screen is "ON" even if solenoid is not energized due to short circuit.)
Related (Code: 02300 Solenoid 1)
information • Setting the solenoid to OFF interconnects travel junction circuit.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine and operate left/right travel lever for steering.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V03, and connect the T-adapter to male side.
Defective travel junction
1
solenoid Between V03 (male) (1) and (2) 20 to 60 Ω
Resistance
Between V03 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V03, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP02 (female) (85) or V03
Resistance Min. 1 MΩ
(female) (1)
If no failure is found by above checks, pump controller is defective. (Since this is an
3 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to travel junction valve solenoid

40-916 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DW91KY]

FAILURE CODE [DW91KY] (ALL-K-C6TA-410-20-B)

Action level Failure code Travel Junction Solenoid Hot Short Circuit
Failure
L01 DW91KY (Pump controller system)
Detail of fail-
Current flows when driving travel junction solenoid circuit stops.
ure
Action of
Stops driving travel junction solenoid.
controller
Phenomenon
It is hard to steer the machine at travel.
on machine
• Controller's command (ON/OFF) to travel junction solenoid can be checked with monitor-
ing function. (As long as controller's command to solenoid is OFF, sensor state displayed
on monitoring screen is OFF even if solenoid is not energized due to hot short circuit.)
Related (Code: 02300 Solenoid 1)
information • Setting the solenoid to OFF interconnects travel junction circuit.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine and operate left/right travel lever for steering.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector V03, and connect the T-adapter to female side.
1
harness 3. Turn the starting switch to ON position.
Voltage Between V03 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
2 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to travel junction valve solenoid

HB365LC-3 40-917
FAILURE CODE [DWA2KA] 40 TROUBLESHOOTING

FAILURE CODE [DWA2KA] (ALL-K-PT01-410-00-B)

Action level Failure code Attachment Single or 2-Way Change Solenoid Open Circuit
Failure
L03 DWA2KA (Pump controller system)
Detail of fail- When output to attachment return selector solenoid is ON, no current flows in the circuit, so the
ure open circuit is detected.
Action of None in particular (Since no current flows, solenoid is not energized.)
controller If cause of failure disappears, machine becomes normal by itself.
Phenomenon
Hydraulic circuit for attachment is not single-acting circuit.
on machine
• Controller's command (ON/OFF) to attachment return selector solenoid can be checked
with monitoring function. (As long as controller's command to solenoid is "ON", sensor
state displayed on monitoring screen is "ON" even if solenoid is not energized due to open
Related circuit.)
information (Code: 02301 “Solenoid 2”)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position and set machine to mode other than break-
er mode (B).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V07, and connect the T-adapter to male side.
Defective attachment re-
1
turn selector solenoid Between V07 (male) (1) and (2) 20 to 60 Ω
Resistance
Between V07 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
Defective circuit related 2. Disconnect the connector V07, and connect the T-adapter to female side.
2 to ATT single/multiple se-
3. Turn the starting switch to ON position.
lector solenoid
Voltage Between V07 (female) (1) and (2) 1 to 4.5 V
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V07, and connect the T-adapter to
each female side.
Open circuit in wiring har- Between CP02 (female) (86) and V07 (female) (1) Max. 1 Ω
3
ness
Between CP02 (female) (115) and V07 (female) (2) Max. 1 Ω
Resistance
Between CP02 (female) (117) and V07 (female) (2) Max. 1 Ω
Between CP02 (female) (120) and V07 (female) (2) Max. 1 Ω
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

40-918 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DWA2KA]

Circuit diagram related to ATT single or 2-way selector solenoid

HB365LC-3 40-919
FAILURE CODE [DWA2KB] 40 TROUBLESHOOTING

FAILURE CODE [DWA2KB] (ALL-K-PT01-410-10-B)

Action level Failure code Attachment Single or 2-Way Change Solenoid Short Circuit
Failure
L03 DWA2KB (Pump controller system)
Detail of fail- Abnormal current flows when pump controller drives attachment return selector solenoid, so pump
ure controller determines that short circuit exists in attachment return selector solenoid circuit.
Stops driving attachment return selector solenoid.
Action of
Even if cause of failure disappears, machine does not become normal until starting switch is turned
controller
to OFF position.
Phenomenon
Hydraulic circuit for attachment is not single-acting circuit.
on machine
• Controller's command (ON/OFF) to attachment return selector solenoid can be checked
with monitoring function. (As long as controller's command to solenoid is "ON", sensor
state displayed on monitoring screen is "ON" even if solenoid is not energized due to short
Related
circuit.)
information (Code: 02301 Solenoid 2)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position and set machine in breaker mode (B).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V07, and connect the T-adapter to male side.
Defective attachment re-
1
turn selector solenoid Between V07 (male) (1) and (2) 20 to 60 Ω
Resistance
Between V07 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V07, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP02 (female) (86) or V07
Resistance Min. 1 MΩ
(female) (1)
If no failure is found by above checks, pump controller is defective. (Since this is an
3 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to ATT single or 2-way selector solenoid

40-920 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DWA2KY]

FAILURE CODE [DWA2KY] (ALL-K-PT01-410-20-B)

Action level Failure code Attachment Single or 2-Way Change Solenoid Hot Short Circuit
Failure
L03 DWA2KY (Pump controller system)
Detail of fail-
Current flows when driving attachment return selector solenoid circuit stops.
ure
• None in particular
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon
Hydraulic circuit for attachment is not 2–way-acting circuit.
on machine
• Controller's command (ON/OFF) to attachment return selector solenoid can be checked
with monitoring function. (As long as controller's command to solenoid is OFF, sensor
state displayed on monitoring screen is OFF even if solenoid is not energized due to hot
Related
short circuit.)
information (Code: 02301 Solenoid 2)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position and set machine in breaker mode (B).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector V07, and connect the T-adapter to female side.
1
harness 3. Turn the starting switch to ON position.
Voltage Between V07 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
2 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to ATT single or 2-way selector solenoid

HB365LC-3 40-921
FAILURE CODE [DWK0KA] 40 TROUBLESHOOTING

FAILURE CODE [DWK0KA] (ALL-K-PT02-410-00-B)

Action level Failure code 2-Stage Relief Solenoid Open Circuit

Failure
L01 DWK0KA (Pump controller system)
Detail of fail- When output to 2-stage relief solenoid is ON, no current flows in the circuit, so the open circuit is
ure detected.
Action of None in particular (Since no current flows, solenoid is not energized.)
controller If cause of failure disappears by itself, machine becomes normal.
Phenomenon Traveling force is weak (main relief valve is not switched to high pressure setting).
on machine One-touch power maximizing function does not operate.
• Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with monitoring
function. (As long as controller's command to solenoid is ON, sensor state displayed on
monitoring screen is ON even if solenoid is not energized due to open circuit.)
(Code: 02300 Solenoid 1)
Related
• As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
information be measured at pump controller connector.
• Controller detects open circuit when controller does not drive solenoid.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V08, and connect the T-adapter to male side.
Defective 2-stage relief
1
solenoid Between V08 (male) (1) and (2) 20 to 60 Ω
Resistance
Between V08 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
Defective circuit related 2. Disconnect the connector V08, and connect the T-adapter to female side.
2
to 2-stage relief solenoid 3. Turn the starting switch to ON position.
Voltage Between V08 (female) (1) and (2) 1 to 4.5 V
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V08, and connect the T-adapter to
each female side.
Open circuit in wiring har- Between CP02 (female) (109) and V08 (female) (1) Max. 1 Ω
3
ness
Between CP02 (female) (115) and V08 (female) (2) Max. 1 Ω
Resistance
Between CP02 (female) (117) and V08 (female) (2) Max. 1 Ω
Between CP02 (female) (120) and V08 (female) (2) Max. 1 Ω
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

40-922 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DWK0KA]

Circuit diagram related to 2-stage relief solenoid system

HB365LC-3 40-923
FAILURE CODE [DWK0KB] 40 TROUBLESHOOTING

FAILURE CODE [DWK0KB] (ALL-K-PT02-410-10-B)

Action level Failure code 2-Stage Relief Solenoid Open Circuit

Failure
L01 DWK0KB (Pump controller system)
Detail of fail-
Controller detects short circuit in driving 2-stage relief solenoid.
ure
Stops driving 2-stage relief solenoid circuit.
Action of
Even if cause of failure disappears, machine does not become normal until starting switch is set to
controller
OFF position.
Phenomenon Traveling force is weak (main relief valve is not switched to high pressure setting).
on machine One-touch power maximizing function does not operate.
• Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with monitoring
function. (As long as controller's command to solenoid is ON, sensor state displayed on
monitoring screen is ON even if solenoid is not energized due to short circuit.)
(Code: 02300 Solenoid 1)
Related
• As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
information be measured at pump controller connector.
• Controller detects open circuit when controller does not drive solenoid.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V08, and connect the T-adapter to male side.
Defective 2-stage relief
1
solenoid Between V08 (male) (1) and (2) 20 to 60 Ω
Resistance
Between V08 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V08, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP02 (female) (109) or
Resistance Min. 1 MΩ
V08 (female) (1)
If no failure is found by above checks, pump controller is defective. (Since this is an
3 Defective pump controller
internal defect, troubleshooting cannot be performed).

40-924 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DWK0KB]

Circuit diagram related to 2-stage relief solenoid system

HB365LC-3 40-925
FAILURE CODE [DWK0KY] 40 TROUBLESHOOTING

FAILURE CODE [DWK0KY] (ALL-K-PT02-410-20-B)

Action level Failure code 2-Stage Relief Solenoid Hot Short Circuit
Failure
L01 DWK0KY (Pump controller system)
Detail of fail-
Current flows when driving 2-stage relief solenoid circuit stops.
ure
Action of • None in particular
controller • If cause of failure disappears, machine becomes normal by itself.
Phenomenon Traveling force is weak (main relief valve is not switched to high pressure setting).
on machine One-touch power maximizing function does not operate.
• Controller's command (ON/OFF) to 2-stage relief solenoid can be checked with monitoring
function. (As long as controller's command to solenoid is ON, sensor state displayed on
monitoring screen is ON even if solenoid is not energized due to short circuit.)
(Code: 02300 Solenoid 1)
Related
• As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
information be measured at pump controller connector.
• Controller detects open circuit when controller does not drive solenoid.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector V08, and connect the T-adapter to female side.
1
harness 3. Turn the starting switch to ON position.
Voltage Between V08 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
2 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to 2-stage relief solenoid system

40-926 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DWK2KA]

FAILURE CODE [DWK2KA] (ALL-K-C071-410-00-B)

Action level Failure code Variable Back Pressure Solenoid Open Circuit
Failure
L01 DWK2KA (Pump controller system)
Detail of fail-
Controller detects open circuit in variable back pressure solenoid.
ure
Action of None in particular (Since no current flows, solenoid is not energized.)
controller If cause of failure disappears, machine becomes normal by itself.
Phenomenon
Fuel consumption is degraded.
on machine
• Controller's command (ON/OFF) to variable back pressure solenoid can be checked with
monitoring function. (As long as controller's command to solenoid is ON, sensor state dis-
played on monitoring screen is ON even if solenoid is not energized due to short circuit.)
Related (Code: 02301 solenoid 2)
information • When controller's command to solenoid is ON, back pressure valve set pressure decreas-
es.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V25, and connect the T-adapter to male side.
Defective variable back
1
pressure solenoid Between V25 (male) (1) and (2) 20 to 60 Ω
Resistance
Between V25 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
Defective circuit related 2. Disconnect the connector V25, and connect the T-adapter to female side.
2 to variable back pressure
3. Turn the starting switch to ON position.
solenoid
Voltage Between V25 (female) (1) and (2) Min. 20 V
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V25, and connect the T-adapter to
each female side.
Open circuit in wiring har- Between CP02 (female) (113) and V25 (female) (1) Max. 1 Ω
3
ness
Between CP02 (female) (115) and V25 (female) (2) Max. 1 Ω
Resistance
Between CP02 (female) (117) and V25 (female) (2) Max. 1 Ω
Between CP02 (female) (120) and V25 (female) (2) Max. 1 Ω
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-927
FAILURE CODE [DWK2KA] 40 TROUBLESHOOTING

Circuit diagram related to variable back pressure solenoid

40-928 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DWK2KB]

FAILURE CODE [DWK2KB] (ALL-K-C071-410-10-B)

Action level Failure code Variable Back Pressure Solenoid Short Circuit
Failure
L01 DWK2KB (Pump controller system)
Detail of fail-
Controller detects short circuit in variable back pressure solenoid.
ure
Stops driving variable back pressure solenoid.
Action of
Even if cause of failure disappears, machine does not become normal until starting switch is turned
controller
to OFF position.
Phenomenon
Fuel consumption is degraded.
on machine
• Controller's command (ON/OFF) to variable back pressure solenoid can be checked with
monitoring function. (As long as controller's command to solenoid is ON, sensor state dis-
played on monitoring screen is ON even if solenoid is not energized due to short circuit.)
Related (Code: 02301 solenoid 2)
information • When controller's command to solenoid is ON, back pressure valve set pressure decreas-
es.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V25, and connect the T-adapter to male side.
Defective variable back
1
pressure solenoid Between V25 (male) (1) and (2) 20 to 60 Ω
Resistance
Between V25 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V25, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP02 (female) (113) or
Resistance Min. 1 MΩ
V25 (female) (1)
If no failure is found by above checks, pump controller is defective. (Since this is an
3 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-929
FAILURE CODE [DWK2KB] 40 TROUBLESHOOTING

Circuit diagram related to variable back pressure solenoid

40-930 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DWK2KY]

FAILURE CODE [DWK2KY] (ALL-K-C071-410-20-B)

Action level Failure code Variable Back Pressure Solenoid Hot Short Circuit
Failure
L01 DWK2KY (Pump controller system)
Detail of fail-
Controller detects hot short circuit in variable back pressure solenoid.
ure
Action of
Stops driving variable back pressure solenoid.
controller
Phenomenon
Fuel consumption is degraded.
on machine
• Controller's command (ON/OFF) to variable back pressure solenoid can be checked with
monitoring function. (As long as controller's command to solenoid is OFF, sensor state dis-
played on monitoring screen is OFF even if solenoid is not energized due to hot short cir-
cuit.)
Related (Code: 02301 solenoid 2)
information • When controller's command to solenoid is ON, back pressure valve set pressure decreas-
es.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector V25, and connect the T-adapter to female side.
1
harness 3. Turn the starting switch to ON position.
Voltage Between V25 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
2 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to variable back pressure solenoid

HB365LC-3 40-931
FAILURE CODE [DWN5KA] 40 TROUBLESHOOTING

FAILURE CODE [DWN5KA] (ALL-K-ACN5-410-02-B)

Action level Failure code Fan clutch solenoid open circuit

Failure
L03 DWN5KA (Pump controller system)
Detail of fail-
Controller detects open circuit in fan clutch solenoid.
ure
• None in particular
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon Fan speed is not controlled, there by it becomes the maximum rotation speed according to the en-
on machine gine speed.

• Fan speed can be checked with monitoring function. (code:10007)

Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
be measured at pump controller connector.
information
• After repair is completed, check if the failure code is cleared by the following procedure.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V13, and connect the T-adapter to male side.
Defective fan clutch sole-
1
noid Between V13 (male) (3) and (4) 20 to 32 Ω
Resistance
Between V13 (male) (4) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
Defective circuit related 2. Disconnect the connector V13, and connect the T-adapter to female side.
2
to fan clutch solenoid 3. Turn the starting switch to ON position.
Voltage Between V13 (female) (4) and (3) Min. 20 V
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V13, and connect the T-adapter to
Open circuit in wiring har- each female side.
3
ness
Between CP02 (female) (99) and V13 (female) (4) Max. 1 Ω
Resistance
Between CP02 (female) (117) and V13 (female) (3) Max. 1 Ω
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

40-932 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DWN5KA]

Circuit diagram related to fan clutch

HB365LC-3 40-933
FAILURE CODE [DWN5KB] 40 TROUBLESHOOTING

FAILURE CODE [DWN5KB] (ALL-K-ACN5-410-03-B)

Action level Failure code Fan clutch solenoid short circuit

Failure
L03 DWN5KB (Pump controller system)
Detail of fail-
Controller detects short circuit in fan clutch solenoid.
ure
• Stops driving fan clutch solenoid.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon Fan speed is not controlled, there by it becomes the maximum rotation speed according to the en-
on machine gine speed.

• Fan speed can be checked with monitoring function. (code:10007)

Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
be measured at pump controller connector.
information
• After repair is completed, check if the failure code is cleared by the following procedure.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V13, and connect the T-adapter to male side.
Defective fan clutch sole-
1
noid Between V13 (male) (3) and (4) 20 to 32 Ω
Resistance
Between V13 (male) (4) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V13, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP02 (female) (99) or V13
Resistance Min. 1 MΩ
(female) (4)
If no failure is found by above checks, pump controller is defective. (Since this is an
3 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to fan clutch

40-934 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DWN5KY]

FAILURE CODE [DWN5KY] (ALL-K-ACN5-410-04-B)

Action level Failure code Fan clutch solenoid hot short circuit
Failure
L03 DWN5KY (Pump controller system)
Detail of fail-
Controller detects hot short circuit in fan clutch solenoid.
ure
• Stops driving fan clutch solenoid.
Action of
• Even if cause of failure is removed, machine does not return to a normal state until starting
controller
switch is turned to ON position after it is turned to OFF position once.
Phenomenon Fan speed is not controlled, there by it becomes the maximum rotation speed according to the en-
on machine gine speed.

• Fan speed can be checked with monitoring function. (code:10007)

Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
be measured at pump controller connector.
information
• After repair is completed, check if the failure code is cleared by the following procedure.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector V13, and connect the T-adapter to female side.
1
harness 3. Turn the starting switch to ON position.
Voltage Between V13 (female) (3) and (4) Max. 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
2 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to fan clutch

HB365LC-3 40-935
FAILURE CODE [DXA8KA] 40 TROUBLESHOOTING

FAILURE CODE [DXA8KA] (ALL-K-C3V8-410-00-B)

Action level Failure code Front Pump PC-EPC Solenoid Open Circuit
Failure
L03 DXA8KA (Pump controller system)
Detail of fail- No current flows when pump controller drives front pump PC-EPC solenoid, so pump controller de-
ure termines that open circuit exists in front pump PC-EPC solenoid circuit.
Action of None in particular (Since no current flows, solenoid is not energized.)
controller If cause of failure disappears, machine becomes normal by itself.
Phenomenon
If pump load increases, engine speed decreases largely and engine may stop.
on machine
• When solenoid and wiring harness are normal, engine can be prevented from stopping by
setting pump drive secondary switch to ON position.
Related • Drive current of front pump PC-EPC solenoid can be checked with monitoring function.
information (Code: 01300 PC-EPC front solenoid current)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Operation mistake of Set the pump secondary drive switch at its normal position (lower side).
1 pump secondary drive
switch
1. Turn the starting switch to OFF position.
2. Disconnect the connector V11, and connect the T-adapter to male side.
Defective F pump PC-
2
EPC solenoid Between V11 (male) (1) and (2) 3 to 14 Ω
Resistance
Between V11 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
Defective circuit related 2. Disconnect the connector V11, and connect the T-adapter to female side.
3 to F pump PC-EPC sole-
3. Turn the starting switch to ON position.
noid
Voltage Between V11 (female) (1) and (2) Min. 20 V
1. Turn the starting switch to OFF position.
2. Disconnect the connector S25 and connect the T-adapter to male side.

Between S25 (male) (3) Switch position: Normal Max. 1 Ω

and (2) Switch position: Drive Min. 1 MΩ

Between S25 (male) (6) Switch position: Normal Max. 1 Ω

Defective pump secon- and (5) Switch position: Drive Min. 1 MΩ
4
dary drive switch
Resistance Between S25 (male) (2)
Switch position: Normal Min. 1 MΩ
and (5)
Between S25 (male) (3)
Switch position: Normal Min. 1 MΩ
and (5)
Between S25 (male) (2) and ground Min. 1 MΩ
Between S25 (male) (3) and ground Min. 1 MΩ

40-936 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXA8KA]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02, S25, and V11, and connect the T-adapt-
er to each female side.
Between CP02 (female) (96) and S25 (female) (3) Max. 1 Ω
Open circuit in wiring har- Between S25 (female) (2) and V11 (female) (1) Max. 1 Ω
5
ness
Between S25 (female) (5) and V11 (female) (2) Max. 1 Ω
Resistance
Between CP02 (female) (115) and S25 (female) (6) Max. 1 Ω
Between CP02 (female) (117) and S25 (female) (6) Max. 1 Ω
Between CP02 (female) (120) and S25 (female) (6) Max. 1 Ω
If no failure is found by above checks, pump controller is defective. (Since this is an
6 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-937
FAILURE CODE [DXA8KA] 40 TROUBLESHOOTING

Circuit diagram related to PC-EPC solenoid system

40-938 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXA8KB]

FAILURE CODE [DXA8KB] (ALL-K-C3V8-410-10-B)

Action level Failure code Front Pump PC-EPC Solenoid Short Circuit
Failure
L03 DXA8KB (Pump controller system)
Detail of fail- Abnormal current flows when pump controller drives front pump PC-EPC solenoid, so pump control-
ure ler determines that short circuit exists in front pump PC-EPC solenoid circuit.
Stops output to front pump PC-EPC solenoid.
Action of
Even if cause of failure disappears, machine does not become normal until starting switch is turned
controller
to OFF position.
Phenomenon
If pump load increases, engine speed decreases largely and engine may stop.
on machine
• When solenoid and wiring harness are normal, engine can be prevented from stopping by
setting pump drive secondary switch to ON position.
Related • Drive current of front pump PC-EPC solenoid can be checked with monitoring function.
information (Code: 01300)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V11, and connect the T-adapter to male side.
Defective F pump PC-
1
EPC solenoid Between V11 (male) (1) and (2) 3 to 14 Ω
Resistance
Between V11 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connector S25 and connect the T-adapter to male side.

Between S25 (male) (3) Switch position: Normal Max. 1 Ω

and (2) Switch position: Drive Min. 1 MΩ

Between S25 (male) (6) Switch position: Normal Max. 1 Ω

Defective pump secon- and (5) Switch position: Drive Min. 1 MΩ
2
dary drive switch
Resistance Between S25 (male) (2)
Switch position: Normal Min. 1 MΩ
and (5)
Between S25 (male) (3)
Switch position: Normal Min. 1 MΩ
and (5)
Between S25 (male) (2) and ground Min. 1 MΩ
Between S25 (male) (3) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02, S25, and V11, and connect the T-adapt-
er to any female side.
Ground fault in wiring
3 Between ground and either CP02 (female) (96) or S25
harness Min. 1 MΩ
(female) (3)
Resistance
Between ground and either S25 (female) (2) or V11
Min. 1 MΩ
(female) (1)
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-939
FAILURE CODE [DXA8KB] 40 TROUBLESHOOTING

Circuit diagram related to PC-EPC solenoid system

40-940 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXA9KA]

FAILURE CODE [DXA9KA] (ALL-K-C3V9-410-00-B)

Action level Failure code Rear Pump PC-EPC Solenoid Open Circuit
Failure
L03 DXA9KA (Pump controller system)
Detail of fail- No current flows when pump controller drives rear pump PC-EPC Solenoid, so pump controller de-
ure termines that open circuit exists in rear pump PC-EPC Solenoid circuit.
Action of None in particular (Since no current flows, solenoid is not energized.)
controller If cause of failure disappears, machine becomes normal by itself.
Phenomenon
If pump load increases, engine speed decreases largely and engine may stop.
on machine
• When solenoid and wiring harness are normal, engine can be prevented from stopping by
setting pump drive secondary switch to ON position.
Related • Drive current of rear pump PC-EPC Solenoid can be checked with monitoring function.
information (Code: 01302 PC-EPC rear solenoid current)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Operation mistake of Set the pump secondary drive switch at its normal position (lower side).
1 pump secondary drive
switch
1. Turn the starting switch to OFF position.
2. Disconnect the connector V12, and connect the T-adapter to male side.
Defective R pump PC-
2
EPC solenoid Between V12 (male) (1) and (2) 3 to 14 Ω
Resistance
Between V12 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
Defective circuit related 2. Disconnect the connector V12, and connect the T-adapter to female side.
3 to R pump PC-EPC sole-
3. Turn the starting switch to ON position.
noid
Voltage Between V12 (female) (1) and (2) Min. 20 V
1. Turn the starting switch to OFF position.
2. Disconnect the connector S25 and connect the T-adapter to male side.

Between S25 (male) (8) Switch position: Normal Max. 1 Ω

and (9) Switch position: Drive Min. 1 MΩ

Between S25 (male) (11) Switch position: Normal Max. 1 Ω

Defective pump secon- and (12) Switch position: Drive Min. 1 MΩ
4
dary drive switch
Resistance Between S25 (male) (8)
Switch position: Normal Min. 1 MΩ
and (11)
Between S25 (male) (9)
Switch position: Normal Min. 1 MΩ
and (11)
Between S25 (male) (8) and ground Min. 1 MΩ
Between S25 (male) (9) and ground Min. 1 MΩ

HB365LC-3 40-941
FAILURE CODE [DXA9KA] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02, S25, and V12, and connect the T-adapt-
er to each female side.
Between CP02 (female) (104) and S25 (female) (9) Max. 1 Ω
Open circuit in wiring har- Between S25 (female) (8) and V12 (female) (1) Max. 1 Ω
5
ness
Between S25 (female) (11) and V12 (female) (2) Max. 1 Ω
Resistance
Between CP02 (female) (115) and S25 (female) (12) Max. 1 Ω
Between CP02 (female) (117) and S25 (female) (12) Max. 1 Ω
Between CP02 (female) (120) and S25 (female) (12) Max. 1 Ω
If no failure is found by above checks, pump controller is defective. (Since this is an
6 Defective pump controller
internal defect, troubleshooting cannot be performed).

40-942 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXA9KA]

Circuit diagram related to PC-EPC solenoid system

HB365LC-3 40-943
FAILURE CODE [DXA9KB] 40 TROUBLESHOOTING

FAILURE CODE [DXA9KB] (ALL-K-C3V9-410-10-B)

Action level Failure code Rear Pump PC-EPC Solenoid Short Circuit
Failure
L03 DXA9KB (Pump controller system)
Detail of fail- Abnormal current flows when pump controller drives rear pump PC-EPC Solenoid, so pump control-
ure ler determines that short circuit exists in rear pump PC-EPC Solenoid circuit.
Stops output to rear pump PC-EPC Solenoid.
Action of
Even if cause of failure disappears, machine does not become normal until starting switch is turned
controller
to OFF position.
Phenomenon
If pump load increases, engine speed decreases largely and engine may stop.
on machine
• When solenoid and wiring harness are normal, engine can be prevented from stopping by
setting pump drive secondary switch to ON position.
Related • Drive current of rear pump PC-EPC Solenoid can be checked with monitoring function.
information (Code: 01302)
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V12, and connect the T-adapter to male side.
Defective R pump PC-
1
EPC solenoid Between V12 (male) (1) and (2) 3 to 14 Ω
Resistance
Between V12 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connector S25 and connect the T-adapter to male side.

Between S25 (male) (8) Switch position: Normal Max. 1 Ω

and (9) Switch position: Drive Min. 1 MΩ

Between S25 (male) (11) Switch position: Normal Max. 1 Ω

Defective pump secon- and (12) Switch position: Drive Min. 1 MΩ
2
dary drive switch
Resistance Between S25 (male) (8)
Switch position: Normal Min. 1 MΩ
and (11)
Between S25 (male) (9)
Switch position: Normal Min. 1 MΩ
and (11)
Between S25 (male) (8) and ground Min. 1 MΩ
Between S25 (male) (9) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02, S25, and V12, and connect the T-adapt-
er to any female side.
Ground fault in wiring
3 Between ground and either CP02 (female) (104) or
harness Min. 1 MΩ
S25 (female) (9)
Resistance
Between ground and either S25 (female) (8) or V12
Min. 1 MΩ
(female) (1)
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

40-944 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXA9KB]

Circuit diagram related to PC-EPC solenoid system

HB365LC-3 40-945
FAILURE CODE [DXE0KA] 40 TROUBLESHOOTING

FAILURE CODE [DXE0KA] (ALL-K-C3VA-410-00-B)

Action level Failure code LS-EPC Solenoid Open Circuit

Failure
L01 DXE0KA (Pump controller system)
Detail of fail- No current flows when pump controller drives LS-EPC solenoid, so pump controller determines that
ure open circuit exists in LS-EPC solenoid circuit.
Action of None in particular (Since no current flows, solenoid is not energized.)
controller If cause of failure disappears, machine becomes normal by itself.
Phenomenon Travel speed is high when travel speed selection is Lo. and Mi.
on machine Operation speed of work equipment and swing is high in fine control mode (L).
• Drive current of LS-EPC solenoid can be checked with monitoring function.
Related (Code: 01500LS-EPC solenoid current)
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V19, and connect the T-adapter to male side.
Defective LS-EPC sole-
1
noid Between V19 (male) (1) and (2) 3 to 14 Ω
Resistance
Between V19 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
Defective circuit related 2. Disconnect the connector V19, and connect the T-adapter to female side.
2
to LS-EPC solenoid 3. Turn the starting switch to ON position.
Voltage Between V19 (female) (1) and (2) Min. 20 V
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V19, and connect the T-adapter to
each female side.
Open circuit in wiring har- Between CP02 (female) (88) and V19 (female) (1) Max. 1 Ω
3
ness
Between CP02 (female) (115) and V19 (female) (2) Max. 1 Ω
Resistance
Between CP02 (female) (117) and V19 (female) (2) Max. 1 Ω
Between CP02 (female) (120) and V19 (female) (2) Max. 1 Ω
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

40-946 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXE0KA]

Circuit diagram related to LS-EPC solenoid system

HB365LC-3 40-947
FAILURE CODE [DXE0KB] 40 TROUBLESHOOTING

FAILURE CODE [DXE0KB] (ALL-K-C3VA-410-10-B)

Action level Failure code LS-EPC Solenoid Short Circuit

Failure
L01 DXE0KB (Pump controller system)
Detail of fail- Abnormal current flows when pump controller drives LS-EPC solenoid, so pump controller deter-
ure mines that short circuit exists in LS-EPC solenoid circuit.
Stops output to LS-EPC solenoid.
Action of
Even if cause of failure disappears, machine does not become normal until starting switch is turned
controller
to OFF position.
Phenomenon Travel speed is high when travel speed selection is Lo. and Mi.
on machine Operation speed of work equipment and swing is high in fine control mode (L).
• Drive current of LS-EPC solenoid can be checked with monitoring function.
Related (Code: 01500LS-EPC solenoid current)
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V19, and connect the T-adapter to male side.
Defective LS-EPC sole-
1
noid Between V19 (male) (1) and (2) 3 to 14 Ω
Resistance
Between V19 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V19, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP02 (female) (88) or V19
Resistance Min. 1 MΩ
(female) (1)
If no failure is found by above checks, pump controller is defective. (Since this is an
3 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to LS-EPC solenoid system

40-948 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXE4KA]

FAILURE CODE [DXE4KA] (ALL-K-PT03-410-00-B)

Action level Failure code Attachment Flow Regulating EPC Solenoid Open Circuit
Failure
― DXE4KA (Pump controller system)
Detail of fail-
Controller detects open circuit in attachment flow rate adjustment EPC solenoid.
ure
Action of None in particular (Since no current flows, solenoid is not energized.)
controller If cause of failure disappears, machine becomes normal by itself.
Phenomenon
Attachment does not move.
on machine
• Drive current of attachment flow rate adjustment (service current) EPC solenoid can be
checked with monitoring function.
Related
(Code: 01700 attachment solenoid current)
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position and set machine in breaker mode (B).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Defective EPC solenoid 2. Disconnect the connector V30, and connect the T-adapter to male side.
1 for attachment oil flow
adjustment Between V30 (male) (1) and (2) 3 to 14 Ω
Resistance
Between V30 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
Defective circuit related
to EPC solenoid for at- 2. Disconnect the connector V30, and connect the T-adapter to female side.
2
tachment oil flow adjust- 3. Turn the starting switch to ON position.
ment
Voltage Between V30 (female) (1) and (2) 1 to 4.5 V
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V30, and connect the T-adapter to
each female side.
Open circuit in wiring har- Between CP02 (female) (97) and V30 (female) (1) Max. 1 Ω
3
ness
Between CP02 (female) (115) and V30 (female) (2) Max. 1 Ω
Resistance
Between CP02 (female) (117) and V30 (female) (2) Max. 1 Ω
Between CP02 (female) (120) and V30 (female) (2) Max. 1 Ω
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-949
FAILURE CODE [DXE4KA] 40 TROUBLESHOOTING

Circuit diagram related to ATT flow rate throttling EPC

40-950 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXE4KB]

FAILURE CODE [DXE4KB] (ALL-K-PT03-410-10-B)

Action level Failure code Attachment Flow Regulating EPC Solenoid Short Circuit
Failure
― DXE4KB (Pump controller system)
Detail of fail-
Controller detects short circuit in attachment flow rate EPC solenoid.
ure
Stops driving attachment flow rate adjustment EPC solenoid.
Action of
Even if cause of failure disappears, machine does not become normal until starting switch is turned
controller
to OFF position.
Phenomenon
Attachment does not move.
on machine
• Drive current of attachment flow rate adjustment (service current) EPC solenoid can be
checked with monitoring function.
Related
(Code: 01700 attachment solenoid current)
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position and set machine in breaker mode (B).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Defective EPC solenoid 2. Disconnect the connector V30, and connect the T-adapter to male side.
1 for attachment oil flow
adjustment Between V30 (male) (1) and (2) 3 to 14 Ω
Resistance
Between V30 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V30, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP02 (female) (97) or V30
Resistance Min. 1 MΩ
(female) (1)
If no failure is found by above checks, pump controller is defective. (Since this is an
3 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to ATT flow rate throttling EPC

HB365LC-3 40-951
FAILURE CODE [DXE4KY] 40 TROUBLESHOOTING

FAILURE CODE [DXE4KY] (ALL-K-PT03-410-20-B)

Action level Failure code Attachment Flow EPC Hot Short Circuit
Failure
― DXE4KY (Pump controller system)
Detail of fail-
Controller detects hot short circuit in attachment flow EPC.
ure
• Stops driving attachment flow rate adjustment EPC solenoid.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon
Attachment does not move.
on machine
• Drive current of attachment flow rate adjustment (service current) EPC solenoid can be
checked with monitoring function.
Related
(Code: 01700 attachment solenoid current)
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position and set machine in breaker mode (B).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector V30, and connect the T-adapter to female side.
1
harness 3. Turn the starting switch to ON position.
Voltage Between V30 (female) (1) and (2) Max. 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
2 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to ATT flow rate throttling EPC

40-952 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXE5KA]

FAILURE CODE [DXE5KA] (ALL-K-C083-410-00-B)

Action level Failure code Merge-divider Main Solenoid Open Circuit

Failure
L01 DXE5KA (Pump controller system)
Detail of fail- No current flows when pump controller drives merge-divider (main) EPC solenoid, so pump control-
ure ler determines that open circuit exists in merge-divider (main) EPC solenoid circuit.
Stops output command to merge-divider main solenoid and merge-divider SL solenoid to put pump
Action of in merging condition constantly.
controller Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position.
Phenomenon Sole operation speed of work equipment and swing is high in fine control mode (L).
on machine It is hard to steer the machine at travel.
• Drive current to merge-divider (main) EPC solenoid can be checked with monitoring func-
tion.
Related
(Code: 08000 Merge-divider main solenoid current)
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V23, and connect the T-adapter to male side.
Defective merge-divider
1
(main) EPC solenoid Between V23 (male) (1) and (2) 3 to 14 Ω
Resistance
Between V23 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
Defective circuit related 2. Disconnect the connector V23, and connect the T-adapter to female side.
2 to merge-divider main
3. Turn the starting switch to ON position.
solenoid
Voltage Between V23 (female) (1) and (2) 1 to 4.5 V
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V23, and connect the T-adapter to
each female side.
Open circuit in wiring har- Between CP02 (female) (112) and V23 (female) (1) Max. 1 Ω
3
ness
Between CP02 (female) (115) and V23 (female) (2) Max. 1 Ω
Resistance
Between CP02 (female) (117) and V23 (female) (2) Max. 1 Ω
Between CP02 (female) (120) and V23 (female) (2) Max. 1 Ω
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-953
FAILURE CODE [DXE5KA] 40 TROUBLESHOOTING

Circuit diagram related to merge-divider main solenoid

40-954 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXE5KB]

FAILURE CODE [DXE5KB] (ALL-K-C083-410-10-B)

Action level Failure code Merge-divider Main Solenoid Short Circuit

Failure
L01 DXE5KB (Pump controller system)
Detail of fail- Abnormal current flows when pump controller drives merge-divider (main) EPC solenoid, so pump
ure controller determines that short circuit exists in merge-divider (main) EPC solenoid circuit.
Stops output command to merge-divider main solenoid and merge-divider SL solenoid to put pump
Action of in merging condition constantly.
controller Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position.
Phenomenon Sole operation speed of work equipment and swing is high in fine control mode (L).
on machine It is hard to steer the machine at travel.
• Drive current to merge-divider (main) EPC solenoid can be checked with monitoring func-
tion.
Related
(Code: 08000 Merge-divider main solenoid current)
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V23, and connect the T-adapter to male side.
Defective merge-divider
1
(main) EPC solenoid Between V23 (male) (1) and (2) 3 to 14 Ω
Resistance
Between V23 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V23, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP02 (female) (112) or
Resistance Min. 1 MΩ
V23 (female) (1)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector V23, and connect the T-adapter to female side.
3
harness 3. Turn the starting switch to ON position.
Voltage Between V23 (female) (1) and (2) 1 to 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-955
FAILURE CODE [DXE5KB] 40 TROUBLESHOOTING

Circuit diagram related to merge-divider main solenoid

40-956 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXE6KA]

FAILURE CODE [DXE6KA] (ALL-K-C087-410-00-B)

Action level Failure code Merge-divider LS solenoid open circuit

Failure
L01 DXE6KA (Pump controller system)
Detail of fail- No current flows when pump controller drives merge-divider (LS) EPC solenoid, so pump controller
ure determines that open circuit exists in merge-divider (LS) EPC solenoid circuit.
Stops output command to merge-divider main solenoid and merge-divider SL solenoid to put pump
Action of in merging condition constantly.
controller Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position.
Phenomenon Sole operation speed of work equipment and swing is high in fine control mode (L).
on machine It is hard to steer the machine at travel.
• Drive current to merge-divider (LS) EPC solenoid can be checked with monitoring func-
tion.
Related
(Code: 08001 Merge-divider LS solenoid current)
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine and travel lever is operated independently.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V24, and connect the T-adapter to male side.
Defective merge-divider
1
(LS) EPC solenoid Between V24 (male) (1) and (2) 3 to 14 Ω
Resistance
Between V24 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
Defective circuit related 2. Disconnect the connector V24, and connect the T-adapter to female side.
2 to merge-divider (LS)
3. Turn the starting switch to ON position.
EPC solenoid
Voltage Between V24 (female) (1) and (2) 1 to 4.5 V
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V24, and connect the T-adapter to
each female side.
Open circuit in wiring har- Between CP02 (female) (89) and V24 (female) (1) Max. 1 Ω
3
ness
Between CP02 (female) (115) and V24 (female) (2) Max. 1 Ω
Resistance
Between CP02 (female) (117) and V24 (female) (2) Max. 1 Ω
Between CP02 (female) (120) and V24 (female) (2) Max. 1 Ω
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-957
FAILURE CODE [DXE6KA] 40 TROUBLESHOOTING

Circuit diagram related to merge-divider LS solenoid

40-958 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXE6KB]

FAILURE CODE [DXE6KB] (ALL-K-C087-410-10-B)

Action level Failure code Merge-divider LS solenoid short circuit

Failure
L01 DXE6KB (Pump controller system)
Detail of fail- Abnormal current flows when pump controller drives merge-divider (LS) EPC solenoid, so pump
ure controller determines that short circuit exists in merge-divider (LS) EPC solenoid circuit.
Stops output command to merge-divider main solenoid and merge-divider SL solenoid to put pump
Action of in merging condition constantly.
controller Even if cause of failure disappears, machine does not become normal until starting switch is turned
to OFF position.
Phenomenon Sole operation speed of work equipment and swing is high in fine control mode (L).
on machine It is hard to steer the machine at travel.
• Drive current to merge-divider (LS) EPC solenoid can be checked with monitoring func-
tion.
Related
(Code: 08001 Merge-divider LS solenoid current)
information
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Start engine and travel lever is operated independently.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector V24, and connect the T-adapter to male side.
Defective merge-divider
1
(LS) EPC solenoid Between V24 (male) (1) and (2) 3 to 14 Ω
Resistance
Between V24 (male) (1) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and V24, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either CP02 (female) (89) or V24
Resistance Min. 1 MΩ
(female) (1)
1. Turn the starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect the connector V24, and connect the T-adapter to female side.
3
harness 3. Turn the starting switch to ON position.
Voltage Between V24 (female) (1) and (2) 1 to 4.5 V
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-959
FAILURE CODE [DXE6KB] 40 TROUBLESHOOTING

Circuit diagram related to merge-divider LS solenoid

40-960 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXE7KA]

FAILURE CODE [DXE7KA] (ALL-K-LTB4-410-00-B)

Action level Failure code Attachment Flow Regulating EPC 2 Solenoid Open Circuit
Failure
- DXE7KA (Pump controller system)
Detail of fail-
Controller detects open circuit in attachment flow rate adjustment EPC2 solenoid.
ure
• Stops driving attachment flow rate adjustment EPC1, EPC2, EPC3, and EPC4 solenoids.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon
Attachment does not move.
on machine
• Drive current of attachment flow rate adjustment EPC2 solenoid can be checked with
monitoring function (code: 01702).
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position and set machine in attachment mode
(ATT).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment
1 flow rate adjustment EPC 2. Disconnect connector V92, and connect T-adapter to male side.
2 (internal open circuit)
Resistance Between V92 (male) (1) and (2) 7 to 14 Ω
1. Turn starting switch to OFF position.
Open circuit, short circuit, 2. Disconnect connector V92, and connect T-adapter to female side.
ground fault, hot short 3. Turn starting switch to ON position.
2 circuit of wiring harness,
or defective pump con- 4. Shake the wiring harness by hand while measuring the voltage. If the volt-
troller age becomes 0 V while shaking, wiring harness is open.
Voltage Between V92 (female) (1) and (2) 1 to 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors CP02 and V92, and connect T-adapters to each fe-
Open circuit in wiring har- male side.
3
ness Between CP02 (female) (110) and V92 (female) (1) Max. 1 Ω
Resistance Between each of CP02 (female) (115), (117), (120) and
Max. 1 Ω
V92 (female) (2)
If no failure is found by preceding checks, pump controller is defective. (In case of
4 Defective pump controller an internal defect, troubleshooting is impossible as an assembly. Replace whole
assembly).

HB365LC-3 40-961
FAILURE CODE [DXE7KA] 40 TROUBLESHOOTING

Circuit diagram related to ATT flow rate adjustment EPC

40-962 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXE7KB]

FAILURE CODE [DXE7KB] (ALL-K-LTB4-410-10-B)

Action level Failure code Attachment Flow Regulating EPC 2 Solenoid Short Circuit
Failure
- DXE7KB (Pump controller system)
Detail of fail-
Controller detects short circuit in attachment flow rate adjustment EPC2 solenoid.
ure
• Stops driving attachment flow rate adjustment EPC1, EPC2, EPC3, and EPC4 solenoids.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon
Attachment does not move.
on machine
• Drive current of attachment flow rate adjustment EPC2 solenoid can be checked with
monitoring function (code: 01702).
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position and set machine in attachment mode
(ATT).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment
2. Disconnect connector V92, and connect T-adapter to male side.
flow rate adjustment EPC
1
2 (internal short circuit or Between V92 (male) (1) and (2) 7 to 14 Ω
ground fault) Resistance
Between V92 (male) (1) and ground Min. 1 MΩ
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors CP02 and V92, and connect T-adapters to each fe-
2 harness (contact with male side.
ground circuit)
Between ground and CP02 (female) (110) or V92 (fe-
Resistance Min. 1 MΩ
male) (1)
If no failure is found by preceding checks, pump controller is defective. (In case of
3 Defective pump controller an internal defect, troubleshooting is impossible as an assembly. Replace whole
assembly).

HB365LC-3 40-963
FAILURE CODE [DXE7KB] 40 TROUBLESHOOTING

Circuit diagram related to ATT flow rate adjustment EPC

40-964 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXE7KY]

FAILURE CODE [DXE7KY] (ALL-K-LTB4-410-20-B)

Action level Failure code Attachment Flow Regulating EPC 2 Hot Short Circuit
Failure
- DXE7KY (Pump controller system)
Detail of fail-
Controller detects hot short circuit in attachment flow regulating EPC 2.
ure
• Stops driving attachment flow rate adjustment EPC1, EPC2, EPC3, and EPC4 solenoids.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon
Attachment does not move.
on machine
• Drive current of attachment flow rate adjustment EPC2 solenoid can be checked with
monitoring function (code: 01702).
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position and set machine in attachment mode
(ATT).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment
2. Disconnect connector V92, and connect T-adapter to male side.
flow rate adjustment EPC
1
2 (internal short circuit or Between V92 (male) (1) and (2) 7 to 14 Ω
ground fault) Resistance
Between V92 (male) (1) and ground Min. 1 MΩ
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector V92, and connect T-adapter to female side.
2
harness 3. Turn starting switch to ON position.
Voltage Between V92 (female) (1) and ground Max. 4.5 V
If no failure is found by preceding checks, pump controller is defective. (In case of
3 Defective pump controller an internal defect, troubleshooting is impossible as an assembly. Replace whole
assembly).

HB365LC-3 40-965
FAILURE CODE [DXE7KY] 40 TROUBLESHOOTING

Circuit diagram related to ATT flow rate adjustment EPC

40-966 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXE8KA]

FAILURE CODE [DXE8KA] (ALL-K-LTB5-410-00-B)

Action level Failure code Attachment Flow Regulating EPC 3 Solenoid Open Circuit
Failure
- DXE8KA (Pump controller system)
Detail of fail-
Controller detects open circuit in attachment flow rate adjustment EPC3 solenoid.
ure
• Stops driving attachment flow rate adjustment EPC1, EPC2, EPC3, and EPC4 solenoids.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon
Attachment does not move.
on machine
• Drive current of attachment flow rate adjustment EPC3 solenoid can be checked with
monitoring function (code: 01703).
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position and set machine in attachment mode
(ATT).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment
1 flow rate adjustment EPC 2. Disconnect connector V93, and connect T-adapter to male side.
3 (internal open circuit)
Resistance Between V93 (male) (1) and (2) 7 to 14 Ω
1. Turn starting switch to OFF position.
Open circuit, short circuit, 2. Disconnect connector V93, and connect T-adapter to female side.
ground fault, hot short 3. Turn starting switch to ON position.
2 circuit of wiring harness,
or defective pump con- 4. Shake the wiring harness by hand while measuring the voltage. If the volt-
troller age becomes 0 V while shaking, wiring harness is open.
Voltage Between V93 (female) (1) and (2) 1 to 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors CP02 and V93, and connect T-adapters to each fe-
Open circuit in wiring har- male side.
3
ness Between CP02 (female) (87) and V93 (female) (1) Max. 1 Ω
Resistance BetweenV93 (female) (2) and CP02 (female) (115),
Max. 1 Ω
(117), and (120)
If no failure is found by preceding checks, pump controller is defective. (In case of
4 Defective pump controller an internal defect, troubleshooting is impossible as an assembly. Replace whole
assembly).

HB365LC-3 40-967
FAILURE CODE [DXE8KA] 40 TROUBLESHOOTING

Circuit diagram related to ATT flow rate adjustment EPC

40-968 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXE8KB]

FAILURE CODE [DXE8KB] (ALL-K-LTB5-410-10-B)

Action level Failure code Attachment Flow Regulating EPC 3 Solenoid Short Circuit
Failure
- DXE8KB (Pump controller system)
Detail of fail-
Controller detects short circuit in attachment flow rate adjustment EPC3 solenoid.
ure
• Stops driving attachment flow rate adjustment EPC1, EPC2, EPC3, and EPC4 solenoids.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon
Attachment does not move.
on machine
• Drive current of attachment flow rate adjustment EPC3 solenoid can be checked with
monitoring function (code: 01703).
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position and set machine in attachment mode
(ATT).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment
2. Disconnect connector V93, and connect T-adapter to male side.
flow rate adjustment EPC
1
3 (internal short circuit or Between V93 (male) (1) and (2) 7 to 14 Ω
ground fault) Resistance
Between V93 (male) (1) and ground Min. 1 MΩ
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors CP02 and V93, and connect T-adapters to each fe-
2 harness (contact with male side.
ground circuit)
Between CP02 (female) (87) and ground, or between
Resistance Min. 1 MΩ
V91 (female) (1) and ground
If no failure is found by preceding checks, pump controller is defective. (In case of
3 Defective pump controller an internal defect, troubleshooting is impossible as an assembly. Replace whole
assembly).

HB365LC-3 40-969
FAILURE CODE [DXE8KB] 40 TROUBLESHOOTING

Circuit diagram related to ATT flow rate adjustment EPC

40-970 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXE8KY]

FAILURE CODE [DXE8KY] (ALL-K-LTB5-410-20-B)

Action level Failure code Attachment Flow Regulating EPC 3 Hot Short Circuit
Failure
- DXE8KY (Pump controller system)
Detail of fail-
Controller detects hot short circuit in attachment flow regulating EPC 3.
ure
• Stops driving attachment flow rate adjustment EPC1, EPC2, EPC3, and EPC4 solenoids.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon
Attachment does not move.
on machine
• Drive current of attachment flow rate adjustment EPC3 solenoid can be checked with
monitoring function (code: 01703).
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position and set machine in attachment mode
(ATT).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment
2. Disconnect connector V93, and connect T-adapter to male side.
flow rate adjustment EPC
1
3 (internal short circuit or Between V93 (male) (1) and (2) 7 to 14 Ω
ground fault) Resistance
Between V93 (male) (1) and ground Min. 1 MΩ
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector V93, and connect T-adapter to female side.
2
harness 3. Turn starting switch to ON position.
Voltage Between V93 (female) (1) and ground Max. 4.5 V
If no failure is found by preceding checks, pump controller is defective. (In case of
3 Defective pump controller an internal defect, troubleshooting is impossible as an assembly. Replace whole
assembly).

HB365LC-3 40-971
FAILURE CODE [DXE8KY] 40 TROUBLESHOOTING

Circuit diagram related to ATT flow rate adjustment EPC

40-972 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXE9KA]

FAILURE CODE [DXE9KA] (ALL-K-LTB6-410-00-B)

Action level Failure code Attachment Flow Regulating EPC 4 Solenoid Open Circuit
Failure
- DXE9KA (Pump controller system)
Detail of fail-
Controller detects open circuit in attachment flow rate adjustment EPC4 solenoid.
ure
• Stops driving attachment flow rate adjustment EPC1, EPC2, EPC3, and EPC4 solenoids.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon
Attachment does not move.
on machine
• Drive current of attachment flow rate adjustment EPC4 solenoid can be checked with
monitoring function (code: 01704).
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position and set machine in attachment mode
(ATT).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment
1 flow rate adjustment EPC 2. Disconnect connector V94, and connect T-adapter to male side.
4 (internal open circuit)
Resistance Between V94 (male) (1) and (2) 7 to 14 Ω
1. Turn starting switch to OFF position.
Open circuit, short circuit, 2. Disconnect connector V94, and connect T-adapter to female side.
ground fault, hot short 3. Turn starting switch to ON position.
2 circuit of wiring harness,
or defective pump con- 4. Shake the wiring harness by hand while measuring the voltage. If the volt-
troller age becomes 0 V while shaking, wiring harness is open.
Voltage Between V94 (female) (1) and (2) 1 to 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors CP02 and V92, and connect T-adapters to each fe-
Open circuit in wiring har- male side.
3
ness Between CP02 (female) (95) and V94 (female) (1) Max. 1 Ω
Resistance BetweenV94 (female) (2) and CP02 (female) (115),
Max. 1 Ω
(117), and (120)
If no failure is found by preceding checks, pump controller is defective. (In case of
4 Defective pump controller an internal defect, troubleshooting is impossible as an assembly. Replace whole
assembly).

HB365LC-3 40-973
FAILURE CODE [DXE9KA] 40 TROUBLESHOOTING

Circuit diagram related to ATT flow rate adjustment EPC

40-974 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXE9KB]

FAILURE CODE [DXE9KB] (ALL-K-LTB6-410-10-B)

Action level Failure code Attachment Flow Regulating EPC 4 Solenoid Short Circuit
Failure
- DXE9KB (Pump controller system)
Detail of fail-
Controller detects short circuit in attachment flow rate adjustment EPC4 solenoid.
ure
• Stops driving attachment flow rate adjustment EPC1, EPC2, EPC3, and EPC4 solenoids.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon
Attachment does not move.
on machine
• Drive current of attachment flow rate adjustment EPC4 solenoid can be checked with
monitoring function (code: 01704).
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position and set machine in attachment mode
(ATT).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment
2. Disconnect connector V94, and connect T-adapter to male side.
flow rate adjustment EPC
1
4 (internal short circuit or Between V94 (male) (1) and (2) 7 to 14 Ω
ground fault) Resistance
Between V94 (male) (1) and ground Min. 1 MΩ
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors CP02 and V94, and connect T-adapters to each fe-
2 harness (contact with male side.
ground circuit)
Between CP02 (female) (95) and ground, or between
Resistance Min. 1 MΩ
V94 (female) (1) and ground
If no failure is found by preceding checks, pump controller is defective. (In case of
3 Defective pump controller an internal defect, troubleshooting is impossible as an assembly. Replace whole
assembly).

HB365LC-3 40-975
FAILURE CODE [DXE9KB] 40 TROUBLESHOOTING

Circuit diagram related to ATT flow rate adjustment EPC

40-976 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXE9KY]

FAILURE CODE [DXE9KY] (ALL-K-LTB6-410-20-B)

Action level Failure code Attachment Flow Regulating EPC 4 Hot Short Circuit
Failure
- DXE9KY (Pump controller system)
Detail of fail-
Controller detects hot short circuit in attachment flow regulating EPC 4.
ure
• Stops driving attachment flow rate adjustment EPC1, EPC2, EPC3, and EPC4 solenoids.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon
Attachment does not move.
on machine
• Drive current of attachment flow rate adjustment EPC4 solenoid can be checked with
monitoring function (code: 01704).
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position and set machine in attachment mode
(ATT).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment
2. Disconnect connector V94, and connect T-adapter to male side.
flow rate adjustment EPC
1
4 (internal short circuit or Between V94 (male) (1) and (2) 7 to 14 Ω
ground fault) Resistance
Between V94 (male) (1) and ground Min. 1 MΩ
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector V94, and connect T-adapter to female side.
2
harness 3. Turn starting switch to ON position.
Voltage Between V94 (female) (1) and ground Max. 4.5 V
If no failure is found by preceding checks, pump controller is defective. (In case of
3 Defective pump controller an internal defect, troubleshooting is impossible as an assembly. Replace whole
assembly).

HB365LC-3 40-977
FAILURE CODE [DXE9KY] 40 TROUBLESHOOTING

Circuit diagram related to ATT flow rate adjustment EPC

40-978 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXEAKA]

FAILURE CODE [DXEAKA] (ALL-K-LTB7-410-00-B)

Action level Failure code Attachment Flow Regulating EPC 5 Solenoid Open Circuit
Failure
- DXEAKA (Pump controller system)
Detail of fail-
Controller detects open circuit in attachment flow rate adjustment EPC1 solenoid.
ure
• Stops driving attachment flow rate adjustment EPC1, EPC2, EPC3, and EPC4 solenoids.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon
Attachment does not move.
on machine
• Drive current of attachment flow rate adjustment EPC1 solenoid can be checked with
monitoring function (code: 01701).
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position and set machine in attachment mode
(ATT).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment
1 flow rate adjustment EPC 2. Disconnect connector V91, and connect T-adapter to male side.
1 (internal open circuit)
Resistance Between V91 (male) (1) and (2) 7 to 14 Ω
1. Turn starting switch to OFF position.
Open circuit, short circuit, 2. Disconnect connector V91, and connect T-adapter to female side.
ground fault, hot short 3. Turn starting switch to ON position.
2 circuit of wiring harness,
or defective pump con- 4. Shake the wiring harness by hand while measuring the voltage. If the volt-
troller age becomes 0 V while shaking, wiring harness is open.
Voltage Between V91 (female) (1) and (2) 1 to 4.5 V
1. Turn starting switch to OFF position.
2. Disconnect connectors CP02 and V92, and connect T-adapters to each fe-
Open circuit in wiring har- male side.
3
ness Between CP02 (female) (102) and V91 (female) (1) Max. 1 Ω
Resistance Between each of CP02 (female) (115), (117), (120) and
Max. 1 Ω
V91 (female) (2)
If no failure is found by preceding checks, pump controller is defective. (In case of
4 Defective pump controller an internal defect, troubleshooting is impossible as an assembly. Replace whole
assembly).

HB365LC-3 40-979
FAILURE CODE [DXEAKA] 40 TROUBLESHOOTING

Circuit diagram related to ATT flow rate adjustment EPC

40-980 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXEAKB]

FAILURE CODE [DXEAKB] (ALL-K-LTB7-410-10-B)

Action level Failure code Attachment Flow Regulating EPC 5 Solenoid Short Circuit
Failure
- DXEAKB (Pump controller system)
Detail of fail-
Controller detects short circuit in attachment flow rate adjustment EPC1 solenoid.
ure
• Stops driving attachment flow rate adjustment EPC1, EPC2, EPC3, and EPC4 solenoids.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon
Attachment does not move.
on machine
• Drive current of attachment flow rate adjustment EPC1 solenoid can be checked with
monitoring function (code: 01701).
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position and set machine in attachment mode
(ATT).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment
2. Disconnect connector V91, and connect T-adapter to male side.
flow rate adjustment EPC
1
1 (internal short circuit or Between V91 (male) (1) and (2) 7 to 14 Ω
ground fault) Resistance
Between V91 (male) (1) and ground Min. 1 MΩ
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Disconnect connectors CP02 and V91, and connect T-adapters to each fe-
2 harness (contact with male side.
ground circuit)
Between ground and CP02 (female) (102) or V91 (fe-
Resistance Min. 1 MΩ
male) (1)
If no failure is found by preceding checks, pump controller is defective. (In case of
3 Defective pump controller an internal defect, troubleshooting is impossible as an assembly. Replace whole
assembly).

HB365LC-3 40-981
FAILURE CODE [DXEAKB] 40 TROUBLESHOOTING

Circuit diagram related to ATT flow rate adjustment EPC

40-982 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DXEAKY]

FAILURE CODE [DXEAKY] (ALL-K-LTB7-410-20-B)

Action level Failure code Attachment Flow Regulating EPC 1 Hot Short Circuit
Failure
- DXEAKY (Pump controller system)
Detail of fail-
Controller detects hot short circuit in attachment flow regulating EPC 1.
ure
• Stops driving attachment flow rate adjustment EPC1, EPC2, EPC3, and EPC4 solenoids.
Action of
• Even if cause of failure disappears, machine does not become normal until starting switch
controller
is turned to OFF position.
Phenomenon
Attachment does not stop move.
on machine
• Drive current of attachment flow rate adjustment EPC1 solenoid can be checked with
monitoring function (code: 01701).
Related
• After repairing, check if the failure code is cleared by the following procedure.
information
Procedure: Turn the starting switch to ON position and set machine in attachment mode
(ATT).

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective attachment
2. Disconnect connector V91, and connect T-adapter to male side.
flow rate adjustment EPC
1
1 (internal short circuit or Between V91 (male) (1) and (2) 7 to 14 Ω
ground fault) Resistance
Between V91 (male) (1) and ground Min. 1 MΩ
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector V91, and connect T-adapter to female side.
2
harness 3. Turn starting switch to ON position.
Voltage Between V91 (female) (1) and ground Max. 4.5 V
If no failure is found by preceding checks, pump controller is defective. (In case of
3 Defective pump controller an internal defect, troubleshooting is impossible as an assembly. Replace whole
assembly).

HB365LC-3 40-983
FAILURE CODE [DXEAKY] 40 TROUBLESHOOTING

Circuit diagram related to ATT flow rate adjustment EPC

40-984 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DY20KA]

FAILURE CODE [DY20KA] (ALL-K-K730-410-00-B)

Action level Failure code Wiper Motor Open Circuit

Failure
― DY20KA (Pump controller system)
Detail of fail- A W signal at the top end of wiper motor working area is not input during operation of the windshield
ure wiper.
Action of Stops output for operation to wiper motor.
controller If cause of failure disappears, machine becomes normal by itself.
Phenomenon
Wiper motor does not work.
on machine
• Signal input (ON/OFF) of W contact signal that indicates wiper working area end can be
checked with monitoring function.
(Code: 02204 Switch input 5)
Related
• As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
information be measured at pump controller connector.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position and turn wiper switch to INT or ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector M05, and connect the T-adapter to female side.
Windshield wiper position:
Max. 1 Ω
Working area top end
Between M05 (female) (6)
and (5) Windshield wiper position:
Other than working area Min. 1 MΩ
top end
1 Defective wiper motor
Windshield wiper position:
Max. 1 Ω
Resistance Between M05 (female) (4) Stowage area
and (5) Windshield wiper position:
Min. 1 MΩ
Working area
Between M05 (female) (1) and (3) Max. 20 Ω
Between M05 (female) (1) and ground Min. 1 MΩ
Between M05 (female) (3) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01, CP02 and M05, and connect the T-
adapter to female side of CP01 and CP02 and male side of M05.
Open circuit in wiring har- Between CP02 (female) (119) and M05 (male) (3) Max. 1 Ω
2
ness
Between CP02 (female) (114) and M05 (male) (1) Max. 1 Ω
Resistance
Between CP01 (female) (56) and M05 (male) (6) Max. 1 Ω
Between M05 (male) (5) and ground Max. 1 Ω
If no failure is found by above checks, pump controller is defective. (Since this is an
3 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-985
FAILURE CODE [DY20KA] 40 TROUBLESHOOTING

Circuit diagram related to wiper

40-986 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DY20MA]

FAILURE CODE [DY20MA] (ALL-K-K730-410-10-B)

Action level Failure code Wiper Motor Defective Function

Failure
― DY20MA (Pump controller system)
Detail of fail-
A P signal in wiper motor stowage area is not input at the stowage of the windshield wiper.
ure
Action of Stops output for resting to wiper motor.
controller If cause of failure disappears, machine becomes normal by itself.
Phenomenon
Windshield wiper is not stowed.
on machine
• Condition of P contact signal of wiper stowage area can be checked with monitoring func-
tion.
(Code: 02204 Switch input 5)
Related • As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
information be measured at pump controller connector.
• After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position and turn wiper switch from INT/ON to OFF
position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector M05, and connect the T-adapter to female side.
Windshield wiper position:
Max. 1 Ω
Working area top end
Between M05 (female) (6)
and (5) Windshield wiper position:
Other than working area Min. 1 MΩ
top end
1 Defective wiper motor
Windshield wiper position:
Max. 1 Ω
Resistance Between M05 (female) (4) Stowage area
and (5) Windshield wiper position:
Min. 1 MΩ
Working area
Between M05 (female) (1) and (3) Max. 20 Ω
Between M05 (female) (1) and ground Min. 1 MΩ
Between M05 (female) (3) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP01, CP02 and M05, and connect the T-
adapter to female side of CP01 and CP02 and male side of M05.
Open circuit in wiring har- Between CP02 (female) (119) and M05 (male) (3) Max. 1 Ω
2
ness
Between CP02 (female) (114) and M05 (male) (1) Max. 1 Ω
Resistance
Between CP01 (female) (75) and M05 (male) (4) Max. 1 Ω
Between M05 (male) (5) and ground Max. 1 Ω
If no failure is found by above checks, pump controller is defective. (Since this is an
3 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-987
FAILURE CODE [DY20MA] 40 TROUBLESHOOTING

Circuit diagram related to wiper

40-988 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DY2CKB]

FAILURE CODE [DY2CKB] (ALL-K-K7C0-410-00-B)

Action level Failure code Washer Motor Short Circuit

Failure
― DY2CKB (Pump controller system)
Detail of fail- When outputting current to window washer motor, abnormal current flows and short circuit is detect-
ure ed.
Stops output to washer motor.
Action of
Even if cause of failure disappears, machine does not become normal until starting switch is turned
controller
to OFF position.
Phenomenon
Wind washer does not operate.
on machine
Related After repairing, check if the failure code is cleared by the following procedure.
information Procedure: Turn starting switch to ON position and turn washer switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1 Defective fuse
2 Defective washer motor
3 Defective diode
Ground fault in wiring
4
harness
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.4 in fuse box F01. Check visually if it is not burnt out.
4. When it is not burnt out, check if it is blown out by continuity test.
• When it is burnt out, check the wiring harness for ground fault.
• When it is not burnt out but it has no continuity, replace the fuse.
1. Turn the starting switch to OFF position.
2. Disconnect the connector M06 and connect the T-adapter to male side.
Between M06 (male) (1) and (2) 5 to 20 Ω
Resistance
Between ground and M06 (male) (1) or (2) Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connector D02, and connect the T-adapter to male side.
REMARK
Measure it with diode range.
Between D02 (male) (6)(+) and (2)(-) Continuity
Continuity No continui-
Between D02 (male) (2)(+) and (6)(-)
ty
1. Turn the starting switch to OFF position.
2. Remove the fuse No.4 in fuse box F01
3. Disconnect the connectors M06, CP01, and D02, and connect the T-adapt-
er to any female side.
Between ground and any of F01-4, M06 (female) (2),
Min. 1 MΩ
and D02 (female) (2)
Resistance
Between ground and any of CP01 (female) (3), M06
Min. 1 MΩ
(female) (1), and D02 (female) (6)

HB365LC-3 40-989
FAILURE CODE [DY2CKB] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Remove the fuse No.4 in fuse box F01
3. Disconnect the connectors CP01 and M06, and connect the T-adapter to
female side of CP01.
Hot short circuit in wiring
5 4. Turn the starting switch to ON position.
harness
REMARK
Ignore failure codes displayed on machine monitor.
Voltage Between CP01 (female) (3) and ground Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an
6 Defective pump controller
internal defect, troubleshooting cannot be performed).

Circuit diagram related to windshield washer drive system

40-990 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DY2DKB]

FAILURE CODE [DY2DKB] (ALL-K-K730-410-30-B)

Action level Failure code Wiper Motor (Normal Rotation) Short Circuit
Failure
― DY2DKB (Pump controller system)
Detail of fail- When power to normal rotation side of wiper motor drive is supplied, short circuit was detected be-
ure cause of abnormal current flown to the circuit.
Stops output to wiper motor drive normal rotation side.
Action of
Even if cause of failure disappears, machine does not become normal until starting switch is turned
controller
to OFF position.
Phenomenon
Windshield wiper does not work.
on machine
• As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
Related be measured at pump controller connector.
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position and turn wiper switch to INT or ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector M05, and connect the T-adapter to female side.
Windshield wiper position:
Max. 1 Ω
Working area top end
Between M05 (female) (6)
and (5) Windshield wiper position:
Other than working area Min. 1 MΩ
top end
1 Defective wiper motor
Windshield wiper position:
Max. 1 Ω
Resistance Between M05 (female) (4) Stowage area
and (5) Windshield wiper position:
Min. 1 MΩ
Working area
Between M05 (female) (1) and (3) Max. 20 Ω
Between M05 (female) (1) and ground Min. 1 MΩ
Between M05 (female) (3) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and M05, and connect the T-adapter to
Ground fault in wiring
2 either CP02 (female) or M05 (male).
harness
Between ground and either CP02 (female) (119) or
Resistance Min. 1 MΩ
M05 (male) (3)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and M05, and connect the T-adapter to
Short circuit in wiring har-
3 either CP02 (female) or M05 (male).
ness
Between CP02 (female) (119) and (114), or between
Resistance Min. 1 MΩ
M05 (male) (1) and (3)
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-991
FAILURE CODE [DY2DKB] 40 TROUBLESHOOTING

Circuit diagram related to wiper

40-992 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [DY2EKB]

FAILURE CODE [DY2EKB] (ALL-K-K730-410-40-B)

Action level Failure code Wiper Motor (Reverse Rotation) Short Circuit
Failure
― DY2EKB (Pump controller system)
Detail of fail- When driving reverse side of wiper motor drive circuit, short circuit was detected because of abnor-
ure mal current flown to the circuit.
Stops output to wiper motor drive reverse side.
Action of
Even if cause of failure disappears, machine does not become normal until starting switch is turned
controller
to OFF position.
Phenomenon
Windshield wiper does not work.
on machine
• As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
Related be measured at pump controller connector.
information • After repairing, check if the failure code is cleared by the following procedure.
Procedure: Turn starting switch to ON position and turn wiper switch to INT or ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector M05, and connect the T-adapter to female side.
Windshield wiper position:
Max. 1 Ω
Working area top end
Between M05 (female) (6)
and (5) Windshield wiper position:
Other than working area Min. 1 MΩ
top end
1 Defective wiper motor
Windshield wiper position:
Max. 1 Ω
Resistance Between M05 (female) (4) Stowage area
and (5) Windshield wiper position:
Min. 1 MΩ
Working area
Between M05 (female) (1) and (3) Max. 20 Ω
Between M05 (female) (1) and ground Min. 1 MΩ
Between M05 (female) (3) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and M05, and connect the T-adapter to
Ground fault in wiring
2 either CP02 (female) or M05 (male).
harness
Between ground and either CP02 (female) (114) or
Resistance Min. 1 MΩ
M05 (male) (1)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CP02 and M05, and connect the T-adapter to
Short circuit in wiring har-
3 either CP02 (female) or M05 (male).
ness
Between CP02 (female) (119) and (114), or between
Resistance Min. 1 MΩ
M05 (male) (1) and (3)
If no failure is found by above checks, pump controller is defective. (Since this is an
4 Defective pump controller
internal defect, troubleshooting cannot be performed).

HB365LC-3 40-993
FAILURE CODE [DY2EKB] 40 TROUBLESHOOTING

Circuit diagram related to wiper

40-994 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA00NS]

FAILURE CODE [GA00NS] (ALL-K-PQJB-410-60-B)

Action level Failure code Hybrid equipment overheat

Failure
L02 GA00NS (Hybrid controller system)

• Temperature of either of hybrid components exceeds the following system stop tempera-
ture.
Detail of fail- • Swing motor coil: 160 °C, motor-generator: 190 °C
ure • Temperature of each part inside inverter
Booster transformer: 130 °C, booster IGBT junction: 135 °C, booster IGBT base: 100 °C,
swing motor IGBT junction: 135 °C, motor-generator IGBT base: 100 °C
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related
Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information
If other failure codes are displayed, perform troubleshooting for them first.

No. Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting for “ELECTRIC SWING MOTOR TEMPERATURE IN-
Defective hybrid cooling CREASES ABNORMALLY”, “MOTOR-GENERATOR TEMPERATURE INCREAS-
1
system circuit ES ABNORMALLY”, “INVERTER TEMPERATURE INCREASES ABNORMALLY”,
“CAPACITOR TEMPERATURE INCREASES ABNORMALLY” in Y mode.

HB365LC-3 40-995
FAILURE CODE [GA01KA] 40 TROUBLESHOOTING

FAILURE CODE [GA01KA] (ALL-K-PQJE-410-10-B)

Action level Failure code Power cable interlock open circuit

Failure
L03 GA01KA (Hybrid controller system)
Detail of fail-
Open circuit or short circuit of power cable interlock circuit is detected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

• Check if the connector of power cable is fitted correctly and there is no film
1 Defective power cable breakage, etc.
• Check if the cover of the connecting part is not coming off.
1. Turn the starting switch to OFF position.
2. Disconnect connector GM01, and connect T-adapter to male side.
Defective motor-genera-
2
tor Between GM01 (male) (7) and (8) Max. 1 Ω
Resistance
Between ground and either GM01 (female) (7) or (8) Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect connector PM01, and connect T-adapter to male side.
Defective electric swing
3
motor Between PM01 (male) (9) and (10) Max. 1 Ω
Resistance
Between ground and either PM01 (male) (9) or (10) Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02, PM01, and GM01, and connect the T-
adapter to each female side.
Open circuit in wiring har-
4
ness Between HC02 (female) (14) and PM01 (female) (10) Max. 1 Ω
Resistance Between HC02 (female) (24) and GM01 (female) (7) Max. 1 Ω
Between PM01 (female) (9) and GM01 (female) (8) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02, PM01 and GM01, and connect the T-
adapter to any female side.
Between ground and either HC02 (female) (14) or
Ground fault in wiring Min. 1 MΩ
5 PM01 (female) (10)
harness
Between ground and either HC02 (female) (24) or
Resistance Min. 1 MΩ
GM01 (female) (7)
Between ground and either PM01 (female) (9) or
Min. 1 MΩ
GM01 (female) (8)

40-996 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA01KA]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect connector HC02, and connect T-adapter to female side.
Hot short circuit in wiring
6 3. Turn the starting switch to ON position.
harness
Between ground and either HC02 (female) (14) or
Voltage Max. 1 V
HC02 (female) (24)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
7
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to power cable interlock

HB365LC-3 40-997
FAILURE CODE [GA02KZ] 40 TROUBLESHOOTING

FAILURE CODE [GA02KZ] (ALL-K-PQJE-410-20-B)

Action level Failure code DC Line open and short circuit

Failure
L04 GA02KZ (Hybrid controller system)
Detail of fail-
Insulation of cable connecting capacitor and inverter is deteriorated.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

• Check if the connector of power cable is fitted correctly and there is no film
1 Defective power cable breakage, etc.
• Check if the cover of the connecting part is not coming off.
1. Turn the starting switch to OFF position.
2. Disconnect the inverter side and the capacitor side of connectors HC06
Open circuit in power ca- and HB01.
2 ble Between HC06 (DC+) (female) and capacitor side (DC
(capacitor) Max. 1 Ω
+) (female)
Resistance
Between HB01(DC-) (female) and capacitor side (DC-)
Max. 1 Ω
(female)
1. Turn the starting switch to OFF position.
2. Disconnect the inverter side and the capacitor side of connectors HC06
and HB01.
REMARK
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
Deterioration of insulation
• Measure it by mega-ohm tester.
3 in power cable
(capacitor) Between HC06 (DC+) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HC06 (DC+) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)
Resistance
Between HB01 (DC-) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HB01 (DC-) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)

40-998 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA02KZ]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the inverter side of connectors HC06(DC+) and HB01(DC-).
REMARK
• Wipe dirt of capacitor (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
Deterioration of insulation
4
in capacitor system Between HC06 (DC+) (male): tester (red) and capaci-
Min. 10 MΩ
tor (case): tester (black)
Between HC06 (DC+) (male): tester (black) and capac-
Min. 10 MΩ
itor (case): tester (red)
Resistance
Between HB01 (DC-) (male): tester (red) and capacitor
Min. 10 MΩ
(case): tester (black)
Between HB01 (DC-) (male): tester (black) and capaci-
Min. 10 MΩ
tor (case): tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
5
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

Place of shield (Q part)

HB365LC-3 40-999
FAILURE CODE [GA02KZ] 40 TROUBLESHOOTING

Circuit diagram related to high-voltage equipment

40-1000 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA04KG]

FAILURE CODE [GA04KG] (ALL-K-PQGF-410-00-B)

Action level Failure code Hardware source voltage high error in DC line before boosting
Failure
L03 GA04KG (Hybrid controller system)
Detail of fail-
Hardware detects 466 V or more of capacitor voltage.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE

Related
Use electric charge release tool (796-426-1800) to release electric charge of capacitor.

information • Capacitor voltage can be checked with monitoring function. (Code: 09300)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the inverter side and the capacitor side of connectors HC06
Open circuit in power ca- and HB01.
1 ble Between HC06 (DC+) (female) and capacitor side (DC
(capacitor) Max. 1 Ω
+) (female)
Resistance
Between HB01(DC-) (female) and capacitor side (DC-)
Max. 1 Ω
(female)
1. Turn the starting switch to OFF position.
2. Disconnect the inverter side and the capacitor side of connectors HC06
and HB01.
REMARK
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
Deterioration of insulation
• Measure it by mega-ohm tester.
2 in power cable
(capacitor) Between HC06 (DC+) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HC06 (DC+) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)
Resistance
Between HB01 (DC-) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HB01 (DC-) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)

HB365LC-3 40-1001
FAILURE CODE [GA04KG] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the inverter side of connectors HC06(DC+) and HB01(DC-).
REMARK
• Wipe dirt of capacitor (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
Deterioration of insulation
3
in capacitor system Between HC06 (DC+) (male): tester (red) and capaci-
Min. 10 MΩ
tor (case): tester (black)
Between HC06 (DC+) (male): tester (black) and capac-
Min. 10 MΩ
itor (case): tester (red)
Resistance
Between HB01 (DC-) (male): tester (red) and capacitor
Min. 10 MΩ
(case): tester (black)
Between HB01 (DC-) (male): tester (black) and capaci-
Min. 10 MΩ
tor (case): tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
4
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

Place of shield (Q part)

40-1002 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA04KG]

Circuit diagram related to high-voltage equipment

HB365LC-3 40-1003
FAILURE CODE [GA05KG] 40 TROUBLESHOOTING

FAILURE CODE [GA05KG] (ALL-K-PQGF-410-10-B)

Action level Failure code Software power voltage high error in DC line before boosting
Failure
L03 GA05KG (Hybrid controller system)
Detail of fail-
Software detects 440 V or more of capacitor voltage.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE

Related
Use electric charge release tool (796-426-1800) to release electric charge of capacitor.

information • Capacitor voltage can be checked with monitoring function. (Code: 09300)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the inverter side and the capacitor side of connectors HC06
Open circuit in power ca- and HB01.
1 ble Between HC06 (DC+) (female) and capacitor side (DC
(capacitor) Max. 1 Ω
+) (female)
Resistance
Between HB01(DC-) (female) and capacitor side (DC-)
Max. 1 Ω
(female)
1. Turn the starting switch to OFF position.
2. Disconnect the inverter side and the capacitor side of connectors HC06
and HB01.
REMARK
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
Deterioration of insulation
• Measure it by mega-ohm tester.
2 in power cable
(capacitor) Between HC06 (DC+) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HC06 (DC+) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)
Resistance
Between HB01 (DC-) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HB01 (DC-) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)

40-1004 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA05KG]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the inverter side of connectors HC06(DC+) and HB01(DC-).
REMARK
• Wipe dirt of capacitor (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
Deterioration of insulation
3
in capacitor system Between HC06 (DC+) (male): tester (red) and capaci-
Min. 10 MΩ
tor (case): tester (black)
Between HC06 (DC+) (male): tester (black) and capac-
Min. 10 MΩ
itor (case): tester (red)
Resistance
Between HB01 (DC-) (male): tester (red) and capacitor
Min. 10 MΩ
(case): tester (black)
Between HB01 (DC-) (male): tester (black) and capaci-
Min. 10 MΩ
tor (case): tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
4
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

Place of shield (Q part)

HB365LC-3 40-1005
FAILURE CODE [GA05KG] 40 TROUBLESHOOTING

Circuit diagram related to high-voltage equipment

40-1006 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA05KP]

FAILURE CODE [GA05KP] (ALL-K-PQGF-410-20-B)

Action level Failure code Software output voltage low error in DC line before boosting
Failure
L03 GA05KP (Hybrid controller system)
Detail of fail-
Software detects less than 150 V of capacitor voltage.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE

Related
Use electric charge release tool (796-426-1800) to release electric charge of capacitor.

information • Capacitor voltage can be checked with monitoring function. (Code: 09300)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the inverter side and the capacitor side of connectors HC06
Open circuit in power ca- and HB01.
1 ble Between HC06 (DC+) (female) and capacitor side (DC
(capacitor) Max. 1 Ω
+) (female)
Resistance
Between HB01(DC-) (female) and capacitor side (DC-)
Max. 1 Ω
(female)
1. Turn the starting switch to OFF position.
2. Disconnect the inverter side and the capacitor side of connectors HC06
and HB01.
REMARK
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
Deterioration of insulation
• Measure it by mega-ohm tester.
2 in power cable
(capacitor) Between HC06 (DC+) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HC06 (DC+) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)
Resistance
Between HB01 (DC-) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HB01 (DC-) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)

HB365LC-3 40-1007
FAILURE CODE [GA05KP] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the inverter side of connectors HC06(DC+) and HB01(DC-).
REMARK
• Wipe dirt of capacitor (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
Deterioration of insulation
3
in capacitor system Between HC06 (DC+) (male): tester (red) and capaci-
Min. 10 MΩ
tor (case): tester (black)
Between HC06 (DC+) (male): tester (black) and capac-
Min. 10 MΩ
itor (case): tester (red)
Resistance
Between HB01 (DC-) (male): tester (red) and capacitor
Min. 10 MΩ
(case): tester (black)
Between HB01 (DC-) (male): tester (black) and capaci-
Min. 10 MΩ
tor (case): tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
4
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

Place of shield (Q part)

40-1008 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA05KP]

Circuit diagram related to high-voltage equipment

HB365LC-3 40-1009
FAILURE CODE [GA06KZ] 40 TROUBLESHOOTING

FAILURE CODE [GA06KZ] (ALL-K-PQGF-410-30-B)

Action level Failure code DC line voltage sensor before booster open and short circuit
Failure
L03 GA06KZ (Hybrid controller system)
Detail of fail-
Abnormality of capacitor voltage sensor inside inverter is detected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE

Related
Use electric charge release tool (796-426-1800) to release electric charge of capacitor.

information • Capacitor voltage can be checked with monitoring function. (Code: 09300)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

40-1010 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA08KG]

FAILURE CODE [GA08KG] (ALL-K-PQGR-410-00-B)

Action level Failure code Hardware source voltage high error in DC line after boosting
Failure
L03 GA08KG (Hybrid controller system)
Detail of fail-
Hardware detects overvoltage error in power train.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE

Related
Use electric charge release tool (796-426-1800) to release electric charge of capacitor.

information • Power train voltage can be checked with monitoring function. (Code: 09200)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the inverter side and the capacitor side of connectors HC06
Open circuit in power ca- and HB01.
1 ble Between HC06 (DC+) (female) and capacitor side (DC
(capacitor) Max. 1 Ω
+) (female)
Resistance
Between HB01(DC-) (female) and capacitor side (DC-)
Max. 1 Ω
(female)
1. Turn the starting switch to OFF position.
2. Disconnect the inverter side and the capacitor side of connectors HC06
and HB01.
REMARK
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
Deterioration of insulation
• Measure it by mega-ohm tester.
2 in power cable
(capacitor) Between HC06 (DC+) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HC06 (DC+) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)
Resistance
Between HB01 (DC-) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HB01 (DC-) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)

HB365LC-3 40-1011
FAILURE CODE [GA08KG] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the inverter side of connectors HC06(DC+) and HB01(DC-).
REMARK
• Wipe dirt of capacitor (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
Deterioration of insulation
3
in capacitor system Between HC06 (DC+) (male): tester (red) and capaci-
Min. 10 MΩ
tor (case): tester (black)
Between HC06 (DC+) (male): tester (black) and capac-
Min. 10 MΩ
itor (case): tester (red)
Resistance
Between HB01 (DC-) (male): tester (red) and capacitor
Min. 10 MΩ
(case): tester (black)
Between HB01 (DC-) (male): tester (black) and capaci-
Min. 10 MΩ
tor (case): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
Open circuit in power ca- If the connector on the capacitor side has already disconnected, leave it as
4 ble
it is.
(electric swing motor)
Between HC05 (U) (male) and PM02 (U) (male) Max. 1 Ω
Resistance Between HC05 (V) (male) and PM02 (V) (male) Max. 1 Ω
Between HC05 (W) (male) and PM02 (W) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
Internal short circuit in If the connector on the capacitor side has already disconnected, leave it as
5 power cable
it is.
(electric swing motor)
Between HC05 (U) (male) and HC05 (V) (male) Min. 10 MΩ
Resistance Between HC05 (V) (male) and HC05 (W) (male) Min. 10 MΩ
Between HC05 (W) (male) and HC05 (U) (male) Min. 10 MΩ

40-1012 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA08KG]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
Deterioration of insulation Between HC05 (U) (male): tester (red) and cable hous-
6 in power cable Min. 10 MΩ
ing metal (P part): tester (black)
(electric swing motor)
Between HC05 (U) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
Between HC05 (V) (male): tester (red) and cable hous-
Min. 10 MΩ
ing metal (P part): tester (black)
Resistance
Between HC05 (V) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
Between HC05 (W) (male): tester (red) and cable
Min. 10 MΩ
housing metal (P part): tester (black)
Between HC05 (W) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05, HC06(DC+) and HB01(DC-).
REMARK
Open circuit between
7 phases of electric swing There is a coil resistance of motor in the motor-generator.
motor system
Between HC05 (U) (male) and HC05 (V) (male) Max. 1 Ω
Resistance Between HC05 (V) (male) and HC05 (W) (male) Max. 1 Ω
Between HC05 (W) (male) and HC05 (U) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05, HC06(DC+) and HB01(DC-).
REMARK
• Wipe dirt of the inverter (case).
• Measure one phase any of (U), (V) and (W).
Deterioration of insulation
8 in electric swing motor • When the measured values are not stable, use the value measured af-
system ter 1 minute.
• Measure it by mega-ohm tester.
HC05 (U) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC05 (U) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)

HB365LC-3 40-1013
FAILURE CODE [GA08KG] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Open circuit in power ca- it is.
9 ble
(motor-generator) Between HC03 (A1) (male) and GM02 (A1) (male) Max. 1 Ω
Between HC03 (B1) (male) and GM02 (B1) (male) Max. 1 Ω
Between HC03 (C1) (male) and GM02 (C1) (male) Max. 1 Ω
Resistance
Between HC04 (A2) (male) and GM03 (A2) (male) Max. 1 Ω
Between HC04 (B2) (male) and GM03 (B2) (male) Max. 1 Ω
Between HC04 (C2) (male) and GM03 (C2) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Internal short circuit in it is.
10 power cable
(motor-generator) Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
Resistance
Between HC04 (A2) (male) and HC04 (B2) (male) Min. 10 MΩ
Between HC04 (B2) (male) and HC04 (C2) (male) Min. 10 MΩ
Between HC04 (C2) (male) and HC04 (A2) (male) Min. 10 MΩ

40-1014 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA08KG]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC03 (A1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC03 (B1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
Deterioration of insulation HC03 (B1) (male): tester (black) and cable housing
11 in power cable Min. 10 MΩ
metal (P part): tester (red)
(motor-generator)
HC03 (C1) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC03 (C1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
Resistance
HC04 (A2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (A2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (B2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (B2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (C2) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC04 (C2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Open circuit between
12 phases of motor-genera- There is a coil resistance of motor in the motor-generator.
tor system
Between HC03 (A1) (male) and HC04 (A2) (male) Max. 1 Ω
Resistance Between HC03 (B1) (male) and HC04 (B2) (male) Max. 1 Ω
Between HC03 (C1) (male) and HC04 (C2) (male) Max. 1 Ω

HB365LC-3 40-1015
FAILURE CODE [GA08KG] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Short circuit between
13 phases of motor-genera- Measure one either HC03 or HC04.
tor system.
Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Resistance Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
• Wipe dirt of the inverter (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
Deterioration of insulation er (black)
14 in motor-generator sys-
tem HC03 (A1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (B1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC03 (B1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (C1) (male): tester (red) and inverter (case):
Min. 10 MΩ
tester (black)
HC03 (C1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect both the inverter side and the capacitor side of connectors HC03,
HC04, HC05, HC06 and HB01.
REMARK
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
Deterioration of insulation • Measure it by mega-ohm tester.
15
in inverter
Between HC06 (DC+) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HC06 (DC+) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)
Resistance
Between HB01 (DC-) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HB01 (DC-) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
16
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

40-1016 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA08KG]

Place of shield (Q part)

HB365LC-3 40-1017
FAILURE CODE [GA08KG] 40 TROUBLESHOOTING

Circuit diagram related to high-voltage equipment

40-1018 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA09KG]

FAILURE CODE [GA09KG] (ALL-K-PQGR-410-10-B)

Action level Failure code Software power voltage high error in DC line after boosting
Failure
L03 GA09KG (Hybrid controller system)
Detail of fail-
Software detects overvoltage error in power train.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE

Related
Use electric charge release tool (796-426-1800) to release electric charge of capacitor.

information • Power train voltage can be checked with monitoring function. (Code: 09200)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the inverter side and the capacitor side of connectors HC06
Open circuit in power ca- and HB01.
1 ble Between HC06 (DC+) (female) and capacitor side (DC
(capacitor) Max. 1 Ω
+) (female)
Resistance
Between HB01(DC-) (female) and capacitor side (DC-)
Max. 1 Ω
(female)
1. Turn the starting switch to OFF position.
2. Disconnect the inverter side and the capacitor side of connectors HC06
and HB01.
REMARK
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
Deterioration of insulation
• Measure it by mega-ohm tester.
2 in power cable
(capacitor) Between HC06 (DC+) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HC06 (DC+) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)
Resistance
Between HB01 (DC-) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HB01 (DC-) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)

HB365LC-3 40-1019
FAILURE CODE [GA09KG] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the inverter side of connectors HC06(DC+) and HB01(DC-).
REMARK
• Wipe dirt of capacitor (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
Deterioration of insulation
3
in capacitor system Between HC06 (DC+) (male): tester (red) and capaci-
Min. 10 MΩ
tor (case): tester (black)
Between HC06 (DC+) (male): tester (black) and capac-
Min. 10 MΩ
itor (case): tester (red)
Resistance
Between HB01 (DC-) (male): tester (red) and capacitor
Min. 10 MΩ
(case): tester (black)
Between HB01 (DC-) (male): tester (black) and capaci-
Min. 10 MΩ
tor (case): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
Open circuit in power ca- If the connector on the capacitor side has already disconnected, leave it as
4 ble
it is.
(electric swing motor)
Between HC05 (U) (male) and PM02 (U) (male) Max. 1 Ω
Resistance Between HC05 (V) (male) and PM02 (V) (male) Max. 1 Ω
Between HC05 (W) (male) and PM02 (W) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
Internal short circuit in If the connector on the capacitor side has already disconnected, leave it as
5 power cable
it is.
(electric swing motor)
Between HC05 (U) (male) and HC05 (V) (male) Min. 10 MΩ
Resistance Between HC05 (V) (male) and HC05 (W) (male) Min. 10 MΩ
Between HC05 (W) (male) and HC05 (U) (male) Min. 10 MΩ

40-1020 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA09KG]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
Deterioration of insulation Between HC05 (U) (male): tester (red) and cable hous-
6 in power cable Min. 10 MΩ
ing metal (P part): tester (black)
(electric swing motor)
Between HC05 (U) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
Between HC05 (V) (male): tester (red) and cable hous-
Min. 10 MΩ
ing metal (P part): tester (black)
Resistance
Between HC05 (V) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
Between HC05 (W) (male): tester (red) and cable
Min. 10 MΩ
housing metal (P part): tester (black)
Between HC05 (W) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05, HC06(DC+) and HB01(DC-).
REMARK
Open circuit between
7 phases of electric swing There is a coil resistance of motor in the motor-generator.
motor system
Between HC05 (U) (male) and HC05 (V) (male) Max. 1 Ω
Resistance Between HC05 (V) (male) and HC05 (W) (male) Max. 1 Ω
Between HC05 (W) (male) and HC05 (U) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05, HC06(DC+) and HB01(DC-).
REMARK
• Wipe dirt of the inverter (case).
• Measure one phase any of (U), (V) and (W).
Deterioration of insulation
8 in electric swing motor • When the measured values are not stable, use the value measured af-
system ter 1 minute.
• Measure it by mega-ohm tester.
HC05 (U) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC05 (U) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)

HB365LC-3 40-1021
FAILURE CODE [GA09KG] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Open circuit in power ca- it is.
9 ble
(motor-generator) Between HC03 (A1) (male) and GM02 (A1) (male) Max. 1 Ω
Between HC03 (B1) (male) and GM02 (B1) (male) Max. 1 Ω
Between HC03 (C1) (male) and GM02 (C1) (male) Max. 1 Ω
Resistance
Between HC04 (A2) (male) and GM03 (A2) (male) Max. 1 Ω
Between HC04 (B2) (male) and GM03 (B2) (male) Max. 1 Ω
Between HC04 (C2) (male) and GM03 (C2) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Internal short circuit in it is.
10 power cable
(motor-generator) Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
Resistance
Between HC04 (A2) (male) and HC04 (B2) (male) Min. 10 MΩ
Between HC04 (B2) (male) and HC04 (C2) (male) Min. 10 MΩ
Between HC04 (C2) (male) and HC04 (A2) (male) Min. 10 MΩ

40-1022 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA09KG]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC03 (A1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC03 (B1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
Deterioration of insulation HC03 (B1) (male): tester (black) and cable housing
11 in power cable Min. 10 MΩ
metal (P part): tester (red)
(motor-generator)
HC03 (C1) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC03 (C1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
Resistance
HC04 (A2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (A2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (B2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (B2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (C2) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC04 (C2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Open circuit between
12 phases of motor-genera- There is a coil resistance of motor in the motor-generator.
tor system
Between HC03 (A1) (male) and HC04 (A2) (male) Max. 1 Ω
Resistance Between HC03 (B1) (male) and HC04 (B2) (male) Max. 1 Ω
Between HC03 (C1) (male) and HC04 (C2) (male) Max. 1 Ω

HB365LC-3 40-1023
FAILURE CODE [GA09KG] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Short circuit between
13 phases of motor-genera- Measure one either HC03 or HC04.
tor system.
Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Resistance Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
• Wipe dirt of the inverter (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
Deterioration of insulation er (black)
14 in motor-generator sys-
tem HC03 (A1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (B1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC03 (B1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (C1) (male): tester (red) and inverter (case):
Min. 10 MΩ
tester (black)
HC03 (C1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect both the inverter side and the capacitor side of connectors HC03,
HC04, HC05, HC06 and HB01.
REMARK
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
Deterioration of insulation • Measure it by mega-ohm tester.
15
in inverter
Between HC06 (DC+) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HC06 (DC+) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)
Resistance
Between HB01 (DC-) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HB01 (DC-) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
16
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

40-1024 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA09KG]

Place of shield (Q part)

HB365LC-3 40-1025
FAILURE CODE [GA09KG] 40 TROUBLESHOOTING

Circuit diagram related to high-voltage equipment

40-1026 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA09KP]

FAILURE CODE [GA09KP] (ALL-K-PQGR-410-20-B)

Action level Failure code Software output voltage low error in DC line after boosting
Failure
L03 GA09KP (Hybrid controller system)
Detail of fail-
Software detects abnormal output voltage low in power train.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE

Related
Use electric charge release tool (796-426-1800) to release electric charge of capacitor.

information • Power train voltage can be checked with monitoring function. (Code: 09200)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

HB365LC-3 40-1027
FAILURE CODE [GA0AKZ] 40 TROUBLESHOOTING

FAILURE CODE [GA0AKZ] (ALL-K-PQGR-410-30-B)

Action level Failure code DC line voltage sensor after booster open and short circuit
Failure
L03 GA0AKZ (Hybrid controller system)
Detail of fail-
Abnormality of power train voltage sensor inside inverter is detected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE

Related
Use electric charge release tool (796-426-1800) to release electric charge of capacitor.

information • Power train voltage can be checked with monitoring function. (Code: 09200)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

40-1028 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA0BKZ]

FAILURE CODE [GA0BKZ] (ALL-K-PQJE-410-30-B)

Action level Failure code AC Line open and short circuit

Failure
L04 GA0BKZ (Hybrid controller system)
Detail of fail-
Insulation of cable connecting swing motor or motor-generator and inverter is deteriorated.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Start the engine, and then turn starting switch to OFF position.

No. Cause Procedure, measuring location, criteria and remarks

• Check if the connector of power cable is fitted correctly and there is no film
1 Defective power cable breakage, etc.
• Check if the cover of the connecting part is not coming off.
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
Open circuit in power ca- If the connector on the capacitor side has already disconnected, leave it as
2 ble
it is.
(electric swing motor)
Between HC05 (U) (male) and PM02 (U) (male) Max. 1 Ω
Resistance Between HC05 (V) (male) and PM02 (V) (male) Max. 1 Ω
Between HC05 (W) (male) and PM02 (W) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
Internal short circuit in If the connector on the capacitor side has already disconnected, leave it as
3 power cable
it is.
(electric swing motor)
Between HC05 (U) (male) and HC05 (V) (male) Min. 10 MΩ
Resistance Between HC05 (V) (male) and HC05 (W) (male) Min. 10 MΩ
Between HC05 (W) (male) and HC05 (U) (male) Min. 10 MΩ

HB365LC-3 40-1029
FAILURE CODE [GA0BKZ] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
Deterioration of insulation Between HC05 (U) (male): tester (red) and cable hous-
4 in power cable Min. 10 MΩ
ing metal (P part): tester (black)
(electric swing motor)
Between HC05 (U) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
Between HC05 (V) (male): tester (red) and cable hous-
Min. 10 MΩ
ing metal (P part): tester (black)
Resistance
Between HC05 (V) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
Between HC05 (W) (male): tester (red) and cable
Min. 10 MΩ
housing metal (P part): tester (black)
Between HC05 (W) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05, HC06(DC+) and HB01(DC-).
REMARK
Open circuit between
5 phases of electric swing There is a coil resistance of motor in the motor-generator.
motor system
Between HC05 (U) (male) and HC05 (V) (male) Max. 1 Ω
Resistance Between HC05 (V) (male) and HC05 (W) (male) Max. 1 Ω
Between HC05 (W) (male) and HC05 (U) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05, HC06(DC+) and HB01(DC-).
REMARK
• Wipe dirt of the inverter (case).
• Measure one phase any of (U), (V) and (W).
Deterioration of insulation
6 in electric swing motor • When the measured values are not stable, use the value measured af-
system ter 1 minute.
• Measure it by mega-ohm tester.
HC05 (U) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC05 (U) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)

40-1030 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA0BKZ]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Open circuit in power ca- it is.
7 ble
(motor-generator) Between HC03 (A1) (male) and GM02 (A1) (male) Max. 1 Ω
Between HC03 (B1) (male) and GM02 (B1) (male) Max. 1 Ω
Between HC03 (C1) (male) and GM02 (C1) (male) Max. 1 Ω
Resistance
Between HC04 (A2) (male) and GM03 (A2) (male) Max. 1 Ω
Between HC04 (B2) (male) and GM03 (B2) (male) Max. 1 Ω
Between HC04 (C2) (male) and GM03 (C2) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Internal short circuit in it is.
8 power cable
(motor-generator) Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
Resistance
Between HC04 (A2) (male) and HC04 (B2) (male) Min. 10 MΩ
Between HC04 (B2) (male) and HC04 (C2) (male) Min. 10 MΩ
Between HC04 (C2) (male) and HC04 (A2) (male) Min. 10 MΩ

HB365LC-3 40-1031
FAILURE CODE [GA0BKZ] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC03 (A1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC03 (B1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
Deterioration of insulation HC03 (B1) (male): tester (black) and cable housing
9 in power cable Min. 10 MΩ
metal (P part): tester (red)
(motor-generator)
HC03 (C1) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC03 (C1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
Resistance
HC04 (A2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (A2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (B2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (B2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (C2) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC04 (C2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Open circuit between
10 phases of motor-genera- There is a coil resistance of motor in the motor-generator.
tor system
Between HC03 (A1) (male) and HC04 (A2) (male) Max. 1 Ω
Resistance Between HC03 (B1) (male) and HC04 (B2) (male) Max. 1 Ω
Between HC03 (C1) (male) and HC04 (C2) (male) Max. 1 Ω

40-1032 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA0BKZ]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Short circuit between
11 phases of motor-genera- Measure one either HC03 or HC04.
tor system.
Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Resistance Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
• Wipe dirt of the inverter (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
Deterioration of insulation er (black)
12 in motor-generator sys-
tem HC03 (A1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (B1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC03 (B1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (C1) (male): tester (red) and inverter (case):
Min. 10 MΩ
tester (black)
HC03 (C1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect both the inverter side and the capacitor side of connectors HC03,
HC04, HC05, HC06 and HB01.
REMARK
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
Deterioration of insulation • Measure it by mega-ohm tester.
13
in inverter
Between HC06 (DC+) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HC06 (DC+) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)
Resistance
Between HB01 (DC-) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HB01 (DC-) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
14
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1033
FAILURE CODE [GA0BKZ] 40 TROUBLESHOOTING

Place of shield (Q part)

40-1034 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA0BKZ]

Circuit diagram related to high-voltage equipment

HB365LC-3 40-1035
FAILURE CODE [GA10MA] 40 TROUBLESHOOTING

FAILURE CODE [GA10MA] (ALL-K-PQGR-410-70-B)

Action level Failure code Hybrid controller malfunction

Failure
L04 GA10MA (Hybrid controller system)
Detail of fail-
Inverter (hybrid controller) malfunction
ure
Action of
None in particular
controller
Phenomenon
Inverter (hybrid controller) does not operate normally.
on machine

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connector HC01, and connect the T-adapter to female
side.
Defective power supply 4. Turn the battery disconnect switch to ON position.
1 circuit of inverter (hybrid
controller) 5. Turn the starting switch to ON position.
REMARK
If there is no failure, troubleshooting for No. 2 is not required.
Between HC01 (female) (5) and (17) 20 to 30 V
Voltage
Between HC01 (female) (11) and (23) 20 to 30 V
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.17 in fuse box F01.
4. Disconnect the connector HC01, and connect the T-adapter to female
Open circuit in wiring har-
2 side.
ness
Between HC01 (female) (5) and F01 -17 Max. 1 Ω
Between HC01 (female) (11) and F01 -17 Max. 1 Ω
Resistance
Between HC01 (female) (17) and ground Max. 1 Ω
Between HC01 (female) (23) and ground Max. 1 Ω

40-1036 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA10MA]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connector HC01, and connect the T-adapter to female
side.
Defective inverter (hybrid 4.
Turn the battery disconnect switch to ON position.
3 controller) ACC signal
circuit 5. Turn the starting switch to ON position.
REMARK
If there is no failure, troubleshooting for No. 4 is not required.
Between HC01 (female) (6) and (17) 20 to 30 V
Voltage
Between HC01 (female) (12) and (23) 20 to 30 V
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.14 in fuse box F01.
4. Disconnect the connector HC01, and connect the T-adapter to female
Open circuit in wiring har-
4 side.
ness
Between HC01 (female) (6) and F01 -14 Max. 1 Ω
Between HC01 (female) (12) and F01 -14 Max. 1 Ω
Resistance
Between HC01 (female) (17) and ground Max. 1 Ω
Between HC01 (female) (23) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect connectors CM02 and K02, and connect T-adapter to each
Defective CAN 2 termi- male side.
5
nating resistor
Between CM02 (male) (7) and (9) 120 ± 12 Ω
Resistance
Between K02 (male) (A) and (B) 120 ± 12 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors CM02, HC01, and K02, and connect the T-
Open circuit in wiring har- adapter to each female side.
6 ness (CAN 2 communi- Between CM02 (female) (7) and HC01 (female) (1) Max. 1 Ω
cation line)
Between CM02 (female) (8) and HC01 (female) (1) Max. 1 Ω
Resistance Between CM02 (female) (9) and HC01 (female) (11) Max. 1 Ω
Between HC01 (female) (1) and K02 (female) (A) Max. 1 Ω
Between HC01 (female) (11) and K02 (female) (B) Max. 1 Ω

HB365LC-3 40-1037
FAILURE CODE [GA10MA]
No. Cause
Ground fault in wiring
7 harness (CAN 2 commu-
nication line)
Hot short circuit in wiring
8 harness (CAN 2 commu-
nication line)
Defective CAN 1 termi-
9
nating resistor
Open circuit in wiring har-
10 ness (CAN 1 communi-
cation line)
40-1038
40 TROUBLESHOOTING
Procedure, measuring location, criteria and remarks
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors HC01 and CM02, and connect the T-adapter to
either female side.
4. Disconnect the connectors, terminals, and fuses of all the devices which
branch out from connectors HC01 (1) and (11).
Between ground and any of HC01 (female) (1), CM02
Min. 1 MΩ
(female) (7), and (8)
Resistance
Between ground and either HC01 (female) (11) or
Min. 1 MΩ
CM02 (female) (9)
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Insert T-adapter into connector K02.
4. Turn the battery disconnect switch to ON position.
5. Turn the starting switch to ON position.
REMARK
Voltage of CANH and CANL is 2.5 ± 1 V including during communication, so regard
wiring harness as normal if measured voltage is 1 to 4 V.
Between K02(A) and ground 1 to 4 V
Voltage
Between K02(B) and ground 1 to 4 V
1. Turn the starting switch to OFF position.
2. Disconnect the connectors C23 and CM02, and connect the T-adapter to
each male side.
Between CM02 (male) (10) and (12) 120 ± 12 Ω
Resistance
Between C23 (male) (A) and (B) 120 ± 12 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors CM02, HC02 and C23, and connect the T-
adapter to each female side.
Between CM02 (female) (10) and HC02 (female) (21) Max. 1 Ω
Between CM02 (female) (11) and HC02 (female) (21) Max. 1 Ω
Resistance Between CM02 (female) (12) and HC02 (female) (31) Max. 1 Ω
Between HC02 (female) (21) and C23 (female) (A) Max. 1 Ω
Between HC02 (female) (31) and C23 (female) (B) Max. 1 Ω
HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA10MA]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors HC02 and CM02, and connect the T-adapter to
Ground fault in wiring either female side.
11 harness (CAN 1 commu- 4. Disconnect the connectors, terminals, and fuses of all the devices which
nication line) branch out from connectors HC02 (21) and (31).
Between ground and any of HC02 (female) (21), CM02
Min. 1 MΩ
(female) (10), and (11)
Resistance
Between ground and either HC02 (female) (31) or
Min. 1 MΩ
CM02 (female) (12)
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Insert the T-adapter into connector C23.
4. Turn the battery disconnect switch to ON position.
Hot short circuit in wiring
12 harness (CAN 1 commu- 5. Turn the starting switch to ON position.
nication line) REMARK
Voltage of CANH and CANL is 2.5 ± 1 V including during communication, so regard
wiring harness as normal if measured voltage is 1 to 4 V.
Between ground and C23 (A) 1 to 4 V
Voltage
Between ground and C23 (B) 1 to 4 V
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
13
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1039
FAILURE CODE [GA10MA] 40 TROUBLESHOOTING

Circuit diagram related to CAN communication 1

40-1040 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA10MA]

CIRCUIT DIAGRAM (CAN2 COMMUNICATION)

HB365LC-3 40-1041
FAILURE CODE [GA10MA] 40 TROUBLESHOOTING

Circuit diagram related to inverter (hybrid controller) power supply

40-1042 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA10MC]

FAILURE CODE [GA10MC] (ALL-K-PQGR-410-40-B)

Action level Failure code Hybrid controller malfunction

Failure
- GA10MC (Hybrid controller system)
Detail of fail-
Inverter (hybrid controller) malfunction
ure
Action of
None in particular
controller
Phenomenon
Inverter (hybrid controller) does not operate normally.
on machine

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

HB365LC-3 40-1043
FAILURE CODE [GA12NK] 40 TROUBLESHOOTING

FAILURE CODE [GA12NK] (ALL-K-PQGR-410-50-B)

Action level Failure code Hybrid controller power supply voltage not rising
Failure
L03 GA12NK (Hybrid controller system)
Detail of fail-
Electric system inside inverter does not start up.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and GM01, and connect the T-adapter to
each female side.
Open circuit in wiring har-
1
ness Between HC02 (female) (4) and GM01 (female) (2) Max. 1 Ω
Resistance Between HC02 (female) (7) and GM01 (female) (1) Max. 1 Ω
Between HC02 (female) (33) and GM01 (female) (3) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and GM01, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either HC02 (female) (4) or
Resistance Min. 1 MΩ
GM01 (female) (2)
1. Turn the starting switch to OFF position.
2. Disconnect the connector GM01, and connect the T-adapter to female
Hot short circuit in wiring side.
3
harness
3. Turn the starting switch to ON position.
Voltage Between GM01 (female) (2) and ground Max. 1 V

40-1044 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA12NK]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Open circuit in power ca- it is.
4 ble
(motor-generator) Between HC03 (A1) (male) and GM02 (A1) (male) Max. 1 Ω
Between HC03 (B1) (male) and GM02 (B1) (male) Max. 1 Ω
Between HC03 (C1) (male) and GM02 (C1) (male) Max. 1 Ω
Resistance
Between HC04 (A2) (male) and GM03 (A2) (male) Max. 1 Ω
Between HC04 (B2) (male) and GM03 (B2) (male) Max. 1 Ω
Between HC04 (C2) (male) and GM03 (C2) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Internal short circuit in it is.
5 power cable
(motor-generator) Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
Resistance
Between HC04 (A2) (male) and HC04 (B2) (male) Min. 10 MΩ
Between HC04 (B2) (male) and HC04 (C2) (male) Min. 10 MΩ
Between HC04 (C2) (male) and HC04 (A2) (male) Min. 10 MΩ

HB365LC-3 40-1045
FAILURE CODE [GA12NK] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC03 (A1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC03 (B1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
Deterioration of insulation HC03 (B1) (male): tester (black) and cable housing
6 in power cable Min. 10 MΩ
metal (P part): tester (red)
(motor-generator)
HC03 (C1) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC03 (C1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
Resistance
HC04 (A2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (A2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (B2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (B2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (C2) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC04 (C2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Open circuit between
7 phases of motor-genera- There is a coil resistance of motor in the motor-generator.
tor system
Between HC03 (A1) (male) and HC04 (A2) (male) Max. 1 Ω
Resistance Between HC03 (B1) (male) and HC04 (B2) (male) Max. 1 Ω
Between HC03 (C1) (male) and HC04 (C2) (male) Max. 1 Ω

40-1046 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA12NK]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Short circuit between
8 phases of motor-genera- Measure one either HC03 or HC04.
tor system.
Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Resistance Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
• Wipe dirt of the inverter (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
Deterioration of insulation er (black)
9 in motor-generator sys-
tem HC03 (A1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (B1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC03 (B1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (C1) (male): tester (red) and inverter (case):
Min. 10 MΩ
tester (black)
HC03 (C1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the inverter side and the capacitor side of connectors HC06
Open circuit in power ca- and HB01.
10 ble Between HC06 (DC+) (female) and capacitor side (DC
(capacitor) Max. 1 Ω
+) (female)
Resistance
Between HB01(DC-) (female) and capacitor side (DC-)
Max. 1 Ω
(female)

HB365LC-3 40-1047
FAILURE CODE [GA12NK] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the inverter side and the capacitor side of connectors HC06
and HB01.
REMARK
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
Deterioration of insulation
• Measure it by mega-ohm tester.
11 in power cable
(capacitor) Between HC06 (DC+) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HC06 (DC+) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)
Resistance
Between HB01 (DC-) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HB01 (DC-) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the inverter side of connectors HC06(DC+) and HB01(DC-).
REMARK
• Wipe dirt of capacitor (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
Deterioration of insulation
12
in capacitor system Between HC06 (DC+) (male): tester (red) and capaci-
Min. 10 MΩ
tor (case): tester (black)
Between HC06 (DC+) (male): tester (black) and capac-
Min. 10 MΩ
itor (case): tester (red)
Resistance
Between HB01 (DC-) (male): tester (red) and capacitor
Min. 10 MΩ
(case): tester (black)
Between HB01 (DC-) (male): tester (black) and capaci-
Min. 10 MΩ
tor (case): tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
13
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to 5 V sensor power supply (hybrid)

40-1048 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA12NK]

Circuit diagram related to high-voltage equipment

HB365LC-3 40-1049
FAILURE CODE [GA13KP] 40 TROUBLESHOOTING

FAILURE CODE [GA13KP] (ALL-K-PQJE-410-50-B)

Action level Failure code Hybrid controller sensor power supply output voltage low error
Failure
L03 GA13KP (Hybrid controller system)
Detail of fail-
Voltage of 5V sensor power supply output circuit is 2.5 V or less.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect connector GM01, and turn the starting switch to ON position.
3. After check, turn the starting switch to OFF position.
REMARK
1 Defective 5 V sensor • If this failure code is not displayed by disconnecting, the disconnected
connector is defective. Perform the steps 1 to 3.
• Since connector is disconnected, other failure codes are also dis-
played. Ignore all of displayed failure codes other than this one.
Connector Engine built-in generator GM01
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and GM01, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either HC02 (female) (7) or
Resistance Min. 1 MΩ
GM01 (female) (1)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
3
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

40-1050 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA13KP]

Circuit diagram related to 5 V sensor power supply (hybrid)

HB365LC-3 40-1051
FAILURE CODE [GA13KY] 40 TROUBLESHOOTING

FAILURE CODE [GA13KY] (ALL-K-PQJE-410-60-B)

Action level Failure code Hybrid controller sensor power supply short circuit
Failure
L03 GA13KY (Hybrid controller system)
Detail of fail-
Voltage of 5V sensor power supply output circuit is 6 V or more.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect connector GM01, and turn the starting switch to ON position.
3. After check, turn the starting switch to OFF position.
REMARK
1 Defective 5 V sensor • If this failure code is not displayed by disconnecting, the disconnected
connector is defective. Perform the steps 1 to 3.
• Since connector is disconnected, other failure codes are also dis-
played. Ignore all of displayed failure codes other than this one.
Connector Engine built-in generator GM01
1. Turn the starting switch to OFF position.
2. Disconnect the connector GM01, and connect the T-adapter to female
Hot short circuit in wiring side.
2
harness
3. Turn the starting switch to ON position.
Voltage Between GM01 (female) (1) and (3) 4.5 to 5.5 V
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
3
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

40-1052 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA13KY]

Circuit diagram related to 5 V sensor power supply (hybrid)

HB365LC-3 40-1053
FAILURE CODE [GA15KZ] 40 TROUBLESHOOTING

FAILURE CODE [GA15KZ] (ALL-K-PQGR-410-60-B)

Action level Failure code Hybrid controller insulation deterioration sensor open and short cir-
Failure cuit
L03 GA15KZ (Hybrid controller system)
Detail of fail-
Sensor to detect deteriorated insulation of hybrid component and ground cable is abnormal.
ure
Action of
None in particular
controller
Phenomenon
Electric leakage cannot be detected.
on machine
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the inverter side and the capacitor side of connectors HC06
Open circuit in power ca- and HB01.
1 ble Between HC06 (DC+) (female) and capacitor side (DC
(capacitor) Max. 1 Ω
+) (female)
Resistance
Between HB01(DC-) (female) and capacitor side (DC-)
Max. 1 Ω
(female)
1. Turn the starting switch to OFF position.
2. Disconnect the inverter side and the capacitor side of connectors HC06
and HB01.
REMARK
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
Deterioration of insulation
• Measure it by mega-ohm tester.
2 in power cable
(capacitor) Between HC06 (DC+) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HC06 (DC+) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)
Resistance
Between HB01 (DC-) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HB01 (DC-) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)

40-1054 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA15KZ]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the inverter side of connectors HC06(DC+) and HB01(DC-).
REMARK
• Wipe dirt of capacitor (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
Deterioration of insulation
3
in capacitor system Between HC06 (DC+) (male): tester (red) and capaci-
Min. 10 MΩ
tor (case): tester (black)
Between HC06 (DC+) (male): tester (black) and capac-
Min. 10 MΩ
itor (case): tester (red)
Resistance
Between HB01 (DC-) (male): tester (red) and capacitor
Min. 10 MΩ
(case): tester (black)
Between HB01 (DC-) (male): tester (black) and capaci-
Min. 10 MΩ
tor (case): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
Open circuit in power ca- If the connector on the capacitor side has already disconnected, leave it as
4 ble
it is.
(electric swing motor)
Between HC05 (U) (male) and PM02 (U) (male) Max. 1 Ω
Resistance Between HC05 (V) (male) and PM02 (V) (male) Max. 1 Ω
Between HC05 (W) (male) and PM02 (W) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
Internal short circuit in If the connector on the capacitor side has already disconnected, leave it as
5 power cable
it is.
(electric swing motor)
Between HC05 (U) (male) and HC05 (V) (male) Min. 10 MΩ
Resistance Between HC05 (V) (male) and HC05 (W) (male) Min. 10 MΩ
Between HC05 (W) (male) and HC05 (U) (male) Min. 10 MΩ

HB365LC-3 40-1055
FAILURE CODE [GA15KZ] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
Deterioration of insulation Between HC05 (U) (male): tester (red) and cable hous-
6 in power cable Min. 10 MΩ
ing metal (P part): tester (black)
(electric swing motor)
Between HC05 (U) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
Between HC05 (V) (male): tester (red) and cable hous-
Min. 10 MΩ
ing metal (P part): tester (black)
Resistance
Between HC05 (V) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
Between HC05 (W) (male): tester (red) and cable
Min. 10 MΩ
housing metal (P part): tester (black)
Between HC05 (W) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05, HC06(DC+) and HB01(DC-).
REMARK
Open circuit between
7 phases of electric swing There is a coil resistance of motor in the motor-generator.
motor system
Between HC05 (U) (male) and HC05 (V) (male) Max. 1 Ω
Resistance Between HC05 (V) (male) and HC05 (W) (male) Max. 1 Ω
Between HC05 (W) (male) and HC05 (U) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05, HC06(DC+) and HB01(DC-).
REMARK
• Wipe dirt of the inverter (case).
• Measure one phase any of (U), (V) and (W).
Deterioration of insulation
8 in electric swing motor • When the measured values are not stable, use the value measured af-
system ter 1 minute.
• Measure it by mega-ohm tester.
HC05 (U) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC05 (U) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)

40-1056 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA15KZ]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Open circuit in power ca- it is.
9 ble
(motor-generator) Between HC03 (A1) (male) and GM02 (A1) (male) Max. 1 Ω
Between HC03 (B1) (male) and GM02 (B1) (male) Max. 1 Ω
Between HC03 (C1) (male) and GM02 (C1) (male) Max. 1 Ω
Resistance
Between HC04 (A2) (male) and GM03 (A2) (male) Max. 1 Ω
Between HC04 (B2) (male) and GM03 (B2) (male) Max. 1 Ω
Between HC04 (C2) (male) and GM03 (C2) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Internal short circuit in it is.
10 power cable
(motor-generator) Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
Resistance
Between HC04 (A2) (male) and HC04 (B2) (male) Min. 10 MΩ
Between HC04 (B2) (male) and HC04 (C2) (male) Min. 10 MΩ
Between HC04 (C2) (male) and HC04 (A2) (male) Min. 10 MΩ

HB365LC-3 40-1057
FAILURE CODE [GA15KZ] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC03 (A1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC03 (B1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
Deterioration of insulation HC03 (B1) (male): tester (black) and cable housing
11 in power cable Min. 10 MΩ
metal (P part): tester (red)
(motor-generator)
HC03 (C1) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC03 (C1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
Resistance
HC04 (A2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (A2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (B2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (B2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (C2) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC04 (C2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Open circuit between
12 phases of motor-genera- There is a coil resistance of motor in the motor-generator.
tor system
Between HC03 (A1) (male) and HC04 (A2) (male) Max. 1 Ω
Resistance Between HC03 (B1) (male) and HC04 (B2) (male) Max. 1 Ω
Between HC03 (C1) (male) and HC04 (C2) (male) Max. 1 Ω

40-1058 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA15KZ]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Short circuit between
13 phases of motor-genera- Measure one either HC03 or HC04.
tor system.
Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Resistance Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
• Wipe dirt of the inverter (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
Deterioration of insulation er (black)
14 in motor-generator sys-
tem HC03 (A1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (B1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC03 (B1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (C1) (male): tester (red) and inverter (case):
Min. 10 MΩ
tester (black)
HC03 (C1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect both the inverter side and the capacitor side of connectors HC03,
HC04, HC05, HC06 and HB01.
REMARK
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
Deterioration of insulation • Measure it by mega-ohm tester.
15
in inverter
Between HC06 (DC+) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HC06 (DC+) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)
Resistance
Between HB01 (DC-) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HB01 (DC-) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
16
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1059
FAILURE CODE [GA15KZ] 40 TROUBLESHOOTING

Place of shield (Q part)

40-1060 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA15KZ]

Circuit diagram related to high-voltage equipment

HB365LC-3 40-1061
FAILURE CODE [GA17KR] 40 TROUBLESHOOTING

FAILURE CODE [GA17KR] (ALL-K-PQHE-410-00-B)

Action level Failure code Motor-generator driver controller defective communication

Failure
L03 GA17KR (Hybrid controller system)
Detail of fail-
Motor-generator controller detects internal communication error 2 inside inverter.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

40-1062 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA17MB]

FAILURE CODE [GA17MB] (ALL-K-PQHE-410-20-B)

Action level Failure code Motor-generator driver deterioration

Failure
- GA17MB (Hybrid controller system)
Detail of fail-
Motor-generator controller detects internal communication error 1 inside inverter.
ure
Action of Even if cause of failure is eliminated, machine does not become normal until starting switch is
controller turned to OFF position.

Phenomenon
None in particular
on machine
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

HB365LC-3 40-1063
FAILURE CODE [GA18MC] 40 TROUBLESHOOTING

FAILURE CODE [GA18MC] (ALL-K-PQHE-410-30-B)

Action level Failure code Motor-generator driver energizing power supply malfunction
Failure
L03 GA18MC (Hybrid controller system)
Detail of fail-
Electric system inside inverter does not start up.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and GM01, and connect the T-adapter to
each female side.
Open circuit in wiring har-
1
ness Between HC02 (female) (4) and GM01 (female) (2) Max. 1 Ω
Resistance Between HC02 (female) (7) and GM01 (female) (1) Max. 1 Ω
Between HC02 (female) (33) and GM01 (female) (3) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and GM01, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either HC02 (female) (4) or
Resistance Min. 1 MΩ
GM01 (female) (2)
1. Turn the starting switch to OFF position.
2. Disconnect the connector GM01, and connect the T-adapter to female
Hot short circuit in wiring side.
3
harness
3. Turn the starting switch to ON position.
Voltage Between GM01 (female) (2) and ground Max. 1 V

40-1064 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA18MC]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Open circuit in power ca- it is.
4 ble
(motor-generator) Between HC03 (A1) (male) and GM02 (A1) (male) Max. 1 Ω
Between HC03 (B1) (male) and GM02 (B1) (male) Max. 1 Ω
Between HC03 (C1) (male) and GM02 (C1) (male) Max. 1 Ω
Resistance
Between HC04 (A2) (male) and GM03 (A2) (male) Max. 1 Ω
Between HC04 (B2) (male) and GM03 (B2) (male) Max. 1 Ω
Between HC04 (C2) (male) and GM03 (C2) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Internal short circuit in it is.
5 power cable
(motor-generator) Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
Resistance
Between HC04 (A2) (male) and HC04 (B2) (male) Min. 10 MΩ
Between HC04 (B2) (male) and HC04 (C2) (male) Min. 10 MΩ
Between HC04 (C2) (male) and HC04 (A2) (male) Min. 10 MΩ

HB365LC-3 40-1065
FAILURE CODE [GA18MC] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC03 (A1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC03 (B1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
Deterioration of insulation HC03 (B1) (male): tester (black) and cable housing
6 in power cable Min. 10 MΩ
metal (P part): tester (red)
(motor-generator)
HC03 (C1) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC03 (C1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
Resistance
HC04 (A2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (A2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (B2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (B2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (C2) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC04 (C2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Open circuit between
7 phases of motor-genera- There is a coil resistance of motor in the motor-generator.
tor system
Between HC03 (A1) (male) and HC04 (A2) (male) Max. 1 Ω
Resistance Between HC03 (B1) (male) and HC04 (B2) (male) Max. 1 Ω
Between HC03 (C1) (male) and HC04 (C2) (male) Max. 1 Ω

40-1066 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA18MC]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Short circuit between
8 phases of motor-genera- Measure one either HC03 or HC04.
tor system.
Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Resistance Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
• Wipe dirt of the inverter (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
Deterioration of insulation er (black)
9 in motor-generator sys-
tem HC03 (A1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (B1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC03 (B1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (C1) (male): tester (red) and inverter (case):
Min. 10 MΩ
tester (black)
HC03 (C1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
10
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to 5 V sensor power supply (hybrid)

HB365LC-3 40-1067
FAILURE CODE [GA18MC] 40 TROUBLESHOOTING

Circuit diagram related to high-voltage equipment

40-1068 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA19KR]

FAILURE CODE [GA19KR] (ALL-K-PQHE-410-40-B)

Action level Failure code Motor-generator driver sub CPU defective communication
Failure
L03 GA19KR (Hybrid controller system)
Detail of fail-
Sub CPU of motor-generator driver detects defective communication.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

HB365LC-3 40-1069
FAILURE CODE [GA19KT] 40 TROUBLESHOOTING

FAILURE CODE [GA19KT] (ALL-K-PQHE-410-50-B)

Action level Failure code Motor-generator driver sub CPU controller internal error
Failure
L03 GA19KT (Hybrid controller system)
Detail of fail-
Motor-generator controller detects internal communication error 3 inside inverter.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

40-1070 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA1BMA]

FAILURE CODE [GA1BMA] (ALL-K-PQHE-410-70-B)

Action level Failure code Motor-generator driver DC voltage sensor malfunction

Failure
L01 GA1BMA (Hybrid controller system)
Detail of fail-
DC voltage sensor malfunction of motor-generator driver is detected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Check battery voltage and specific gravity of battery electrolyte.
Battery Voltage (1 battery) Min. 12 V
1 Defective battery
Battery Voltage (2 batteries in series) Min. 24 V
Specific gravity of battery electrolyte Min. 1.26
1. Start the engine.
2 Defective alternator Between ground and alter- Engine speed in medium 27.5 to
Voltage
nator terminal R and above 29.5 V
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
3
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1071
FAILURE CODE [GA1BMA] 40 TROUBLESHOOTING

Circuit diagram related to battery relay

40-1072 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA1FKR]

FAILURE CODE [GA1FKR] (ALL-K-PQHT-410-00-B)

Action level Failure code Swing motor driver defective communication

Failure
L03 GA1FKR (Hybrid controller system)
Detail of fail-
Swing motor controller detects communication error 2 inside inverter.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

HB365LC-3 40-1073
FAILURE CODE [GA1FMA] 40 TROUBLESHOOTING

FAILURE CODE [GA1FMA] (ALL-K-PQHT-410-10-B)

Action level Failure code Swing motor driver error

Failure
L03 GA1FMA (Hybrid controller system)
Detail of fail-
Swing motor inverter output circuit error is detected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
Open circuit in power ca- If the connector on the capacitor side has already disconnected, leave it as
1 ble
it is.
(electric swing motor)
Between HC05 (U) (male) and PM02 (U) (male) Max. 1 Ω
Resistance Between HC05 (V) (male) and PM02 (V) (male) Max. 1 Ω
Between HC05 (W) (male) and PM02 (W) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
Internal short circuit in If the connector on the capacitor side has already disconnected, leave it as
2 power cable
it is.
(electric swing motor)
Between HC05 (U) (male) and HC05 (V) (male) Min. 10 MΩ
Resistance Between HC05 (V) (male) and HC05 (W) (male) Min. 10 MΩ
Between HC05 (W) (male) and HC05 (U) (male) Min. 10 MΩ

40-1074 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA1FMA]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
Deterioration of insulation Between HC05 (U) (male): tester (red) and cable hous-
3 in power cable Min. 10 MΩ
ing metal (P part): tester (black)
(electric swing motor)
Between HC05 (U) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
Between HC05 (V) (male): tester (red) and cable hous-
Min. 10 MΩ
ing metal (P part): tester (black)
Resistance
Between HC05 (V) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
Between HC05 (W) (male): tester (red) and cable
Min. 10 MΩ
housing metal (P part): tester (black)
Between HC05 (W) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05, HC06(DC+) and HB01(DC-).
REMARK
Open circuit between
4 phases of electric swing There is a coil resistance of motor in the motor-generator.
motor system
Between HC05 (U) (male) and HC05 (V) (male) Max. 1 Ω
Resistance Between HC05 (V) (male) and HC05 (W) (male) Max. 1 Ω
Between HC05 (W) (male) and HC05 (U) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05, HC06(DC+) and HB01(DC-).
REMARK
• Wipe dirt of the inverter (case).
• Measure one phase any of (U), (V) and (W).
Deterioration of insulation
5 in electric swing motor • When the measured values are not stable, use the value measured af-
system ter 1 minute.
• Measure it by mega-ohm tester.
HC05 (U) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC05 (U) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
6
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1075
FAILURE CODE [GA1FMA] 40 TROUBLESHOOTING

Circuit diagram related to high-voltage equipment

40-1076 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA1GKR]

FAILURE CODE [GA1GKR] (ALL-K-PQHT-410-20-B)

Action level Failure code Swing motor driver sub CPU defective communication
Failure
L03 GA1GKR (Hybrid controller system)
Detail of fail-
Sub CPU of swing motor driver detects defective communication.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

HB365LC-3 40-1077
FAILURE CODE [GA1GKT] 40 TROUBLESHOOTING

FAILURE CODE [GA1GKT] (ALL-K-PQHT-410-30-B)

Action level Failure code Swing motor driver sub CPU controller internal error
Failure
L03 GA1GKT (Hybrid controller system)
Detail of fail-
Swing motor controller detects communication error 3 inside inverter.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

40-1078 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA1GMB]

FAILURE CODE [GA1GMB] (ALL-K-PQHT-410-50-B)

Action level Failure code Swing motor driver sub CPU deterioration
Failure
- GA1GMB (Hybrid controller system)
Detail of fail-
Swing motor controller detects communication error 1 inside inverter.
ure
Action of Even if cause of failure is cleared naturally, machine does not become normal until starting switch is
controller set to OFF position once.

Phenomenon
None
on machine
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

HB365LC-3 40-1079
FAILURE CODE [GA1HKZ] 40 TROUBLESHOOTING

FAILURE CODE [GA1HKZ] (ALL-K-PQHU-410-00-B)

Action level Failure code Swing motor driver phase-U temperature sensor open and short cir-
Failure cuit
L03 GA1HKZ (Hybrid controller system)
Detail of fail-
Swing motor inverter phase U output circuit temperature sensor error is detected.
ure
• Restricts swing speed.
Action of
• If cause of failure is eliminated while swing control lever is in NEUTRAL position, machine
controller
becomes normal by itself.
Phenomenon
Swing speed, etc. is restricted.
on machine
• Swing motor coil temperature can be checked with monitoring function. (Code: 09101)
Related
• After completion of repair, check that the failure code is cleared by the following operation.
information
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

40-1080 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA1JKZ]

FAILURE CODE [GA1JKZ] (ALL-K-PQHU-410-10-B)

Action level Failure code Swing motor driver phase-V temperature sensor open and short cir-
Failure cuit
L03 GA1JKZ (Hybrid controller system)
Detail of fail-
Swing motor inverter phase V output circuit temperature sensor error is detected.
ure
• Restricts swing speed.
Action of
• If cause of failure is eliminated while swing control lever is in NEUTRAL position, machine
controller
becomes normal by itself.
Phenomenon
Swing speed, etc. is restricted.
on machine
• Swing motor coil temperature can be checked with monitoring function. (Code: 09101)
Related
• After completion of repair, check that the failure code is cleared by the following operation.
information
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

HB365LC-3 40-1081
FAILURE CODE [GA1KKZ] 40 TROUBLESHOOTING

FAILURE CODE [GA1KKZ] (ALL-K-PQHU-410-20-B)

Action level Failure code Swing motor driver phase-W temperature sensor open and short cir-
Failure cuit
L03 GA1KKZ (Hybrid controller system)
Detail of fail-
Swing motor inverter phase W output circuit temperature sensor error is detected.
ure
• Restricts swing speed.
Action of
• If cause of failure is eliminated while swing control lever is in NEUTRAL position, machine
controller
becomes normal by itself.
Phenomenon
Swing speed, etc. is restricted.
on machine
• Swing motor coil temperature can be checked with monitoring function. (Code: 09101)
Related
• After completion of repair, check that the failure code is cleared by the following operation.
information
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

40-1082 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA1LKZ]

FAILURE CODE [GA1LKZ] (ALL-K-PQHT-410-90-B)

Action level Failure code Swing motor driver current sensor open and short circuit
Failure
L03 GA1LKZ (Hybrid controller system)
Detail of fail-
Swing motor inverter current flows sensor open or short circuit is detected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

HB365LC-3 40-1083
FAILURE CODE [GA1MKZ] 40 TROUBLESHOOTING

FAILURE CODE [GA1MKZ] (ALL-K-PQHT-410-A0-B)

Action level Failure code Swing motor driver DC voltage sensor open and short circuit
Failure
L03 GA1MKZ (Hybrid controller system)
Detail of fail-
Swing motor inverter DC voltage sensor error is detected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

40-1084 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA1NNS]

FAILURE CODE [GA1NNS] (ALL-K-PQHU-410-30-B)

Action level Failure code Swing motor driver IGBT overheat

Failure
- GA1NNS (Hybrid controller system)
Detail of fail-
Estimated junction temperature of swing motor IGBT inside inverter exceeds 134 °C.
ure
• Restricts swing speed.
Action of
• If cause of failure is eliminated while swing lever is in NEUTRAL position, machine be-
controller
comes normal by itself.
Phenomenon
Swing speed, etc. is restricted.
on machine
• This failure code appears in case of excessive charge or discharge (swing, swing stop) of
Related capacitor.
information • After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

See “CAPACITOR TEMPERATURE INCREASES ABNORMALLY” in Y mode, and
Defective hybrid cooling
1 check the radiator coolant level of the hybrid system cooling circuit and clogging of
system circuit
the radiator fin and the water pump operation.
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
2
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1085
FAILURE CODE [GA1SFS] 40 TROUBLESHOOTING

FAILURE CODE [GA1SFS] (ALL-K-PQL8-410-20-B)

Action level Failure code Contactor sticking

Failure
L03 GA1SFS (Hybrid controller system)
Detail of fail-
Contactor inside inverter sticks.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

40-1086 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA1SMC]

FAILURE CODE [GA1SMC] (ALL-K-PQL8-410-30-B)

Action level Failure code Contactor malfunction

Failure
L03 GA1SMC (Hybrid controller system)
Detail of fail-
Contactor inside inverter cannot be connected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
Related
• Capacitor voltage and booster low-voltage side voltage can be checked with monitoring
information function. (Code: 09300, 09400)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

HB365LC-3 40-1087
FAILURE CODE [GA1TKP] 40 TROUBLESHOOTING

FAILURE CODE [GA1TKP] (ALL-K-PQGF-410-40-B)

Action level Failure code Capacitor output voltage low error

Failure
L03 GA1TKP (Hybrid controller system)
Detail of fail-
Capacitor voltage is 190 V or less.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.
• Capacitor voltage can be checked with monitoring function. (Code: 09300)
Related
• After completion of repair, check that the failure code is cleared by the following operation.
information
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the inverter side and the capacitor side of connectors HC06
Open circuit in power ca- and HB01.
1 ble Between HC06 (DC+) (female) and capacitor side (DC
(capacitor) Max. 1 Ω
+) (female)
Resistance
Between HB01(DC-) (female) and capacitor side (DC-)
Max. 1 Ω
(female)
1. Turn the starting switch to OFF position.
2. Disconnect the inverter side and the capacitor side of connectors HC06
and HB01.
REMARK
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
Deterioration of insulation
• Measure it by mega-ohm tester.
2 in power cable
(capacitor) Between HC06 (DC+) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HC06 (DC+) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)
Resistance
Between HB01 (DC-) (female): tester (red) and con-
Min. 10 MΩ
nector part shield (part Q): tester (black)
Between HB01 (DC-) (female): tester (black) and con-
Min. 10 MΩ
nector part shield (part Q): tester (red)

40-1088 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA1TKP]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the inverter side of connectors HC06(DC+) and HB01(DC-).
REMARK
• Wipe dirt of capacitor (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
Deterioration of insulation
3
in capacitor system Between HC06 (DC+) (male): tester (red) and capaci-
Min. 10 MΩ
tor (case): tester (black)
Between HC06 (DC+) (male): tester (black) and capac-
Min. 10 MΩ
itor (case): tester (red)
Resistance
Between HB01 (DC-) (male): tester (red) and capacitor
Min. 10 MΩ
(case): tester (black)
Between HB01 (DC-) (male): tester (black) and capaci-
Min. 10 MΩ
tor (case): tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
4
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

Place of shield (Q part)

HB365LC-3 40-1089
FAILURE CODE [GA1TKP] 40 TROUBLESHOOTING

Circuit diagram related to high-voltage equipment

40-1090 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA1TNS]

FAILURE CODE [GA1TNS] (ALL-K-PQGF-410-50-B)

Action level Failure code Capacitor overheat

Failure
- GA1TNS (Hybrid controller system)
Detail of fail-
Capacitor cell center temperature exceeds 65 °C.
ure
Action of • Restricts swing speed.
controller • If cause of failure is eliminated, machine becomes normal by itself.
Phenomenon
Swing speed, etc. is restricted.
on machine
• This failure code appears in case of excessive charge or discharge (swing, swing stop) of
capacitor.
• This failure code appears if engine speed largely drops and assistance is performed fre-
quently.
Related
• Capacitor cell center temperature and capacitor base temperature can be checked with
information
monitoring function. (Code: 09306, 09304) Capacitor cell center temperature is estimated
value calculated by using capacitor base temperature.
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector HP01, and connect the T-adapter to male side.
Defective capacitor base
1 0.1 to
temperature sensor Between HP01 (male) (4) and (8)
Resistance 500 kΩ
Between HP01 (male) (4) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HP01, HK01 and HK04, and connect the T-
adapter to each female side.
Open circuit in wiring har- Between HP01 (female) (2) and HK01 (female) (1) Max. 1 Ω
2
ness
Between HP01 (female) (11) and HK01 (female) (2) Max. 1 Ω
Resistance
Between HP01 (female) (3) and HK04 (female) (1) Max. 1 Ω
Between HP01 (female) (10) and HK04 (female) (2) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and HP01, and connect the T-adapter to
Ground fault in wiring
3 either female side.
harness
Between ground and either HC02 (female) (27) or
Resistance Min. 1 MΩ
HP01 (female) (4)
See “CAPACITOR TEMPERATURE INCREASES ABNORMALLY” in Y mode, and
Defective hybrid cooling
4 check the radiator coolant level of the hybrid system cooling circuit and clogging of
system circuit
the radiator fin and the water pump operation.
• Check the engine speed. For details, see standard value table, “Engine
speed at 2-pump relief”.
5 Engine speed failure • For details, see “ENGINE RUNS ROUGH OR IS UNSTABLE” in S mode.
• For details, see “ENGINE SPEED DROPS LARGELY OR ENGINE
STOPS” in H mode.

HB365LC-3 40-1091
FAILURE CODE [GA1TNS] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the inverter side of connectors HC06(DC+) and HB01(DC-).
REMARK
• Wipe dirt of capacitor (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
Deterioration of insulation
6
in capacitor system Between HC06 (DC+) (male): tester (red) and capaci-
Min. 10 MΩ
tor (case): tester (black)
Between HC06 (DC+) (male): tester (black) and capac-
Min. 10 MΩ
itor (case): tester (red)
Resistance
Between HB01 (DC-) (male): tester (red) and capacitor
Min. 10 MΩ
(case): tester (black)
Between HB01 (DC-) (male): tester (black) and capaci-
Min. 10 MΩ
tor (case): tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
7
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to capacitor

40-1092 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA1TNS]

Circuit diagram related to high-voltage equipment

HB365LC-3 40-1093
FAILURE CODE [GA1UKZ] 40 TROUBLESHOOTING

FAILURE CODE [GA1UKZ] (ALL-K-PQGF-410-60-B)

Action level Failure code Capacitor temperature sensor open and short circuit
Failure
L01 GA1UKZ (Hybrid controller system)
Detail of fail- Difference between capacitor base temperature and capacitor bus bar temperature 54.4 °C or high-
ure er.
Action of • Restricts swing speed.
controller • If cause of failure is eliminated, machine becomes normal by itself.
Phenomenon
Swing speed, etc. is restricted.
on machine
• Capacitor base temperature and capacitor bus bar temperature can be checked with mon-
Related itoring function. (Code: 09304, 09305)
information • After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector HP01, and connect the T-adapter to male side.
Defective capacitor base
1 0.1 to
temperature sensor Between HP01 (male) (4) and (8)
Resistance 500 kΩ
Between HP01 (male) (4) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connector HP01, and connect the T-adapter to male side.
Defective capacitor bath
2 0.1 to
bar temperature sensor Between HP01 (male) (5) and (8)
Resistance 500 kΩ
Between HP01 (male) (5) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC01, HC02 and HP01, and connect the T-
adapter to each female side.
Between HC01 (female) (1) and HP01 (female) (1) Max. 1 Ω
Open circuit in wiring har- Between HC01 (female) (7) and HP01 (female) (1) Max. 1 Ω
3
ness
Between HC01 (female) (13) and HP01 (female) (12) Max. 1 Ω
Resistance
Between HC01 (female) (19) and HP01 (female) (12) Max. 1 Ω
Between HC02 (female) (27) and HP01 (female) (4) Max. 1 Ω
Between HC02 (female) (37) and HP01 (female) (5) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connector HP01, and connect the T-adapter to female side.
Hot short circuit in wiring 3. Turn the starting switch to ON position.
4
harness
Between HP01 (female) (4) and ground Max. 5.5 V
Voltage
Between HP01 (female) (5) and ground Max. 5.5 V
See “CAPACITOR TEMPERATURE INCREASES ABNORMALLY” in Y mode, and
Defective hybrid cooling
5 check the radiator coolant level of the hybrid system cooling circuit and clogging of
system circuit
the radiator fin and the water pump operation.

40-1094 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA1UKZ]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the inverter side of connectors HC06(DC+) and HB01(DC-).
REMARK
• Wipe dirt of capacitor (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
Deterioration of insulation
6
in capacitor system Between HC06 (DC+) (male): tester (red) and capaci-
Min. 10 MΩ
tor (case): tester (black)
Between HC06 (DC+) (male): tester (black) and capac-
Min. 10 MΩ
itor (case): tester (red)
Resistance
Between HB01 (DC-) (male): tester (red) and capacitor
Min. 10 MΩ
(case): tester (black)
Between HB01 (DC-) (male): tester (black) and capaci-
Min. 10 MΩ
tor (case): tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
7
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to capacitor

HB365LC-3 40-1095
FAILURE CODE [GA1UKZ] 40 TROUBLESHOOTING

Circuit diagram related to high-voltage equipment

40-1096 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA1VFS]

FAILURE CODE [GA1VFS] (ALL-K-PQL8-410-00-B)

Action level Failure code Capacitor contactor sticking

Failure
L03 GA1VFS (Hybrid controller system)
Detail of fail-
Contactor inside capacitor sticks.
ure
• Restricts swing speed.
Action of
• Even if cause of failure is cleared naturally, machine does not become normal until starting
controller
switch is set to OFF position once.
Phenomenon
Swing speed, etc. is restricted.
on machine

NOTICE
Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
Related • If failure code [GA1VMC] is also displayed, hot short circuit of wiring harness may occur.
information • Capacitor voltage can be checked with monitoring function. (Code: 09300)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector HP01, and connect the T-adapter to female side.
Hot short circuit in wiring 3. Turn the starting switch to ON position.
1
harness
Between HP01 (female) (6) and ground Min. 1 V
Resistance
Between HP01 (female) (7) and ground Min. 1 V
Before performing the "Capacitor Discharge" (50 V or more of capacitor voltage),
2 Defective capacitor check that both 2 LED lamps visible from the inspection window are lit while turning
off the power supply. If they are lit, capacitor is defective.
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
3
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to capacitor contactor

HB365LC-3 40-1097
FAILURE CODE [GA1VMC] 40 TROUBLESHOOTING

FAILURE CODE [GA1VMC] (ALL-K-PQL8-410-10-B)

Action level Failure code Capacitor contactor malfunction

Failure
L03 GA1VMC (Hybrid controller system)
Detail of fail-
Contactor inside capacitor cannot be connected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC01 and HP01, and connect the T-adapter to
Open circuit in wiring har- each female side.
1
ness
Between HC01 (female) (3) and HP01 (female) (6) Max. 1 Ω
Resistance
Between HC01 (female) (9) and HP01 (female) (7) Max. 1 Ω
Before performing the "Capacitor Discharge" (50 V or more of capacitor voltage),
2 Defective capacitor check that both 2 LED lamps visible from the inspection window are lit while turning
off the power supply. If they are lit, capacitor is defective.
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
3
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to capacitor contactor

40-1098 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA1XKZ]

FAILURE CODE [GA1XKZ] (ALL-K-PQGR-410-90-B)

Action level Failure code Booster inductor temperature sensor open and short circuit
Failure
L01 GA1XKZ (Hybrid controller system)
Detail of fail-
Booster inductor temperature sensor error inside inverter is detected.
ure
Action of • Restricts swing speed.
controller • If cause of failure is eliminated, machine becomes normal by itself.
Phenomenon
Swing speed, etc. is restricted.
on machine
• Booster inductor temperature can be checked with monitoring function. (Code: 09402)
• If inductor temperature is normal (same as ambient temperature or within the higher tem-
perature range: 11 to 190 °C), hybrid system cooling circuit is probably defective.
• If either of failure codes [GA00NS], [GA1YNS], [GA1NNS], [GA1ZNS], [GA22NS],
Related [GA25NS], and [GA26NS] is also displayed, hybrid system cooling circuit is probably de-
fective.
information
• When low-pressure pressure sensor described in step 4 in cause 4 is installed, probability
of defective circuit can be checked by monitoring function of service pressure (hybrid wa-
ter pump). (Code: 01142)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Check the coolant level of hybrid radiator.
Check that the level is higher than the sight gauge by visual check.
2. Check for clogging of the hybrid radiator fin.
3. Check the water pump operation (when turning starting switch to ON posi-
tion).

Defective hybrid cooling Check the vibration of the pump with touching by hand.
1 4.
system circuit Check the coolant flow (pressure measurement).
• Remove the plug above the coolant inlet elbow in the electric swing
motor, connect the low pressure sensor. Measure the pressure after
turning starting switch to ON position, and check the water pump op-
eration, etc.
• For details, see TESTING AND ADJUSTING, “WATER PRESSURE
TEST OF THE HYBRID SYSTEM COOLANT”.
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
2
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1099
FAILURE CODE [GA1YNS] 40 TROUBLESHOOTING

FAILURE CODE [GA1YNS] (ALL-K-PQGR-410-A0-B)

Action level Failure code Booster inductor overheat

Failure
- GA1YNS (Hybrid controller system)
Detail of fail-
Temperature of booster inductor inside inverter is 127 °C or higher.
ure
Action of • Restricts swing speed.
controller • If cause of failure is eliminated, machine becomes normal by itself.
Phenomenon
Swing speed, etc. is restricted.
on machine
• This failure code appears in case of excessive charge or discharge (swing, swing stop) of
capacitor.
• This failure code appears if engine speed largely drops and assistance is performed fre-
Related
quently.
information
• Booster inductor temperature can be checked with monitoring function. (Code: 09402)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

See “CAPACITOR TEMPERATURE INCREASES ABNORMALLY” in Y mode, and
Defective hybrid cooling
1 check the radiator coolant level of the hybrid system cooling circuit and clogging of
system circuit
the radiator fin and the water pump operation.
• Check the engine speed. For details, see standard value table, “Engine
speed at 2-pump relief”.
2 Engine speed failure • For details, see “ENGINE RUNS ROUGH OR IS UNSTABLE” in S mode.
• For details, see “ENGINE SPEED DROPS LARGELY OR ENGINE
STOPS” in H mode.
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
3
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

40-1100 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA1ZKZ]

FAILURE CODE [GA1ZKZ] (ALL-K-PQGR-410-B0-B)

Action level Failure code Booster IGBT temperature sensor open and short circuit
Failure
L03 GA1ZKZ (Hybrid controller system)
Detail of fail-
Booster IGBT temperature sensor error inside inverter is detected.
ure
Action of • Restricts swing speed.
controller • If cause of failure is eliminated, machine becomes normal by itself.
Phenomenon
Swing speed, etc. is restricted.
on machine
• Booster IGBT base temperature can be checked with monitoring function. (Code: 09403)
Related
• After completion of repair, check that the failure code is cleared by the following operation.
information
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

HB365LC-3 40-1101
FAILURE CODE [GA1ZNS] 40 TROUBLESHOOTING

FAILURE CODE [GA1ZNS] (ALL-K-PQGR-410-C0-B)

Action level Failure code Booster IGBT temperature sensor overheat

Failure
- GA1ZNS (Hybrid controller system)
Detail of fail-
Temperature of booster IGBT inside inverter is 95 °C or higher.
ure
Action of • Restricts swing speed.
controller • If cause of failure is eliminated, machine becomes normal by itself.
Phenomenon
Swing speed, etc. is restricted.
on machine
• This failure code appears in case of excessive charge or discharge (swing, swing stop) of
capacitor.
Related
• Booster IGBT base temperature can be checked with monitoring function. (Code: 09403)
information
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

See “CAPACITOR TEMPERATURE INCREASES ABNORMALLY” in Y mode, and
Defective hybrid cooling
1 check the radiator coolant level of the hybrid system cooling circuit and clogging of
system circuit
the radiator fin and the water pump operation.
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
2
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

40-1102 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA22NS]

FAILURE CODE [GA22NS] (ALL-K-PQGR-410-E0-B)

Action level Failure code Booster IGBT junction overheat

Failure
- GA22NS (Hybrid controller system)
Detail of fail-
Estimated junction temperature of booster IGBT inside inverter is 130 °C or higher.
ure
• Restricts swing speed.
Action of
• If cause of failure is eliminated while swing lever is in NEUTRAL position, machine be-
controller
comes normal by itself.
Phenomenon
Swing speed, etc. is restricted.
on machine
• This failure code appears in case of excessive charge or discharge (swing, swing stop) of
capacitor.
Related • Booster IGBT junction temperature can be checked with monitoring function. (Code:
information 09404)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

See “CAPACITOR TEMPERATURE INCREASES ABNORMALLY” in Y mode, and
Defective hybrid cooling
1 check the radiator coolant level of the hybrid system cooling circuit and clogging of
system circuit
the radiator fin and the water pump operation.
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
2
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1103
FAILURE CODE [GA23KZ] 40 TROUBLESHOOTING

FAILURE CODE [GA23KZ] (ALL-K-PQHE-410-R0-B)

Action level Failure code Motor-generator driver temperature sensor 0 open and short circuit
Failure
L01 GA23KZ (Hybrid controller system)
Detail of fail-
Open or short circuit of motor-generator driver temperature sensor 0 is detected.
ure
Action of • Restricts swing speed.
controller • If cause of failure is eliminated, machine becomes normal by itself.
Phenomenon
Swing speed, etc. is restricted.
on machine
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

40-1104 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA24KZ]

FAILURE CODE [GA24KZ] (ALL-K-PQHE-410-80-B)

Action level Failure code Motor-generator driver temperature sensor 1 open and short circuit
Failure
L01 GA24KZ (Hybrid controller system)
Detail of fail-
Open or short circuit of motor-generator driver temperature sensor 1 is detected.
ure
Action of • Restricts swing speed.
controller • If cause of failure is eliminated, machine becomes normal by itself.
Phenomenon
Swing speed, etc. is restricted.
on machine
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

HB365LC-3 40-1105
FAILURE CODE [GA25MA] 40 TROUBLESHOOTING

FAILURE CODE [GA25MA] (ALL-K-PQHE-410-90-B)

Action level Failure code Motor-generator driver IGBT 0 error

Failure
L03 GA25MA (Hybrid controller system)
Detail of fail-
Motor-generator driver IGBT 0 error is detected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Open circuit in power ca- it is.
1 ble
(motor-generator) Between HC03 (A1) (male) and GM02 (A1) (male) Max. 1 Ω
Between HC03 (B1) (male) and GM02 (B1) (male) Max. 1 Ω
Between HC03 (C1) (male) and GM02 (C1) (male) Max. 1 Ω
Resistance
Between HC04 (A2) (male) and GM03 (A2) (male) Max. 1 Ω
Between HC04 (B2) (male) and GM03 (B2) (male) Max. 1 Ω
Between HC04 (C2) (male) and GM03 (C2) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Internal short circuit in it is.
2 power cable
(motor-generator) Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
Resistance
Between HC04 (A2) (male) and HC04 (B2) (male) Min. 10 MΩ
Between HC04 (B2) (male) and HC04 (C2) (male) Min. 10 MΩ
Between HC04 (C2) (male) and HC04 (A2) (male) Min. 10 MΩ

40-1106 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA25MA]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC03 (A1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC03 (B1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
Deterioration of insulation HC03 (B1) (male): tester (black) and cable housing
3 in power cable Min. 10 MΩ
metal (P part): tester (red)
(motor-generator)
HC03 (C1) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC03 (C1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
Resistance
HC04 (A2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (A2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (B2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (B2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (C2) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC04 (C2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Open circuit between
4 phases of motor-genera- There is a coil resistance of motor in the motor-generator.
tor system
Between HC03 (A1) (male) and HC04 (A2) (male) Max. 1 Ω
Resistance Between HC03 (B1) (male) and HC04 (B2) (male) Max. 1 Ω
Between HC03 (C1) (male) and HC04 (C2) (male) Max. 1 Ω

HB365LC-3 40-1107
FAILURE CODE [GA25MA] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Short circuit between
5 phases of motor-genera- Measure one either HC03 or HC04.
tor system.
Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Resistance Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
• Wipe dirt of the inverter (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
Deterioration of insulation er (black)
6 in motor-generator sys-
tem HC03 (A1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (B1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC03 (B1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (C1) (male): tester (red) and inverter (case):
Min. 10 MΩ
tester (black)
HC03 (C1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
7
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

40-1108 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA25MA]

Circuit diagram related to high-voltage equipment

HB365LC-3 40-1109
FAILURE CODE [GA25NS] 40 TROUBLESHOOTING

FAILURE CODE [GA25NS] (ALL-K-PQJB-410-40-B)

Action level Failure code Motor-generator driver IGBT 0 overheat

Failure
- GA25NS (Hybrid controller system)
Detail of fail-
Motor-generator driver IGBT temperature is 95 °C or higher.
ure
• Restricts swing speed.
Action of
• If cause of failure is eliminated while swing lever is in NEUTRAL position, machine be-
controller
comes normal by itself.
Phenomenon
Swing speed, etc. is restricted.
on machine
• This failure code appears in case of excessive charge or discharge (swing, swing stop) of
Related capacitor.
information • After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

See “CAPACITOR TEMPERATURE INCREASES ABNORMALLY” in Y mode, and
Defective hybrid cooling
1 check the radiator coolant level of the hybrid system cooling circuit and clogging of
system circuit
the radiator fin and the water pump operation.
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
2
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

40-1110 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA26MA]

FAILURE CODE [GA26MA] (ALL-K-PQHE-410-B0-B)

Action level Failure code Motor-generator driver IGBT 1 error

Failure
L03 GA26MA (Hybrid controller system)
Detail of fail-
Motor-generator driver IGBT 1 error is detected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Open circuit in power ca- it is.
1 ble
(motor-generator) Between HC03 (A1) (male) and GM02 (A1) (male) Max. 1 Ω
Between HC03 (B1) (male) and GM02 (B1) (male) Max. 1 Ω
Between HC03 (C1) (male) and GM02 (C1) (male) Max. 1 Ω
Resistance
Between HC04 (A2) (male) and GM03 (A2) (male) Max. 1 Ω
Between HC04 (B2) (male) and GM03 (B2) (male) Max. 1 Ω
Between HC04 (C2) (male) and GM03 (C2) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Internal short circuit in it is.
2 power cable
(motor-generator) Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
Resistance
Between HC04 (A2) (male) and HC04 (B2) (male) Min. 10 MΩ
Between HC04 (B2) (male) and HC04 (C2) (male) Min. 10 MΩ
Between HC04 (C2) (male) and HC04 (A2) (male) Min. 10 MΩ

HB365LC-3 40-1111
FAILURE CODE [GA26MA] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC03 (A1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC03 (B1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
Deterioration of insulation HC03 (B1) (male): tester (black) and cable housing
3 in power cable Min. 10 MΩ
metal (P part): tester (red)
(motor-generator)
HC03 (C1) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC03 (C1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
Resistance
HC04 (A2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (A2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (B2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (B2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (C2) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC04 (C2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Open circuit between
4 phases of motor-genera- There is a coil resistance of motor in the motor-generator.
tor system
Between HC03 (A1) (male) and HC04 (A2) (male) Max. 1 Ω
Resistance Between HC03 (B1) (male) and HC04 (B2) (male) Max. 1 Ω
Between HC03 (C1) (male) and HC04 (C2) (male) Max. 1 Ω

40-1112 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA26MA]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Short circuit between
5 phases of motor-genera- Measure one either HC03 or HC04.
tor system.
Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Resistance Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
• Wipe dirt of the inverter (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
Deterioration of insulation er (black)
6 in motor-generator sys-
tem HC03 (A1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (B1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC03 (B1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (C1) (male): tester (red) and inverter (case):
Min. 10 MΩ
tester (black)
HC03 (C1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
7
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1113
FAILURE CODE [GA26MA] 40 TROUBLESHOOTING

Circuit diagram related to high-voltage equipment

40-1114 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA26NS]

FAILURE CODE [GA26NS] (ALL-K-PQJB-410-50-B)

Action level Failure code Motor-generator driver IGBT 1 overheat

Failure
- GA26NS (Hybrid controller system)
Detail of fail-
Motor-generator driver IGBT temperature is 95 °C or higher.
ure
• Restricts swing speed.
Action of
• If cause of failure is eliminated while swing lever is in NEUTRAL position, machine be-
controller
comes normal by itself.
Phenomenon
Swing speed, etc. is restricted.
on machine
• This failure code appears in case of excessive charge or discharge (swing, swing stop) of
Related capacitor.
information • After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

See “CAPACITOR TEMPERATURE INCREASES ABNORMALLY” in Y mode, and
Defective hybrid cooling
1 check the radiator coolant level of the hybrid system cooling circuit and clogging of
system circuit
the radiator fin and the water pump operation.
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
2
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1115
FAILURE CODE [GA27KZ] 40 TROUBLESHOOTING

FAILURE CODE [GA27KZ] (ALL-K-PQGF-410-70-B)

Action level Failure code DC current sensor before booster open and short circuit
Failure
L01 GA27KZ (Hybrid controller system)
Detail of fail-
Open or short circuit of DC current sensor is detected before boosting.
ure
Action of
Restricts swing speed.
controller
Phenomenon
Swing speed, etc. is restricted.
on machine
• Capacitor current can be checked with monitoring function. (Code: 09307)
Related
• After completion of repair, check that the failure code is cleared by the following operation.
information
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

40-1116 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA2QKR]

FAILURE CODE [GA2QKR] (ALL-K-0J10-410-10-B)

Action level Failure code CAN 2 defective communication (Hybrid controller)

Failure
L03 GA2QKR (Machine monitor system)
Detail of fail- Machine monitor does not recognize inverter (hybrid controller) through CAN communication 2 line
ure (KOMNET/c).
Action of
Retains information when the failure occurred.
controller

Phenomenon Information to be obtained from inverter (hybrid controller) is not displayed and special functions do
not work. Or update of received data is stopped (such as failure codes and monitoring codes sent
on machine from the inverter (hybrid controller)).
• ACC signal of starting switch is the command to start CAN communication for each con-
troller.
• 5 different failure codes, [D8AQKR], [DA2QKR], [DAFQKR], [DB2QKR], and [GA2QKR]
are used for defective CAN communication by CAN 2 when it is detected by machine
monitor. When all of these 5 failure codes are displayed, ground fault, short circuit or hot
short circuit in wiring harness (CAN communication circuit) can be suspected.
REMARK
Related
If air conditioner is controlled, there is no possibility of ground fault, short circuit, or hot
information
short circuit occurring in wiring harness (CAN communication line).
• Since each controller and machine monitor are connected directly to battery, they are sup-
plied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connector HC01, and connect the T-adapter to female
side.
Defective power supply 4. Turn the battery disconnect switch to ON position.
1 circuit of inverter (hybrid
controller) 5. Turn the starting switch to ON position.
REMARK
If there is no failure, troubleshooting for No. 2 is not required.
Between HC01 (female) (5) and (17) 20 to 30 V
Voltage
Between HC01 (female) (11) and (23) 20 to 30 V

HB365LC-3 40-1117
FAILURE CODE [GA2QKR] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.17 in fuse box F01.
4. Disconnect the connector HC01, and connect the T-adapter to female
Open circuit in wiring har-
2 side.
ness
Between HC01 (female) (5) and F01 -17 Max. 1 Ω
Between HC01 (female) (11) and F01 -17 Max. 1 Ω
Resistance
Between HC01 (female) (17) and ground Max. 1 Ω
Between HC01 (female) (23) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connector HC01, and connect the T-adapter to female
side.
Defective inverter (hybrid 4.
Turn the battery disconnect switch to ON position.
3 controller) ACC signal
circuit 5. Turn the starting switch to ON position.
REMARK
If there is no failure, troubleshooting for No. 4 is not required.
Between HC01 (female) (6) and (17) 20 to 30 V
Voltage
Between HC01 (female) (12) and (23) 20 to 30 V
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.14 in fuse box F01.
4. Disconnect the connector HC01, and connect the T-adapter to female
Open circuit in wiring har-
4 side.
ness
Between HC01 (female) (6) and F01 -14 Max. 1 Ω
Between HC01 (female) (12) and F01 -14 Max. 1 Ω
Resistance
Between HC01 (female) (17) and ground Max. 1 Ω
Between HC01 (female) (23) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect connectors CM02 and K02, and connect T-adapter to each
Defective CAN 2 termi- male side.
5
nating resistor
Between CM02 (male) (7) and (9) 120 ± 12 Ω
Resistance
Between K02 (male) (A) and (B) 120 ± 12 Ω

40-1118 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA2QKR]

No. Cause Procedure, measuring location, criteria and remarks

Open circuit in wiring har-
6 ness (CAN 2 communi-
cation line)
Ground fault in wiring
7 harness (CAN 2 commu-
nication line)
Hot short circuit in wiring
8 harness (CAN 2 commu-
nication line)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
9
controller) (Since this is an internal defect, troubleshooting cannot be performed.)
Defective machine moni-
10
tor
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors CM02, HC01, and K02, and connect the T-
adapter to each female side.
Between CM02 (female) (7) and HC01 (female) (1) Max. 1 Ω
Between CM02 (female) (8) and HC01 (female) (1) Max. 1 Ω
Resistance Between CM02 (female) (9) and HC01 (female) (11) Max. 1 Ω
Between HC01 (female) (1) and K02 (female) (A) Max. 1 Ω
Between HC01 (female) (11) and K02 (female) (B) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors HC01 and CM02, and connect the T-adapter to
either female side.
4. Disconnect the connectors, terminals, and fuses of all the devices which
branch out from connectors HC01 (1) and (11).
Between ground and any of HC01 (female) (1), CM02
Min. 1 MΩ
(female) (7), and (8)
Resistance
Between ground and either HC01 (female) (11) or
Min. 1 MΩ
CM02 (female) (9)
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Insert T-adapter into connector K02.
4. Turn the battery disconnect switch to ON position.
5. Turn the starting switch to ON position.
REMARK
Voltage of CANH and CANL is 2.5 ± 1 V including during communication, so regard
wiring harness as normal if measured voltage is 1 to 4 V.
Between K02(A) and ground 1 to 4 V
Voltage
Between K02(B) and ground 1 to 4 V
If no failure is found by above checks, machine monitor is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1119
FAILURE CODE [GA2QKR] 40 TROUBLESHOOTING

CIRCUIT DIAGRAM (CAN2 COMMUNICATION)

40-1120 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA2QKR]

Circuit diagram related to inverter (hybrid controller) power supply

HB365LC-3 40-1121
FAILURE CODE [GA2RKR] 40 TROUBLESHOOTING

FAILURE CODE [GA2RKR] (ALL-K-0J00-410-00-B)

Action level Failure code CAN 1 defective communication (Hybrid controller)

Failure
L04 GA2RKR (Machine monitor system)
Detail of fail- Machine monitor does not recognize inverter (hybrid controller) through CAN communication 1 line
ure (KOMNET/r).
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Restricts swing speed.
• Information to be obtained from inverter (hybrid controller) is not displayed and special
functions that need information do not work. Or update of received data is stopped.
Phenomenon
• Low-speed matching is disabled.
on machine
• Hoist matching is disabled.
• Swing speed is restricted.
• ACC signal of starting switch is the command to start CAN communication for each con-
troller.
• 3 different failure codes, [DA2RKR], [DB2RKR], and [GA2RKR] are used for defective
CAN communication by CAN 1 when it is detected by machine monitor. When these 3 fail-
ure codes are displayed, ground fault, short circuit or hot short circuit in wiring harness
(CAN communication circuit) can be suspected.
• CAN1 terminating resister is located in machine monitor on operator's cab side and con-
Related
nector “C23” is located on engine side (CAN communication-1 circuit (KOMNET/r) is not
information provided. It is output from connector “ECM J2”).
• Since each controller and machine monitor are connected directly to battery, they are sup-
plied with power even after starting switch is turned to OFF position.
• Since signal of active CAN communication line is pulse voltage, it cannot be measured by
using multimeter.
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connector HC01, and connect the T-adapter to female
side.
Defective power supply 4. Turn the battery disconnect switch to ON position.
1 circuit of inverter (hybrid
controller) 5. Turn the starting switch to ON position.
REMARK
If there is no failure, troubleshooting for No. 2 is not required.
Between HC01 (female) (5) and (17) 20 to 30 V
Voltage
Between HC01 (female) (11) and (23) 20 to 30 V

40-1122 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA2RKR]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.17 in fuse box F01.
4. Disconnect the connector HC01, and connect the T-adapter to female
Open circuit in wiring har-
2 side.
ness
Between HC01 (female) (5) and F01 -17 Max. 1 Ω
Between HC01 (female) (11) and F01 -17 Max. 1 Ω
Resistance
Between HC01 (female) (17) and ground Max. 1 Ω
Between HC01 (female) (23) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connector HC01, and connect the T-adapter to female
side.
Defective inverter (hybrid 4.
Turn the battery disconnect switch to ON position.
3 controller) ACC signal
circuit 5. Turn the starting switch to ON position.
REMARK
If there is no failure, troubleshooting for No. 4 is not required.
Between HC01 (female) (6) and (17) 20 to 30 V
Voltage
Between HC01 (female) (12) and (23) 20 to 30 V
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Remove the fuse No.14 in fuse box F01.
4. Disconnect the connector HC01, and connect the T-adapter to female
Open circuit in wiring har-
4 side.
ness
Between HC01 (female) (6) and F01 -14 Max. 1 Ω
Between HC01 (female) (12) and F01 -14 Max. 1 Ω
Resistance
Between HC01 (female) (17) and ground Max. 1 Ω
Between HC01 (female) (23) and ground Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors C23 and CM02, and connect the T-adapter to
Defective CAN 1 termi- each male side.
5
nating resistor
Between CM02 (male) (10) and (12) 120 ± 12 Ω
Resistance
Between C23 (male) (A) and (B) 120 ± 12 Ω

HB365LC-3 40-1123
FAILURE CODE [GA2RKR] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Open circuit in wiring har-
6 ness (CAN 1 communi-
cation line)
Ground fault in wiring
7 harness (CAN 1 commu-
nication line)
Hot short circuit in wiring
8 harness (CAN 1 commu-
nication line)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
9
controller) (Since this is an internal defect, troubleshooting cannot be performed.)
Defective machine moni-
10
tor
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors CM02, HC02 and C23, and connect the T-
adapter to each female side.
Between CM02 (female) (10) and HC02 (female) (21) Max. 1 Ω
Between CM02 (female) (11) and HC02 (female) (21) Max. 1 Ω
Resistance Between CM02 (female) (12) and HC02 (female) (31) Max. 1 Ω
Between HC02 (female) (21) and C23 (female) (A) Max. 1 Ω
Between HC02 (female) (31) and C23 (female) (B) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Disconnect the connectors HC02 and CM02, and connect the T-adapter to
either female side.
4. Disconnect the connectors, terminals, and fuses of all the devices which
branch out from connectors HC02 (21) and (31).
Between ground and any of HC02 (female) (21), CM02
Min. 1 MΩ
(female) (10), and (11)
Resistance
Between ground and either HC02 (female) (31) or
Min. 1 MΩ
CM02 (female) (12)
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
3. Insert the T-adapter into connector C23.
4. Turn the battery disconnect switch to ON position.
5. Turn the starting switch to ON position.
REMARK
Voltage of CANH and CANL is 2.5 ± 1 V including during communication, so regard
wiring harness as normal if measured voltage is 1 to 4 V.
Between ground and C23 (A) 1 to 4 V
Voltage
Between ground and C23 (B) 1 to 4 V
If no failure is found by above checks, machine monitor is defective. (Since this is
an internal defect, troubleshooting cannot be performed.)

40-1124 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA2RKR]

Circuit diagram related to CAN communication 1

HB365LC-3 40-1125
FAILURE CODE [GA2RKR] 40 TROUBLESHOOTING

Circuit diagram related to inverter (hybrid controller) power supply

40-1126 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA60MC]

FAILURE CODE [GA60MC] (ALL-K-PQHE-410-D0-B)

Action level Failure code Motor-generator malfunction

Failure
L03 GA60MC (Hybrid controller system)
Detail of fail-
Difference between motor-generator speed and engine speed is 200 rpm or more.
ure
Action of
If cause of failure is eliminated, machine becomes normal by itself.
controller
Phenomenon
Swinging is disabled (in case of open circuit or short circuit).
on machine

NOTICE
Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
• Motor-generator speed and engine speed can be checked with monitoring function. (Code:
Related 09602, 01002)
information • Motor-generator speed sensor is installed to rotor of motor-generator, and it can be singly
replaced.
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and GM01, and connect the T-adapter to
each female side.
Open circuit in wiring har-
1
ness Between HC02 (female) (4) and GM01 (female) (2) Max. 1 Ω
Resistance Between HC02 (female) (7) and GM01 (female) (1) Max. 1 Ω
Between HC02 (female) (33) and GM01 (female) (3) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and GM01, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either HC02 (female) (4) or
Resistance Min. 1 MΩ
GM01 (female) (2)
1. Turn the starting switch to OFF position.
2. Disconnect the connector GM01, and connect the T-adapter to female
Hot short circuit in wiring side.
3
harness
3. Turn the starting switch to ON position.
Voltage Between GM01 (female) (2) and ground Max. 1 V
Defective motor-genera- If no failure is found by above checks, motor-generator is defective.
4
tor (Since this is an internal defect, troubleshooting cannot be performed.)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
5
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1127
FAILURE CODE [GA60MC] 40 TROUBLESHOOTING

Circuit diagram related to 5 V sensor power supply (hybrid)

40-1128 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA60N1]

FAILURE CODE [GA60N1] (ALL-K-PQHE-410-E0-B)

Action level Failure code Motor-generator overrun

Failure
- GA60N1 (Hybrid controller system)
Detail of fail-
Motor-generator overrun is detected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and GM01, and connect the T-adapter to
each female side.
Open circuit in wiring har-
1
ness Between HC02 (female) (4) and GM01 (female) (2) Max. 1 Ω
Resistance Between HC02 (female) (7) and GM01 (female) (1) Max. 1 Ω
Between HC02 (female) (33) and GM01 (female) (3) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and GM01, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either HC02 (female) (4) or
Resistance Min. 1 MΩ
GM01 (female) (2)
1. Turn the starting switch to OFF position.
2. Disconnect the connector GM01, and connect the T-adapter to female
Hot short circuit in wiring side.
3
harness
3. Turn the starting switch to ON position.
Voltage Between GM01 (female) (2) and ground Max. 1 V
Defective motor-genera- If no failure is found by above checks, motor-generator is defective.
4
tor (Since this is an internal defect, troubleshooting cannot be performed.)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
5
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1129
FAILURE CODE [GA60N1] 40 TROUBLESHOOTING

Circuit diagram related to 5 V sensor power supply (hybrid)

40-1130 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA61KZ]

FAILURE CODE [GA61KZ] (ALL-K-PQLY-410-00-B)

Action level Failure code Motor-generator temperature sensor open and short circuit
Failure
L01 GA61KZ (Hybrid controller system)
Detail of fail-
Open or short circuit of motor-generator temperature sensor is detected.
ure
Action of • Restricts swing speed.
controller • If cause of failure is eliminated, machine becomes normal by itself.
Phenomenon
Swing speed, etc. is restricted.
on machine
• Replace motor-generator housing to replace motor-generator temperature sensor.
REMARK

Related
For details, see “DISASSEMBLY AND ASSEMBLY, REMOVE AND INSTALL MOTOR-
GENERATOR AND HOUSING ASSEMBLY”.
information
• Motor-generator temperature can be checked with monitoring function. (Code: 09600)
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect connector GM01, and connect T-adapter to male side.
Approx.
-40 °C
4200 kΩ
Approx.
10 °C
210 kΩ
Approx.
25 °C
Defective motor-genera- Between GM01 (male) (4) 100 kΩ
1
tor temperature sensor and (5) Approx.
Resistance 40 °C
50 kΩ
Approx.
90 °C
7.7 kΩ
Approx.
200 °C
440 Ω
Between GM01 (male) (4)
All range Min. 1 MΩ
and ground
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and GM01, and connect the T-adapter to
Open circuit in wiring har- each female side.
2
ness
Between HC02 (female) (28) and GM01 (female) (4) Max. 1 Ω
Resistance
Between HC02 (female) (17) and GM01 (female) (5) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and GM01, and connect the T-adapter to
Ground fault in wiring
3 either female side.
harness
Between ground and either HC02 (female) (28) or
Resistance Min. 1 MΩ
GM01 (female) (4)

HB365LC-3 40-1131
FAILURE CODE [GA61KZ] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector GM01, and connect the T-adapter to female
Hot short circuit in wiring side.
4
harness
3. Turn the starting switch to ON position.
Voltage Between GM01 (female) (4) and ground Max. 5.5 V
See “CAPACITOR TEMPERATURE INCREASES ABNORMALLY” in Y mode, and
Defective hybrid cooling
5 check the radiator coolant level of the hybrid system cooling circuit and clogging of
system circuit
the radiator fin and the water pump operation.
Defective motor-genera- If no failure is found by above checks, motor-generator is defective.
6
tor (Since this is an internal defect, troubleshooting cannot be performed.)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
7
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to motor-generator temperature sensor

40-1132 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA61NS]

FAILURE CODE [GA61NS] (ALL-K-PQLY-410-10-B)

Action level Failure code Motor-generator temperature sensor overheat

Failure
- GA61NS (Hybrid controller system)
Detail of fail-
Motor-generator temperature is 180 °C or higher.
ure
Action of • Restricts swing speed.
controller • If cause of failure is eliminated, machine becomes normal by itself.
Phenomenon
Swing speed, etc. is restricted.
on machine
• This failure code appears in case of excessive charge or discharge (swing, swing stop) of
capacitor.
Related • For details, see “MOTOR-GENERATOR TEMPERATURE INCREASES ABNORMALLY” in
information Y mode.
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

See “CAPACITOR TEMPERATURE INCREASES ABNORMALLY” in Y mode, and
Defective hybrid cooling
1 check the radiator coolant level of the hybrid system cooling circuit and clogging of
system circuit
the radiator fin and the water pump operation.
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and GM01, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either HC02 (female) (28) or
Resistance Min. 1 MΩ
GM01 (female) (4)
Defective motor-genera- If no failure is found by above checks, motor-generator is defective.
3
tor (Since this is an internal defect, troubleshooting cannot be performed.)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
4
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to motor-generator temperature sensor

HB365LC-3 40-1133
FAILURE CODE [GA62KY] 40 TROUBLESHOOTING

FAILURE CODE [GA62KY] (ALL-K-PQHE-410-H0-B)

Action level Failure code Motor-generator phase-A current sensor power supply line short cir-
Failure cuit
- GA62KY (Hybrid controller system)
Detail of fail-
Motor-generator phase A detects overcurrent.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Open circuit in power ca- it is.
1 ble
(motor-generator) Between HC03 (A1) (male) and GM02 (A1) (male) Max. 1 Ω
Between HC03 (B1) (male) and GM02 (B1) (male) Max. 1 Ω
Between HC03 (C1) (male) and GM02 (C1) (male) Max. 1 Ω
Resistance
Between HC04 (A2) (male) and GM03 (A2) (male) Max. 1 Ω
Between HC04 (B2) (male) and GM03 (B2) (male) Max. 1 Ω
Between HC04 (C2) (male) and GM03 (C2) (male) Max. 1 Ω

40-1134 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA62KY]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Internal short circuit in it is.
2 power cable
(motor-generator) Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
Resistance
Between HC04 (A2) (male) and HC04 (B2) (male) Min. 10 MΩ
Between HC04 (B2) (male) and HC04 (C2) (male) Min. 10 MΩ
Between HC04 (C2) (male) and HC04 (A2) (male) Min. 10 MΩ

HB365LC-3 40-1135
FAILURE CODE [GA62KY] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC03 (A1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC03 (B1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
Deterioration of insulation HC03 (B1) (male): tester (black) and cable housing
3 in power cable Min. 10 MΩ
metal (P part): tester (red)
(motor-generator)
HC03 (C1) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC03 (C1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
Resistance
HC04 (A2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (A2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (B2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (B2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (C2) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC04 (C2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Open circuit between
4 phases of motor-genera- There is a coil resistance of motor in the motor-generator.
tor system
Between HC03 (A1) (male) and HC04 (A2) (male) Max. 1 Ω
Resistance Between HC03 (B1) (male) and HC04 (B2) (male) Max. 1 Ω
Between HC03 (C1) (male) and HC04 (C2) (male) Max. 1 Ω

40-1136 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA62KY]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Short circuit between
5 phases of motor-genera- Measure one either HC03 or HC04.
tor system.
Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Resistance Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
• Wipe dirt of the inverter (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
Deterioration of insulation er (black)
6 in motor-generator sys-
tem HC03 (A1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (B1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC03 (B1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (C1) (male): tester (red) and inverter (case):
Min. 10 MΩ
tester (black)
HC03 (C1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
7
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1137
FAILURE CODE [GA62KY] 40 TROUBLESHOOTING

Circuit diagram related to high-voltage equipment

40-1138 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA62KZ]

FAILURE CODE [GA62KZ] (ALL-K-PQHE-410-I0-B)

Action level Failure code Motor-generator phase-A current sensor open and short circuit
Failure
L01 GA62KZ (Hybrid controller system)
Detail of fail-
Open or short circuit of motor-generator phase A is detected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Open circuit in power ca- it is.
1 ble
(motor-generator) Between HC03 (A1) (male) and GM02 (A1) (male) Max. 1 Ω
Between HC03 (B1) (male) and GM02 (B1) (male) Max. 1 Ω
Between HC03 (C1) (male) and GM02 (C1) (male) Max. 1 Ω
Resistance
Between HC04 (A2) (male) and GM03 (A2) (male) Max. 1 Ω
Between HC04 (B2) (male) and GM03 (B2) (male) Max. 1 Ω
Between HC04 (C2) (male) and GM03 (C2) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Internal short circuit in it is.
2 power cable
(motor-generator) Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
Resistance
Between HC04 (A2) (male) and HC04 (B2) (male) Min. 10 MΩ
Between HC04 (B2) (male) and HC04 (C2) (male) Min. 10 MΩ
Between HC04 (C2) (male) and HC04 (A2) (male) Min. 10 MΩ

HB365LC-3 40-1139
FAILURE CODE [GA62KZ] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC03 (A1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC03 (B1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
Deterioration of insulation HC03 (B1) (male): tester (black) and cable housing
3 in power cable Min. 10 MΩ
metal (P part): tester (red)
(motor-generator)
HC03 (C1) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC03 (C1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
Resistance
HC04 (A2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (A2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (B2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (B2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (C2) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC04 (C2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Open circuit between
4 phases of motor-genera- There is a coil resistance of motor in the motor-generator.
tor system
Between HC03 (A1) (male) and HC04 (A2) (male) Max. 1 Ω
Resistance Between HC03 (B1) (male) and HC04 (B2) (male) Max. 1 Ω
Between HC03 (C1) (male) and HC04 (C2) (male) Max. 1 Ω

40-1140 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA62KZ]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Short circuit between
5 phases of motor-genera- Measure one either HC03 or HC04.
tor system.
Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Resistance Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
• Wipe dirt of the inverter (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
Deterioration of insulation er (black)
6 in motor-generator sys-
tem HC03 (A1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (B1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC03 (B1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (C1) (male): tester (red) and inverter (case):
Min. 10 MΩ
tester (black)
HC03 (C1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
7
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1141
FAILURE CODE [GA62KZ] 40 TROUBLESHOOTING

Circuit diagram related to high-voltage equipment

40-1142 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA62MA]

FAILURE CODE [GA62MA] (ALL-K-PQHE-410-J0-B)

Action level Failure code Motor-generator phase-A current sensor malfunction

Failure
L03 GA62MA (Hybrid controller system)
Detail of fail-
Current sensor malfunction of motor-generator driver phase A is detected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

HB365LC-3 40-1143
FAILURE CODE [GA63KY] 40 TROUBLESHOOTING

FAILURE CODE [GA63KY] (ALL-K-PQHE-410-K0-B)

Action level Failure code Motor-generator phase-B current sensor power supply line short cir-
Failure cuit
L01 GA63KY (Hybrid controller system)
Detail of fail-
Motor-generator phase B detects overcurrent.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Open circuit in power ca- it is.
1 ble
(motor-generator) Between HC03 (A1) (male) and GM02 (A1) (male) Max. 1 Ω
Between HC03 (B1) (male) and GM02 (B1) (male) Max. 1 Ω
Between HC03 (C1) (male) and GM02 (C1) (male) Max. 1 Ω
Resistance
Between HC04 (A2) (male) and GM03 (A2) (male) Max. 1 Ω
Between HC04 (B2) (male) and GM03 (B2) (male) Max. 1 Ω
Between HC04 (C2) (male) and GM03 (C2) (male) Max. 1 Ω

40-1144 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA63KY]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Internal short circuit in it is.
2 power cable
(motor-generator) Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
Resistance
Between HC04 (A2) (male) and HC04 (B2) (male) Min. 10 MΩ
Between HC04 (B2) (male) and HC04 (C2) (male) Min. 10 MΩ
Between HC04 (C2) (male) and HC04 (A2) (male) Min. 10 MΩ

HB365LC-3 40-1145
FAILURE CODE [GA63KY] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC03 (A1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC03 (B1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
Deterioration of insulation HC03 (B1) (male): tester (black) and cable housing
3 in power cable Min. 10 MΩ
metal (P part): tester (red)
(motor-generator)
HC03 (C1) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC03 (C1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
Resistance
HC04 (A2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (A2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (B2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (B2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (C2) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC04 (C2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Open circuit between
4 phases of motor-genera- There is a coil resistance of motor in the motor-generator.
tor system
Between HC03 (A1) (male) and HC04 (A2) (male) Max. 1 Ω
Resistance Between HC03 (B1) (male) and HC04 (B2) (male) Max. 1 Ω
Between HC03 (C1) (male) and HC04 (C2) (male) Max. 1 Ω

40-1146 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA63KY]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Short circuit between
5 phases of motor-genera- Measure one either HC03 or HC04.
tor system.
Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Resistance Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
• Wipe dirt of the inverter (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
Deterioration of insulation er (black)
6 in motor-generator sys-
tem HC03 (A1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (B1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC03 (B1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (C1) (male): tester (red) and inverter (case):
Min. 10 MΩ
tester (black)
HC03 (C1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
7
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1147
FAILURE CODE [GA63KY] 40 TROUBLESHOOTING

Circuit diagram related to high-voltage equipment

40-1148 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA63KZ]

FAILURE CODE [GA63KZ] (ALL-K-PQHE-410-L0-B)

Action level Failure code Motor-generator phase-B current sensor open and short circuit
Failure
L01 GA63KZ (Hybrid controller system)
Detail of fail-
Open or short circuit of motor-generator phase B is detected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Open circuit in power ca- it is.
1 ble
(motor-generator) Between HC03 (A1) (male) and GM02 (A1) (male) Max. 1 Ω
Between HC03 (B1) (male) and GM02 (B1) (male) Max. 1 Ω
Between HC03 (C1) (male) and GM02 (C1) (male) Max. 1 Ω
Resistance
Between HC04 (A2) (male) and GM03 (A2) (male) Max. 1 Ω
Between HC04 (B2) (male) and GM03 (B2) (male) Max. 1 Ω
Between HC04 (C2) (male) and GM03 (C2) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Internal short circuit in it is.
2 power cable
(motor-generator) Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
Resistance
Between HC04 (A2) (male) and HC04 (B2) (male) Min. 10 MΩ
Between HC04 (B2) (male) and HC04 (C2) (male) Min. 10 MΩ
Between HC04 (C2) (male) and HC04 (A2) (male) Min. 10 MΩ

HB365LC-3 40-1149
FAILURE CODE [GA63KZ] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC03 (A1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC03 (B1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
Deterioration of insulation HC03 (B1) (male): tester (black) and cable housing
3 in power cable Min. 10 MΩ
metal (P part): tester (red)
(motor-generator)
HC03 (C1) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC03 (C1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
Resistance
HC04 (A2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (A2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (B2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (B2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (C2) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC04 (C2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Open circuit between
4 phases of motor-genera- There is a coil resistance of motor in the motor-generator.
tor system
Between HC03 (A1) (male) and HC04 (A2) (male) Max. 1 Ω
Resistance Between HC03 (B1) (male) and HC04 (B2) (male) Max. 1 Ω
Between HC03 (C1) (male) and HC04 (C2) (male) Max. 1 Ω

40-1150 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA63KZ]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Short circuit between
5 phases of motor-genera- Measure one either HC03 or HC04.
tor system.
Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Resistance Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
• Wipe dirt of the inverter (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
Deterioration of insulation er (black)
6 in motor-generator sys-
tem HC03 (A1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (B1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC03 (B1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (C1) (male): tester (red) and inverter (case):
Min. 10 MΩ
tester (black)
HC03 (C1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
7
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1151
FAILURE CODE [GA63KZ] 40 TROUBLESHOOTING

Circuit diagram related to high-voltage equipment

40-1152 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA63MA]

FAILURE CODE [GA63MA] (ALL-K-PQHE-410-M0-B)

Action level Failure code Motor-generator phase-B current sensor malfunction

Failure
L03 GA63MA (Hybrid controller system)
Detail of fail-
Current sensor malfunction of motor-generator driver phase B is detected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

HB365LC-3 40-1153
FAILURE CODE [GA64KY] 40 TROUBLESHOOTING

FAILURE CODE [GA64KY] (ALL-K-PQHE-410-N0-B)

Action level Failure code Motor-generator phase-C current sensor power supply line short cir-
Failure cuit
L01 GA64KY (Hybrid controller system)
Detail of fail-
Motor-generator phase C detects overcurrent.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Open circuit in power ca- it is.
1 ble
(motor-generator) Between HC03 (A1) (male) and GM02 (A1) (male) Max. 1 Ω
Between HC03 (B1) (male) and GM02 (B1) (male) Max. 1 Ω
Between HC03 (C1) (male) and GM02 (C1) (male) Max. 1 Ω
Resistance
Between HC04 (A2) (male) and GM03 (A2) (male) Max. 1 Ω
Between HC04 (B2) (male) and GM03 (B2) (male) Max. 1 Ω
Between HC04 (C2) (male) and GM03 (C2) (male) Max. 1 Ω

40-1154 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA64KY]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Internal short circuit in it is.
2 power cable
(motor-generator) Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
Resistance
Between HC04 (A2) (male) and HC04 (B2) (male) Min. 10 MΩ
Between HC04 (B2) (male) and HC04 (C2) (male) Min. 10 MΩ
Between HC04 (C2) (male) and HC04 (A2) (male) Min. 10 MΩ

HB365LC-3 40-1155
FAILURE CODE [GA64KY] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC03 (A1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC03 (B1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
Deterioration of insulation HC03 (B1) (male): tester (black) and cable housing
3 in power cable Min. 10 MΩ
metal (P part): tester (red)
(motor-generator)
HC03 (C1) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC03 (C1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
Resistance
HC04 (A2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (A2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (B2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (B2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (C2) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC04 (C2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Open circuit between
4 phases of motor-genera- There is a coil resistance of motor in the motor-generator.
tor system
Between HC03 (A1) (male) and HC04 (A2) (male) Max. 1 Ω
Resistance Between HC03 (B1) (male) and HC04 (B2) (male) Max. 1 Ω
Between HC03 (C1) (male) and HC04 (C2) (male) Max. 1 Ω

40-1156 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA64KY]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Short circuit between
5 phases of motor-genera- Measure one either HC03 or HC04.
tor system.
Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Resistance Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
• Wipe dirt of the inverter (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
Deterioration of insulation er (black)
6 in motor-generator sys-
tem HC03 (A1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (B1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC03 (B1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (C1) (male): tester (red) and inverter (case):
Min. 10 MΩ
tester (black)
HC03 (C1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
7
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1157
FAILURE CODE [GA64KY] 40 TROUBLESHOOTING

Circuit diagram related to high-voltage equipment

40-1158 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA64KZ]

FAILURE CODE [GA64KZ] (ALL-K-PQHE-410-P0-B)

Action level Failure code Motor-generator phase-C current sensor open and short circuit
Failure
L01 GA64KZ (Hybrid controller system)
Detail of fail-
Motor-generator phase C detects overcurrent.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Open circuit in power ca- it is.
1 ble
(motor-generator) Between HC03 (A1) (male) and GM02 (A1) (male) Max. 1 Ω
Between HC03 (B1) (male) and GM02 (B1) (male) Max. 1 Ω
Between HC03 (C1) (male) and GM02 (C1) (male) Max. 1 Ω
Resistance
Between HC04 (A2) (male) and GM03 (A2) (male) Max. 1 Ω
Between HC04 (B2) (male) and GM03 (B2) (male) Max. 1 Ω
Between HC04 (C2) (male) and GM03 (C2) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. REMARK
Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
If the connector on the capacitor side has already disconnected, leave it as
Internal short circuit in it is.
2 power cable
(motor-generator) Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
Resistance
Between HC04 (A2) (male) and HC04 (B2) (male) Min. 10 MΩ
Between HC04 (B2) (male) and HC04 (C2) (male) Min. 10 MΩ
Between HC04 (C2) (male) and HC04 (A2) (male) Min. 10 MΩ

HB365LC-3 40-1159
FAILURE CODE [GA64KZ] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, GM02 and GM03.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC03 (A1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC03 (B1) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
Deterioration of insulation HC03 (B1) (male): tester (black) and cable housing
3 in power cable Min. 10 MΩ
metal (P part): tester (red)
(motor-generator)
HC03 (C1) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC03 (C1) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
Resistance
HC04 (A2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (A2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (B2) (male): tester (red) and cable housing metal
Min. 10 MΩ
(P part): tester (black)
HC04 (B2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
HC04 (C2) (male): tester (red) and cable housing met-
Min. 10 MΩ
al (P part): tester (black)
HC04 (C2) (male): tester (black) and cable housing
Min. 10 MΩ
metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Open circuit between
4 phases of motor-genera- There is a coil resistance of motor in the motor-generator.
tor system
Between HC03 (A1) (male) and HC04 (A2) (male) Max. 1 Ω
Resistance Between HC03 (B1) (male) and HC04 (B2) (male) Max. 1 Ω
Between HC03 (C1) (male) and HC04 (C2) (male) Max. 1 Ω

40-1160 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA64KZ]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
Short circuit between
5 phases of motor-genera- Measure one either HC03 or HC04.
tor system.
Between HC03 (A1) (male) and HC03 (B1) (male) Min. 10 MΩ
Resistance Between HC03 (B1) (male) and HC03 (C1) (male) Min. 10 MΩ
Between HC03 (C1) (male) and HC03 (A1) (male) Min. 10 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC03, HC04, HC06 (DC+) and HB01 (DC-).
REMARK
• Wipe dirt of the inverter (case).
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
HC03 (A1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
Deterioration of insulation er (black)
6 in motor-generator sys-
tem HC03 (A1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (B1) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC03 (B1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
HC03 (C1) (male): tester (red) and inverter (case):
Min. 10 MΩ
tester (black)
HC03 (C1) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
7
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1161
FAILURE CODE [GA64KZ] 40 TROUBLESHOOTING

Circuit diagram related to high-voltage equipment

40-1162 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA64MA]

FAILURE CODE [GA64MA] (ALL-K-PQHE-410-Q0-B)

Action level Failure code Motor-generator phase-C current sensor malfunction

Failure
L03 GA64MA (Hybrid controller system)
Detail of fail-
Current sensor malfunction of motor-generator driver phase C is detected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.

NOTICE
Related Use electric charge release tool (796-426-1800) to release electric charge of capacitor.
information After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

Defective inverter (hybrid Inverter is defective. (Since this is an internal defect, troubleshooting cannot be
1
controller) performed.)

HB365LC-3 40-1163
FAILURE CODE [GA70KB] 40 TROUBLESHOOTING

FAILURE CODE [GA70KB] (ALL-K-PQHT-410-60-B)

Action level Failure code Hybrid swing motor short circuit

Failure
L03 GA70KB (Hybrid controller system)
Detail of fail-
Short circuit of swing motor is detected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
Open circuit in power ca- If the connector on the capacitor side has already disconnected, leave it as
1 ble
it is.
(electric swing motor)
Between HC05 (U) (male) and PM02 (U) (male) Max. 1 Ω
Resistance Between HC05 (V) (male) and PM02 (V) (male) Max. 1 Ω
Between HC05 (W) (male) and PM02 (W) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
Internal short circuit in If the connector on the capacitor side has already disconnected, leave it as
2 power cable
it is.
(electric swing motor)
Between HC05 (U) (male) and HC05 (V) (male) Min. 10 MΩ
Resistance Between HC05 (V) (male) and HC05 (W) (male) Min. 10 MΩ
Between HC05 (W) (male) and HC05 (U) (male) Min. 10 MΩ

40-1164 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA70KB]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
Deterioration of insulation Between HC05 (U) (male): tester (red) and cable hous-
3 in power cable Min. 10 MΩ
ing metal (P part): tester (black)
(electric swing motor)
Between HC05 (U) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
Between HC05 (V) (male): tester (red) and cable hous-
Min. 10 MΩ
ing metal (P part): tester (black)
Resistance
Between HC05 (V) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
Between HC05 (W) (male): tester (red) and cable
Min. 10 MΩ
housing metal (P part): tester (black)
Between HC05 (W) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05, HC06(DC+) and HB01(DC-).
REMARK
Open circuit between
4 phases of electric swing There is a coil resistance of motor in the motor-generator.
motor system
Between HC05 (U) (male) and HC05 (V) (male) Max. 1 Ω
Resistance Between HC05 (V) (male) and HC05 (W) (male) Max. 1 Ω
Between HC05 (W) (male) and HC05 (U) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05, HC06(DC+) and HB01(DC-).
REMARK
• Wipe dirt of the inverter (case).
• Measure one phase any of (U), (V) and (W).
Deterioration of insulation
5 in electric swing motor • When the measured values are not stable, use the value measured af-
system ter 1 minute.
• Measure it by mega-ohm tester.
HC05 (U) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC05 (U) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
6
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1165
FAILURE CODE [GA70KB] 40 TROUBLESHOOTING

Circuit diagram related to high-voltage equipment

40-1166 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA70MD]

FAILURE CODE [GA70MD] (ALL-K-PQLW-410-20-B)

Action level Failure code Hybrid swing motor speed detection error
Failure
L03 GA70MD (Hybrid controller system)
Detail of fail-
Abnormal swing motor speed measured by inverter is detected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.
• If failure code [GA72MA] is displayed, perform troubleshooting for that code first.
Related
• After completion of repair, check that the failure code is cleared by the following operation.
information
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and PM01, and connect the T-adapter to
each female side.
Between HC02 (female) (5) and PM01 (female) (1) Max. 1 Ω
Open circuit in wiring har- Between HC02 (female) (6) and PM01 (female) (3) Max. 1 Ω
1
ness
Between HC02 (female) (15) and PM01 (female) (2) Max. 1 Ω
Resistance
Between HC02 (female) (16) and PM01 (female) (5) Max. 1 Ω
Between HC02 (female) (26) and PM01 (female) (4) Max. 1 Ω
Between HC02 (female) (36) and PM01 (female) (6) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and PM01, and connect the T-adapter to
either female side.
Between ground and either HC02 (female) (5) or PM01
Min. 1 MΩ
(female) (1)
Between ground and either HC02 (female) (6) or PM01
Min. 1 MΩ
(female) (3)
Ground fault in wiring
2 Between ground and either HC02 (female) (15) or
harness Min. 1 MΩ
PM01 (female) (2)
Resistance
Between ground and either HC02 (female) (16) or
Min. 1 MΩ
PM01 (female) (5)
Between ground and either HC02 (female) (26) or
Min. 1 MΩ
PM01 (female) (4)
Between ground and either HC02 (female) (36) or
Min. 1 MΩ
PM01 (female) (6)

HB365LC-3 40-1167
FAILURE CODE [GA70MD] 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect connector HC02, and connect T-adapter to female side.
3. Turn the starting switch to ON position.
Between HC02 (female) (5) and ground Max. 1 V
Hot short circuit in wiring Between HC02 (female) (6) and ground Max. 1 V
3
harness
Between HC02 (female) (15) and ground Max. 1 V
Voltage
Between HC02 (female) (16) and ground Max. 1 V
Between HC02 (female) (26) and ground Max. 1 V
Between HC02 (female) (36) and ground Max. 1 V
Defective electric swing If no failure is found by above checks, electric swing motor is defective.
4
motor (Since this is an internal defect, troubleshooting cannot be performed.)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
5
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to electric swing motor resolver

40-1168 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA70NS]

FAILURE CODE [GA70NS] (ALL-K-PQHU-410-40-B)

Action level Failure code Hybrid swing motor overheat

Failure
- GA70NS (Hybrid controller system)
Detail of fail-
Swing motor temperature is 140 °C or higher.
ure
Action of • Restricts swing speed.
controller • If cause of failure is eliminated, machine becomes normal by itself.
Phenomenon
Swing speed, etc. is restricted.
on machine
• This failure code appears in case of excessive charge or discharge (swing, swing stop) of
capacitor.
• Swing motor coil temperature can be checked with monitoring function. (Code: 09101)
Related
• For details, see “ELECTRIC SWING MOTOR TEMPERATURE INCREASES ABNOR-
information
MALLY” in Y mode.
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

See “CAPACITOR TEMPERATURE INCREASES ABNORMALLY” in Y mode, and
Defective hybrid cooling
1 check the radiator coolant level of the hybrid system cooling circuit and clogging of
system circuit
the radiator fin and the water pump operation.
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and PM01, and connect the T-adapter to
Ground fault in wiring
2 either female side.
harness
Between ground and either HC02 (female) (18) or
Resistance Min. 1 MΩ
PM01 (female) (7)
Defective electric swing If no failure is found by above checks, electric swing motor is defective.
3
motor (Since this is an internal defect, troubleshooting cannot be performed.)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
4
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to electric swing motor temperature sensor

HB365LC-3 40-1169
FAILURE CODE [GA71KZ] 40 TROUBLESHOOTING

FAILURE CODE [GA71KZ] (ALL-K-PQHU-410-50-B)

Action level Failure code Hybrid swing motor temperature sensor open and short circuit
Failure
L01 GA71KZ (Hybrid controller system)
Detail of fail-
Swing motor temperature sensor error is detected.
ure
• Restricts swing speed.
Action of
• If cause of failure is eliminated while swing lever is in NEUTRAL position, machine be-
controller
comes normal by itself.
Phenomenon
Swing speed, etc. is restricted.
on machine
• Swing motor coil temperature can be checked with monitoring function. (Code: 09101)
Related
• After completion of repair, check that the failure code is cleared by the following operation.
information
Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect connector PM01, and connect T-adapter to male side.
Approx.
-40 °C
4200 kΩ
Approx.
10 °C
210 kΩ
Approx.
Defective electric swing 25 °C
Between PM01 (male) (7) 100 kΩ
1 motor temperature sen-
sor and (8) Approx.
Resistance 40 °C
50 kΩ
Approx.
90 °C
7.7 kΩ
Approx.
200 °C
440 Ω
Between PM01 (male) (7)
All range Min. 1 MΩ
and ground
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and PM01, and connect the T-adapter to
Open circuit in wiring har- each female side.
2
ness
Between HC02 (female) (18) and PM01 (female) (7) Max. 1 Ω
Resistance
Between HC02 (female) (17) and PM01 (female) (8) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and PM01, and connect the T-adapter to
Ground fault in wiring
3 either female side.
harness
Between ground and either HC02 (female) (18) or
Resistance Min. 1 MΩ
PM01 (female) (7)

40-1170 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA71KZ]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connector PM01, and connect the T-adapter to female
Hot short circuit in wiring side.
4
harness
3. Turn the starting switch to ON position.
Voltage Between PM01 (female) (4) and ground Max. 5.5 V
See “CAPACITOR TEMPERATURE INCREASES ABNORMALLY” in Y mode, and
Defective hybrid cooling
5 check the radiator coolant level of the hybrid system cooling circuit and clogging of
system circuit
the radiator fin and the water pump operation.
Defective electric swing If no failure is found by above checks, electric swing motor is defective.
6
motor (Since this is an internal defect, troubleshooting cannot be performed.)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
7
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to electric swing motor temperature sensor

HB365LC-3 40-1171
FAILURE CODE [GA72MA] 40 TROUBLESHOOTING

FAILURE CODE [GA72MA] (ALL-K-PQLW-410-00-B)

Action level Failure code Hybrid swing motor resolver malfunction

Failure
L03 GA72MA (Hybrid controller system)
Detail of fail-
Hybrid swing motor resolver malfunction is detected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and PM01, and connect the T-adapter to
each female side.
Between HC02 (female) (5) and PM01 (female) (1) Max. 1 Ω
Open circuit in wiring har- Between HC02 (female) (6) and PM01 (female) (3) Max. 1 Ω
1
ness
Between HC02 (female) (15) and PM01 (female) (2) Max. 1 Ω
Resistance
Between HC02 (female) (16) and PM01 (female) (5) Max. 1 Ω
Between HC02 (female) (26) and PM01 (female) (4) Max. 1 Ω
Between HC02 (female) (36) and PM01 (female) (6) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and PM01, and connect the T-adapter to
either female side.
Between ground and either HC02 (female) (5) or PM01
Min. 1 MΩ
(female) (1)
Between ground and either HC02 (female) (6) or PM01
Min. 1 MΩ
(female) (3)
Ground fault in wiring
2 Between ground and either HC02 (female) (15) or
harness Min. 1 MΩ
PM01 (female) (2)
Resistance
Between ground and either HC02 (female) (16) or
Min. 1 MΩ
PM01 (female) (5)
Between ground and either HC02 (female) (26) or
Min. 1 MΩ
PM01 (female) (4)
Between ground and either HC02 (female) (36) or
Min. 1 MΩ
PM01 (female) (6)

40-1172 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA72MA]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect connector HC02, and connect T-adapter to female side.
3. Turn the starting switch to ON position.
Between HC02 (female) (5) and ground Max. 1 V
Hot short circuit in wiring Between HC02 (female) (6) and ground Max. 1 V
3
harness
Between HC02 (female) (15) and ground Max. 1 V
Voltage
Between HC02 (female) (16) and ground Max. 1 V
Between HC02 (female) (26) and ground Max. 1 V
Between HC02 (female) (36) and ground Max. 1 V
Defective electric swing If no failure is found by above checks, electric swing motor is defective.
4
motor (Since this is an internal defect, troubleshooting cannot be performed.)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
5
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

Circuit diagram related to electric swing motor resolver

HB365LC-3 40-1173
FAILURE CODE [GA72MC] 40 TROUBLESHOOTING

FAILURE CODE [GA72MC] (ALL-K-PQLW-410-10-B)

Action level Failure code Hybrid swing motor resolver malfunction

Failure
L03 GA72MC (Hybrid controller system)
Detail of fail-
Hybrid swing motor resolver malfunction is detected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02 and PM01, and connect the T-adapter to
either female side.
Between ground and either HC02 (female) (5) or PM01
Min. 1 MΩ
(female) (1)
Between ground and either HC02 (female) (6) or PM01
Min. 1 MΩ
(female) (3)
Ground fault in wiring
1 Between ground and either HC02 (female) (15) or
harness Min. 1 MΩ
PM01 (female) (2)
Resistance
Between ground and either HC02 (female) (16) or
Min. 1 MΩ
PM01 (female) (5)
Between ground and either HC02 (female) (26) or
Min. 1 MΩ
PM01 (female) (4)
Between ground and either HC02 (female) (36) or
Min. 1 MΩ
PM01 (female) (6)
Defective electric swing If no failure is found by above checks, electric swing motor is defective.
2
motor (Since this is an internal defect, troubleshooting cannot be performed.)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
3
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

40-1174 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA72MC]

Circuit diagram related to electric swing motor resolver

HB365LC-3 40-1175
FAILURE CODE [GA81KZ] 40 TROUBLESHOOTING

FAILURE CODE [GA81KZ] (ALL-K-PQHT-410-70-B)

Action level Failure code Swing motor power cable open and short circuit
Failure
L03 GA81KZ (Hybrid controller system)
Detail of fail-
Open or short circuit of swing motor power cable is detected.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
Open circuit in power ca- If the connector on the capacitor side has already disconnected, leave it as
1 ble
it is.
(electric swing motor)
Between HC05 (U) (male) and PM02 (U) (male) Max. 1 Ω
Resistance Between HC05 (V) (male) and PM02 (V) (male) Max. 1 Ω
Between HC05 (W) (male) and PM02 (W) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
Internal short circuit in If the connector on the capacitor side has already disconnected, leave it as
2 power cable
it is.
(electric swing motor)
Between HC05 (U) (male) and HC05 (V) (male) Min. 10 MΩ
Resistance Between HC05 (V) (male) and HC05 (W) (male) Min. 10 MΩ
Between HC05 (W) (male) and HC05 (U) (male) Min. 10 MΩ

40-1176 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GA81KZ]

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05 and PM02.
REMARK
• If the connector on the capacitor side has already disconnected, leave
it as it is.
• Wipe the dirt of the metal part of the cable housing.
• When the measured values are not stable, use the value measured af-
ter 1 minute.
• Measure it by mega-ohm tester.
Deterioration of insulation Between HC05 (U) (male): tester (red) and cable hous-
3 in power cable Min. 10 MΩ
ing metal (P part): tester (black)
(electric swing motor)
Between HC05 (U) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
Between HC05 (V) (male): tester (red) and cable hous-
Min. 10 MΩ
ing metal (P part): tester (black)
Resistance
Between HC05 (V) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
Between HC05 (W) (male): tester (red) and cable
Min. 10 MΩ
housing metal (P part): tester (black)
Between HC05 (W) (male): tester (black) and cable
Min. 10 MΩ
housing metal (P part): tester (red)
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05, HC06(DC+) and HB01(DC-).
REMARK
Open circuit between
4 phases of electric swing There is a coil resistance of motor in the motor-generator.
motor system
Between HC05 (U) (male) and HC05 (V) (male) Max. 1 Ω
Resistance Between HC05 (V) (male) and HC05 (W) (male) Max. 1 Ω
Between HC05 (W) (male) and HC05 (U) (male) Max. 1 Ω
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC05, HC06(DC+) and HB01(DC-).
REMARK
• Wipe dirt of the inverter (case).
• Measure one phase any of (U), (V) and (W).
Deterioration of insulation
5 in electric swing motor • When the measured values are not stable, use the value measured af-
system ter 1 minute.
• Measure it by mega-ohm tester.
HC05 (U) (male): tester (red) and inverter (case): test-
Min. 10 MΩ
er (black)
Resistance
HC05 (U) (male): tester (black) and inverter (case):
Min. 10 MΩ
tester (red)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
6
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1177
FAILURE CODE [GA81KZ] 40 TROUBLESHOOTING

Circuit diagram related to high-voltage equipment

40-1178 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GAA0KB]

FAILURE CODE [GAA0KB] (ALL-K-PQGR-410-F0-B)

Action level Failure code Hybrid controller battery relay output short circuit
Failure
L01 GAA0KB (Hybrid controller system)
Detail of fail- When controller outputs 24 V to primary (coil side) circuit of battery relay, abnormal current flows
ure through circuit.
• Stops outputting 24 V to primary (coil side) circuit of battery relay.
Action of
• Even if cause of failure is eliminated, machine does not become normal until starting
controller
switch is turned to OFF position.
Phenomenon
None in particular
on machine
• As T-adapter for inverter (hybrid controller) connector is “socket-type box”, operating volt-
age cannot be measured at inverter (hybrid controller) connector.
Related • Output (ON/OFF) to battery relay can be checked with monitoring function. (Code: 03700)
information • After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position and OFF position, and then wait for 0.5
seconds.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
1 Defective battery relay connect switch to OFF position.
3. Disconnect the battery relay terminals R01 and R02.
Continuity Between battery relay terminals R01 and R02 Continuity
1. Turn the starting switch to OFF position.
2. Check that system operating lamp is not lit, and then turn the battery dis-
connect switch to OFF position.
Ground fault in wiring 3. Disconnect the connector HC01, and connect the T-adapter to female
2
harness side.
4. Disconnect the connectors, terminals, and fuses of all the devices which
branch out from connector HC01 (14).
Resistance Between HC01 (female) (14) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
Defective battery relay 2. Insert the T-adapter into connector D01.
3
circuit 3. For 0.5 seconds after starting switch is turned from ON to OFF position.
Voltage Between D01 (1) and ground 20 to 30 V
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
4
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1179
FAILURE CODE [GAA0KB] 40 TROUBLESHOOTING

Circuit diagram related to battery relay

40-1180 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GAA2KB]

FAILURE CODE [GAA2KB] (ALL-K-JA04-410-30-B)

Action level Failure code Swing parking brake solenoid power supply line short circuit
Failure
L03 GAA2KB (Hybrid controller system)
Detail of fail-
When controller drives swing parking brake solenoid, a short circuit error is detected.
ure
• Stops driving swing parking brake solenoid.
Action of
• Even if cause of failure is cleared naturally, machine does not become normal until starting
controller
switch is set to OFF position once.
Phenomenon
Swing is not enabled (swing parking brake is not canceled).
on machine
• If no failure is found in solenoid or wiring harness, set swing parking brake cancel switch
to CANCEL position to enable swing operation (swing parking brake is not canceled when
stopping).
• Set swing lock switch and emergency switch in OFF position during diagnosis.
• Brake is canceled if current flows to swing parking brake solenoid.
• Controller's command (ON/OFF) to swing parking brake solenoid can be checked with
Related monitoring function (Code: 09700).
information REMARK
As long as controller's command to solenoid is ON, sensor state displayed on monitoring
screen is ON even if solenoid is not energized due to short circuit.
• Power supply of swing parking brake solenoid is HC01 (8) pin of inverter (hybrid controller)
or No.1 of fuse box F01.
• After completion of repair, check that the failure code is cleared by the following operation.
Procedure: Turn the starting switch to ON position.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
Ground fault in wiring 2. Disconnect the connectors CP02 and HC01, and connect the T-adapter to
1
harness each female side.
Resistance Between HC01 (female) (21) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connector HC01, and connect the T-adapter to female
Hot short circuit in wiring side.
2
harness
3. Turn the starting switch to ON position.
Voltage Between HC01 (female) (21) and ground Max. 1 V
If no failure is found by above checks, pump controller is defective. (Since this is an
3 Defective pump controller
internal defect, troubleshooting cannot be performed).
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
4
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1181
FAILURE CODE [GAA2KB] 40 TROUBLESHOOTING

Circuit diagram related to swing parking brake

40-1182 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GAA6KP]

FAILURE CODE [GAA6KP] (ALL-K-PQJE-410-70-B)

Action level Failure code Hybrid controller sensor power supply 2 output voltage low error
Failure
L03 GAA6KP (Hybrid controller system)
Detail of fail-
Voltage of 5V sensor power supply output 2 circuit is 2.5 V or less.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the following connectors one by one, and turn the starting
switch to ON position each time.
3. After check, turn the starting switch to OFF position.
REMARK

1 Defective 5 V sensor • If this failure code is not displayed by disconnecting, the disconnected
sensor is defective. Repeat steps 1 to 3 until it is confirmed that there
is no sensor causing failure.
• Since connector is disconnected, other failure codes are also dis-
played. Ignore all of displayed failure codes other than this one.
Swing LEFT pressure sensor HP04
Sensor
Swing RIGHT pressure sensor HP06
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HC02, HP06 and HP04, and connect the T-
adapter to any female side.
Ground fault in wiring
2 Between ground and any of HC02 (female) (25), HP06
harness Min. 1 MΩ
(female) (3), and HP04 (female) (3)
Resistance
Between HC02 (female) (38) and any of HC02 (fe-
Min. 1 MΩ
male) (25), HP06 (female) (3), and HP04 (female) (3)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
3
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1183
FAILURE CODE [GAA6KP] 40 TROUBLESHOOTING

Circuit diagram related to swing PPC pressure sensor (hybrid)

40-1184 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GAA6KY]

FAILURE CODE [GAA6KY] (ALL-K-PQJE-410-00-B)

Action level Failure code Hybrid controller sensor power supply 2 short circuit
Failure
L03 GAA6KY (Hybrid controller system)
Detail of fail-
Voltage of 5V sensor power supply output 2 circuit is 6 V or more.
ure
• Stops controlling swing motor and motor-generator, and applies swing parking brake.
• Disables low-speed matching function.
Action of
• Disables hoist matching function.
controller
• Even if cause of failure is cleared naturally, machine does not become normal until starting
switch is set to OFF position once.
Phenomenon • Swinging is disabled.
on machine • Low-speed matching is disabled.
Related After completion of repair, check that the failure code is cleared by the following operation.
information Procedure: Turn the starting switch to ON position or start the engine.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the following connectors one by one, and turn the starting
switch to ON position each time.
3. After check, turn the starting switch to OFF position.
REMARK

1 Defective 5 V sensor • If this failure code is not displayed by disconnecting, the disconnected
sensor is defective. Repeat steps 1 to 3 until it is confirmed that there
is no sensor causing failure.
• Since connector is disconnected, other failure codes are also dis-
played. Ignore all of displayed failure codes other than this one.
Swing LEFT pressure sensor HP04
Sensor
Swing RIGHT pressure sensor HP06
1. Turn the starting switch to OFF position.
2. Disconnect the connectors HP06 and HP04, and connect the T-adapter to
Hot short circuit in wiring either female side.
2
harness 3. Turn the starting switch to ON position.
Between ground and either HP06 (female) (3) or HP04
Voltage 4.5 to 5.5 V
(female) (3)
Defective inverter (hybrid If no failure is found by above checks, inverter (hybrid controller) is defective.
3
controller) (Since this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1185
FAILURE CODE [GAA6KY] 40 TROUBLESHOOTING

Circuit diagram related to swing PPC pressure sensor (hybrid)

40-1186 HB365LC-3
40 TROUBLESHOOTING FAILURE CODE [GACA00]

FAILURE CODE [GACA00] (ALL-K-PQG9-410-00-B)

Action level Failure code Hybrid controller power mode switch in operation
Failure
－ GACA00 (Hybrid controller system)
Detail of fail- Output limitation to prevent temperature rise is performed since the monitor temperature gauge
ure pointer of hybrid system indicates just before the red range (A2).
Action of
Restricts power mode output until thermal load on hybrid component is reduced.
controller
Phenomenon
Power mode output is reduced until thermal load on hybrid component is reduced.
on machine
• Hybrid components to be measured by hybrid temperature gauge
• Capacitor cell temperature
• Booster IGBT base temperature
• Booster IGBT junction temperature
Related
• Booster inductor temperature
information
• Swing motor coil temperature
• Motor-generator temperature
• Generator driver temperature
• Swing inverter junction temperature

No. Cause Procedure, measuring location, criteria and remarks

THERMAL LOAD IN-
1 CREASE ON HYBRID
SYSTEM
• Since the monitor temperature gauge pointer of hybrid system indicates
just before the red range (A2), power mode output is restricted in order to
prevent temperature rise on hybrid component.
• When the thermal load on hybrid component is reduced, the output limita-
tion is canceled automatically.

MONITOR TEMPERATURE GAUGE OF HYBRID SYSTEMS

HB365LC-3 40-1187
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 40 TROUBLESHOOTING

TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-

MODE) (ALL-K-150E-001-00-B)

E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) (ALL-K-AK61-410-00-B)

Failure Engine does not start (engine does not crank)

• The engine start circuit is equipped with the start lock function of the following two sys-
tems.
1. Start lock by password of machine monitor
2. Start lock by lock lever
Related infor- • If failure symptom is battery relay operation sound is not heard when starting switch is
mation turned to ON position, perform troubleshooting for E-mode “ENGINE DOES NOT START
(ENGINE DOES NOT CRANK)” as well.
• If failure symptom machine monitor does not light up is displayed while starting switch is
turned to ON position, main power supply system may be defective. Perform troubleshoot-
ing for E-mode “WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE
MONITOR DISPLAYS NOTHING”.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Loose terminal or open
1 Check terminals of starting motor, alternator, battery relay, and ground terminals
circuit in terminal
T04, T08, etc.

Contact between battery 1. Turn starting switch to OFF position.

2
relay and frame (ground) Resistance Between battery relay terminal R01 and ground Max. 1 Ω
Be ready with starting switch at OFF, then perform troubleshooting without turning
starting switch to ON position.
Insufficient battery ca- Battery voltage (measure 2 batteries in Min.24 V
3
pacity series)
Gravity of battery (measure gravity in Min.1.26
each cell)
Defects of engine controller power supply and ACC signal are indicated with failure
Defective engine control-
4 code [DB2QKR] or [DB2RKR]. If these codes appear, perform troubleshooting for
ler system
causes 1 to 3 of [DB2QKR] first.
Defective fuse No. 3 in If fuse is burnt out, circuit may have ground fault. (See cause 22.)
5
fuse box F01

Defective battery relay 1. Turn starting switch to ON position.

6
system If battery relay operation sound is not heard, go to checks on cause 22.
1. Turn starting switch to OFF position and remove fuse No. 3 in fuse box
F01.
Defective fusible link 2. Turn starting switch to ON position (connect ACC).
7 F04, defective wiring har-
ness Between input terminal (1A) of fuse box F01-3 and
Voltage 20 to 30 V
ground
If voltage is abnormal, go to check on cause 10.

40-1188 HB365LC-3
40 TROUBLESHOOTING E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Remove fuse No. 18 in fuse box F01 (to prevent engine from starting dur-
Defective starting switch, ing check).
lock lever switch, starting
3. Insert T-adapter into connector M17.
motor cut relay, personal
8
code relay, battery relay, 4. Turn starting switch to START position and hold it (two persons required
and BR cut relay, har- for this check).
ness
Voltage Between M17 (1) and ground 20 to 30 V
If voltage is abnormal, go to check on cause 13.
• If no failure is found on cause 7, this check is not required.
If fusible link is burnt out, circuit may have ground fault. In this case, per-
form troubleshooting for cause 6 first.
9 Defective fusible link F04 • Fuses No. 1 to 12 are connected to fusible link F04.
• Connected circuit is large in scale. Accordingly, if failure code still displays
after above checks on cause 6, reproduce trouble and find out ground fault
position by sound and burning smell.
If no failure is found by check on cause 8, this check is not required.
1. Turn the starting switch to OFF position.
2. Disconnect connector H15A.
3. After check, turn the starting switch to ON and START position and per-
form troubleshooting again.
Turn the starting switch to
Between starting switch Min. 1 MΩ
OFF position.
terminal B and terminal
BR Turn the starting switch to
Defective starting switch Max. 1 Ω
10 ON position.
(internal open circuit)
Turn the starting switch to
Between starting switch Min. 1 MΩ
OFF position.
Resistance terminal B and terminal
ACC Turn the starting switch to
Max. 1 Ω
ON position.
Turn the starting switch to
Min. 1 MΩ
Between starting switch OFF position.
terminal B and terminal C Turn the starting switch to
Max. 1 Ω
START position.
If no failure is found on cause 8, this check is not required.
1. Turn starting switch to OFF position.
Defective lock lever
switch 2. Disconnect connector S14 and connect T-adapter to female side.
11
(Internal open circuit) Between S14 (female) (1) Lock lever: FREE Min. 1 MΩ
Resistance
and (3) Lock lever: LOCK Max. 1 Ω
If check on cause 8 is normal, this check is not required.
1. Turn starting switch to OFF position.

Defective starting motor 2. Replace the starting motor cut-off relay R06 with the light relay R05.
12
cut-off relay 3. Turn starting switch to ON position.
If the engine can be started, the original starting motor cut-off relay R06 is defec-
tive.

HB365LC-3 40-1189
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found on cause 8, this check is not required.
1. Turn starting switch to OFF position.
Defective personal code
13 relay (internal open or 2. Replace personal code relay R07 with light relay R05.
short circuit) 3. Turn starting switch to ON position.
If the engine can start, the original personal code relay R07 is defective.
If no failure is found on cause 8, this check is not required.
1. Turn starting switch to OFF position.
Defective battery relay
14 cut relay (internal open or 2. Replace battery relay cut-off relay R43 with light relay R05.
short circuit) 3. Turn starting switch to ON position.
If the engine can start, the original battery relay cut-off relay R43 is defective.
If check on cause 7 is normal, this check is not required.
1. Turn starting switch to OFF position, and turn battery disconnect switch to OFF
position.
Open circuit in wiring har- (To avoid short circuit during check)
ness 1 (wire breakage or 2.
15 Disconnect fusible link F04 and fuse No. 3 of fuse box F01.
defective contact of con-
nector) 3. Connect T-adapter to male side of connector F04.

Between battery relay (R03) and F04 (male) (1) Max. 1 Ω

Resistance
Between F04 (male) (2) and F01-1A Max. 1 Ω
If check on cause 7 is normal, this check is not required.
1. Turn starting switch to OFF position, and turn battery disconnect switch to
OFF position.
2. Disconnect fusible link F04, fuse No. 3 of fuse box F01, and battery relay
Ground fault in wiring
R03 (M terminal).
16 harness 1 (contact with
ground circuit) 3. Connect T-adapter to male side of connector F04.
Between ground and battery relay R03 (harness side)
Min. 1 MΩ
Resistance or F04 (male) (1)
Between ground and F04 (male) (2) or F01-1A Min. 1 MΩ
1. Turn starting switch to OFF position.
2. Disconnect connector D01 and connect T-adapter to diode.
No continui-
Defective diode D01 Between D01 (male) (1) (+) and (5) (-)
ty
17 (Internal open or short
Between D01 (male) (5) (+) and (1) (-) Continuity
circuit) Continuity
No continui-
Between D01 (male) (2) (+) and (6) (-)
ty
Between D01 (male) (6) (+) and (2) (-) Continuity
1. Turn the starting switch to OFF position.
Defective alternator (in- 2. Turn the starting switch to ON position.
18
ternal short circuit)
Between alternator termi-
Voltage Power generation input Max. 1 V
nal R (M18) and ground

40-1190 HB365LC-3
40 TROUBLESHOOTING E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)

No. Cause Procedure, measuring location, criteria and remarks

Defective starting motor
19
(internal defect)
1. Turn the starting switch to OFF position.
2. Turn the starting switch to START position to perform troubleshooting.
Between starting motor
terminal B (SB) and Power supply 20 to 30 V
Voltage ground
Between starting motor
Input for starting 20 to 30 V
terminal S and ground
If power supply and input for starting are normal but starting motor does not rotate,
starting motor is defective.
Battery relay
1. Turn starting switch to OFF position.

Resistance Between terminal R02 and starting switch BR terminal Max. 1 Ω

Battery relay
1. Turn starting switch to OFF position.
2. Turn starting switch to ON position.
Between terminals R04 and R01 20 to 30 V
Between terminals R02 and R01 20 to 30 V
Between terminals R03 and R01 20 to 30 V
Voltage Between R01 terminal and ground 20 to 30 V

Open circuit in battery re- If no failure is found in R02 terminal, this check is not
20 required.
lay harness 20 to 30 V
Between terminal BR of starting switch and ground
Battery relay
• If no failure is found in R02 terminal, this check is not required.
1. Turn starting switch to OFF position.
2. Turn battery disconnect switch to OFF position.
3. Disconnect connector D01 and battery relay terminal R02.
4. Connect T-adapter to female side of D01.
Between starting switch BR terminal and D01 (female)
Max. 1 Ω
(5)
Resistance
Between D01 (female) (1) and battery relay terminal
Max. 1 Ω
R02

HB365LC-3 40-1191
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

Open circuit in wiring har-
ness 2 (wire breakage or Check the range of 24 V and identify the open circuit place.
21
defective contact of con-
nector)
Defective battery relay
22
(does not turn ON)
Ground fault in wiring
23 harness 2 (contact with
ground circuit)
Hot short circuit in wiring
24
harness
Alternator, starting motor
1. Turn starting switch to OFF position.
2. Turn battery disconnect switch to OFF position.
3. Insert T-adapter into connectors S14, R07, and M17.
4. Set battery disconnect switch to ON position.
5. Turn the starting switch to START position and implement diagnosis.
REMARK
Between terminal C of starting switch and ground 20 to 30 V
Between S14 (1) and ground 20 to 30 V
Between S14 (3) and ground 20 to 30 V
Voltage Between R07 (4) and ground 20 to 30 V
Between M17 (1) and ground 20 to 30 V
Between alternator terminal B and ground 20 to 30 V
Between starting motor terminal B and ground 20 to 30 V
Battery relay is defective if voltage abnormality in terminal R03 is detected by
check on cause 20.
Alternator, starting motor
1. Turn starting switch to OFF position.
2. Disconnect connectors S14, R06, R07, and M17.
3. Connect T-adapters to each female sides of R06 and R07, and also to the
male side of S14.
4. Remove No. 3 of fuse F01.
Between terminal C of starting switch or R06 (female)
Min. 1 MΩ
(3) and ground
Between ground and R06 (female) (5) or R07 (female)
Min. 1 MΩ
(3)
Resistance Between R07 (female) (4) and ground, or between
Min. 1 MΩ
M17 (female) (1) and ground
Between F01-3 or S14 (male) (1) and ground Min. 1 MΩ
Between S14 (male) (3) or R06 (female) (1) and
Min. 1 MΩ
ground
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector M17.
3. Turn starting switch to ON position.
Voltage Between ground and M17 (2) or CM01 (16) Max. 1 V

40-1192 HB365LC-3
40 TROUBLESHOOTING E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)

Circuit diagram related to engine starting circuit

HB365LC-3 40-1193
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 40 TROUBLESHOOTING

E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK (ALL-K-AM40-410-00-B)

Failure Manual preheating system does not work.

This troubleshooting describes procedures to be followed when manual preheating does not func-
tion to heat the intake air heater mounting section.
• This machine has “Automatic preheating” and “Manual preheating” functions. When either
preheating works, preheating monitor lights up. (When only preheating monitor does not
light up, perform troubleshooting for failure “While preheating is working, preheating moni-
tor does not light up”.)
• If failure symptom “Machine monitor does not light up” or “Battery relay does not make op-
Related infor-
erating sound” is displayed when starting switch is turned to ON position, main electric
mation
power supply system may be defective. In these cases, perform troubleshooting for E-
mode “ENGINE DOES NOT START (ENGINE DOES NOT CRANK)” , “WHEN STARTING
SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING”
respectively.
• If fuse No. 17 in fuse box F01 is blown out, perform troubleshooting for “Machine monitor
displays nothing”.
• Before performing troubleshooting, check that no related failure code is displayed.

No. Cause Procedure, measuring location, criteria and remarks

Looseness of terminal 1. Turn starting switch to OFF position.
1 and wire breakage at ter-
minal part Check terminals of heater relay, battery relay, and intake air heater, etc.

2 Defective fuse If fuse FL is burnt out, circuit may have ground fault, etc.
1. Turn the starting switch to OFF position.
2. Disconnect connector CM01.
Between starting switch terminal R1 and ground (heat- Approx.
Resistance
er relay coil resistance) 20 Ω
Secondary
1. Turn the starting switch to OFF position.
2. Turn the starting switch to ON position.
Between terminal R17 (input on contact side of heater
Voltage 20 to 30 V
relay) and ground
Open or short circuit in Primary
3
wiring harness 1. Turn the starting switch to OFF position.
2. Disconnect heater relay terminal T16.
To prevent current from flowing through heater when starting switch is turned
to HEAT position
3. Turn the starting switch to HEAT position (R1 connected).
Voltage Between heater relay terminal T15 and ground 20 to 30 V
1. Turn the starting switch to OFF position.
2. Disconnect heater relay terminal T16.
Continuity Between R16 (wiring harness side) and ground Continuity

40-1194 HB365LC-3
40 TROUBLESHOOTING E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found in primary side by check on cause 3, this check is not required.
1. Turn starting switch to OFF position.
Defective diode D02 2. Disconnect connector D02 and connect T-adapter to diode.
4 (Internal open or short
No continui-
circuit) Between D02 (male) (1) (+) and (5) (-)
Continuity ty
Between D02 (male) (5) (+) and (1) (-) Continuity
If no failure is found in primary side by check on cause 3, this check is not required.
1. Turn the starting switch to OFF position.
2. Turn the battery disconnect switch to OFF position.
3. Disconnect connector H15A.
4. Turn the starting switch to OFF and HEAT positions to perform trouble-
5 Defective starting switch
shooting.
Turn the starting switch to
Min. 1 MΩ
Between starting switch OFF position.
Resistance
terminal B and terminal R1 Turn starting switch to
Max. 1 Ω
HEAT position.
1. Turn starting switch to OFF position.
Defective intake air heat- 2.
6 Disconnect E01 terminal.
er (internal open circuit)
Continuity Between E01 terminal and ground Continuity
Defective heater relay If failure code is still displayed after above checks on cause 3 and heater relay op-
7 eration sound is not heard, the heater relay is defective.
(Does not turn ON)
If no failure is found by check on cause 2, this check is not required.
1. Turn the starting switch to OFF position.
2. Disconnect the connectors H15A, CM01, D02, and terminals T15, E01,
and starting motor terminal B.
Ground fault in wiring
8 harness (contact with Between heater relay terminal T15 (wiring harness
Min. 1 MΩ
ground circuit) side) and ground
Between heater relay R17 (contact side input terminal)
Resistance Min. 1 MΩ
and ground
Between heater terminal E01 (wiring harness side) and
Min. 1 MΩ
ground

HB365LC-3 40-1195
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 40 TROUBLESHOOTING

CIRCUIT DIAGRAM (ENGINE PREHEATING SYSTEM)

40-1196 HB365LC-3
40 TROUBLESHOOTING E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK

E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK (ALL-K-AM40-410-10-B)

Failure Automatic preheating does not operate.

• Automatic preheating starts when boost temperature is below -4 °C.
(monitoring code Charge Temperature: 18500)
• If the automatic preheating does not work, check if manual preheating works first.
Related infor-
mation • Engine controller checks primary (coil) side of preheat relay (connector R18) and gener-
ates failure code [CA2555] or [CA2556] if it is defective.
• Engine controller generates failure codes [CA153] or [CA154] when defective charge
(boost) temperature sensor is detected.

No. Cause Procedure, measuring location, criteria and remarks

1 Defective fuse
Defective preheat relay
2 (internal open or short
circuit)
Open circuit or ground
3
fault in wiring harness
Open circuit in wiring har-
ness
4 3.
(Wire breakage or defec-
tive contact of connector)
Ground fault in wiring
5
harness
If fuse No. 6 in fuse box F01 is blown, circuit may have ground fault.
1. Turn starting switch to OFF position.
2. Replace preheating relay (connector R18) with, for instance, light relay
(connector R05).
3. Turn starting switch to ON position.
If automatic preheating functions when boost temperature is below -4 °C, original
preheater relay is defective.
1. Turn the starting switch to OFF position.
2. Disconnect the connectors CM01, R18, and D02, and connect T-adapter
to female side of R18.
REMARK
If resistance value is 1 MΩ or more, wiring harness has an open circuit. If resist-
ance value is 1 Ω or less, wiring harness has a short circuit.
Between R18 (female) (5) and ground (coil resistance Approx.
Resistance
of heater relay) 20 Ω
1. Turn the starting switch to OFF position.
2. Disconnect connectors R18 and CM01, and connect T-adapter to female
side of R18.
Remove the fuse No.6 in fuse box F01.
Between R18 (female) (3) and F01 -6 Max. 1 Ω
Resistance Between R18 (female) (5) and heater relay terminal
Max. 1 Ω
T15
If the fuse is not blown out, this check is not required.
1. Turn the starting switch to OFF position.
2. Disconnect the connector R18, and connect the T-adapter to female side.
3. Remove the fuse No.6 in fuse box F01.
Resistance Between R18 (female) (3) and ground Min. 1 MΩ

HB365LC-3 40-1197
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 40 TROUBLESHOOTING

CIRCUIT DIAGRAM (ENGINE PREHEATING SYSTEM)

40-1198 HB365LC-3
 E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR
40 TROUBLESHOOTING DOES NOT LIGHT UP

E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES

NOT LIGHT UP (ALL-K-AM40-410-20-B)

Failure While preheating is working, preheating monitor does not light up.
• This machine has "Automatic preheating" and "Manual preheating" functions. When either
Related
preheating works, preheating monitor lights up.
information
• Check that manual preheating function works normally in advance.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn the starting switch to OFF position.
2. Disconnect the connectors CM01 and R18, and connect the T-adapter to
Open circuit in wiring har- each female side.
1 ness (wire breakage or
defective contact) Between starting switch terminal R1 and CM01 (fe-
Max. 1 Ω
Resistance male) (12)
Between R18 (female) (5) and CM01 (female) (12) Max. 1 Ω
If failure code is still displayed after above checks, machine monitor is defective.
• Reference
1. Turn starting switch to OFF position.
2. Insert T-adapter into connector CM01.
Defective machine moni- 3.
2 Disconnect heater relay terminal R16A.
tor
(To prevent current from flowing through heater when starting switch is turned
to HEAT position)
4. Turn starting switch to HEAT position.
Voltage Between CM01 (12) and (3) 20 to 30 V

HB365LC-3 40-1199
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR
DOES NOT LIGHT UP 40 TROUBLESHOOTING

CIRCUIT DIAGRAM (ENGINE PREHEATING SYSTEM)

40-1200 HB365LC-3
 E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MA-
40 TROUBLESHOOTING CHINE MONITOR DISPLAYS NOTHING

E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE

MONITOR DISPLAYS NOTHING (ALL-K-Q180-410-00-B)

Failure When starting switch is turned to ON position, machine monitor displays nothing.
• When starting switch is turned to ON position, machine monitor displays KOMATSU logo,
screen to input password (if set), screen to check breaker mode (if set), screen of check
before starting, screen to check working mode, screen to check travel speed, and stand-
Related
ard screen in order.
information
• Battery voltage may drop sharply when engine is started, depending on ambient tempera-
ture and battery condition. In this case, machine monitor display may disappear for a
while. This phenomenon is not abnormal.

No. Cause Procedure, measuring location, criteria and remarks

Omission of turning bat- Turn starting switch to OFF position, and check that battery disconnect switch is
1 tery disconnect switch turned ON.
ON

Loose terminal or open 1. Turn starting switch to OFF position.

2
circuit in terminal Check terminals of battery relay.
Be ready with starting switch at OFF, then perform troubleshooting without turning
starting switch to ON position.
Insufficient battery ca- Battery voltage (measure 2 batteries in Min.24 V
3
pacity series)
Gravity of battery (measure gravity in Min.1.26
each cell)
4 Defective fuse F01-14 If fuse is burnt out, circuit may have ground fault. (See cause 9.)
5 Defective fusible link If fusible link F05 is burnt out, circuit probably has ground fault. (See cause 9.)
6 Defective fuse F01-17 If fuse is burnt out, circuit may have ground fault. (See cause 9.)
1. Turn starting switch to OFF position, and turn battery disconnect switch to
OFF position.
2. Insert T-adapter into connector CM01.
3. Turn battery disconnect switch to ON position, and turn starting switch to
Defective wiring harness,
ON position (connect ACC).
7 starting switch, or ma- Between CM01 (1) and (3) 20 to 30 V
chine monitor
Voltage Between CM01 (2) and (4) 20 to 30 V
Between CM01 (10) and (4) 20 to 30 V
1. Turn starting switch to OFF position.
Check terminals of battery relay.
1. Turn the starting switch to OFF position.
2. Disconnect connector H15A.
3. Turn starting switch to ON position and perform troubleshooting again.
Defective starting switch Between starting switch
8 Turn the starting switch to
(internal open circuit) terminal B and terminal Min. 1 MΩ
OFF position.
ACC
Resistance
Between starting switch
Turn the starting switch to
terminal B and terminal Max. 1 Ω
ON position.
ACC

HB365LC-3 40-1201
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MA-
CHINE MONITOR DISPLAYS NOTHING 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found on cause 7, this check is not required.
1. Turn starting switch to OFF position, and turn battery disconnect switch to
OFF position.
2. Disconnect fusible link F05, No. 14 and 17 fuses of fuse box F01, and con-
nector CM01.
3. Connect T-adapters to male side of connector F05 and female side of con-
nector CM01.
Between battery (-) terminal and ground Max. 1 Ω
Open circuit in wiring har-
9 ness Between battery (+) and F05 (male) (1) Max. 1 Ω
(Internal open circuit) Between F05 (male) (2) and F01-16G Max. 1 Ω
Between F01–17 and CM01 (female) (1), (2) Max. 1 Ω
Resistance Between CM01(female) (3) and ground, or between
Max. 1 Ω
CM01 (female) (4) and ground
Between F01–17 and starting switch terminal B Max. 1 Ω
Between starting switch terminal ACC and F01-14E Max. 1 Ω
Between F01-14 and CM01 (female) (10) Max. 1 Ω
If failure code still displays after above checks on causes 3 to 5 and 7, this check is
not required.
1. Turn starting switch to OFF position, and turn battery disconnect switch to
OFF position.
2. Disconnect fusible link F05, fuse No. 17 of fuse box F01, 13D terminal ,
and connectors CM01, and CP01.
3. Connect T-adapters to male side of connector F05 and female side of con-
Ground fault in wiring
harness
nector CM01.
10
(Contact with ground cir- Between battery (+) and ground, or between F05
Min. 1 MΩ
cuit) (male) (1) and ground
Between F05 (male) (2) and ground, or between
Min. 1 MΩ
F01-16G and ground
Resistance
Between ground and F01-17, CM01 (female) (1), (2),
Min. 1 MΩ
or terminal B of starting switch
Between terminal ACC of starting switch and ground,
Min. 1 MΩ
or between CM01 (female) (10) and ground
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
11
tor an internal defect, troubleshooting cannot be performed.)

40-1202 HB365LC-3
 E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MA-
40 TROUBLESHOOTING CHINE MONITOR DISPLAYS NOTHING

Circuit diagram related to monitor power supply

HB365LC-3 40-1203
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH
ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN
YELLOW 40 TROUBLESHOOTING

E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH EN-

GINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW
(ALL-K-AB44-410-00-B)

When starting switch is turned to ON position (with engine stopped), engine oil level monitor lights
Failure
up in yellow.
Related
information

No. Cause Procedure, measuring location, criteria and remarks

Defective engine oil level Perform troubleshooting for failure code [B@BAZK].
1 system (machine monitor
system)
If failure code still displays after above checks on Cause 1, machine monitor may
Defective machine moni- be defective.
2
tor (In case of an internal defect, troubleshooting is impossible as an assembly. Re-
place whole assembly.)

40-1204 HB365LC-3
 E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH
ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS
40 TROUBLESHOOTING UP IN YELLOW

E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH EN-

GINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN
YELLOW (ALL-K-AC40-410-10-B)

When starting switch is turned to ON position (with engine stopped), radiator coolant level monitor
Failure
lights up in yellow.
Related
information

No. Cause Procedure, measuring location, criteria and remarks

Low radiator coolant level Because radiator coolant level may be lowered, check and refill with coolant if level
1 (When system works is lowered.
properly)
Radiator sub-tank cool- Perform troubleshooting for failure code [B@BCZK].
2
ant level switch system

HB365LC-3 40-1205
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN
WHITE WHILE ENGINE IS RUNNING 40 TROUBLESHOOTING

E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE

WHILE ENGINE IS RUNNING (ALL-K-AC00-410-40-B)

Failure Coolant temperature monitor lights up in white while engine is running.

• Signal of coolant temperature sensor is input to engine controller, and then it is transmitted
Related to machine monitor through CAN communication system.
information • Coolant temperature can be checked with monitoring function.
(Code: 04107)

No. Cause Procedure, measuring location, criteria and remarks

Insufficient warm-up op- If monitor is lit in white, engine coolant temperature may be low (approximately
eration of machine 30°C and below). Warm up engine.
1 • Lights up in white: Engine coolant temperature is low.
(When system works
properly) • Lights up in blue: Coolant temperature is proper.
If no failure is found by preceding checks, engine coolant temperature gauge sys-
tem may be defective. Perform following troubleshooting.
Defective engine coolant • E-mode “ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES
2 temperature gauge sys- NOT MOVE FROM MINIMUM OR MAXIMUM”
tem • E-mode “DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIF-
FERS FROM ACTUAL COOLANT TEMPERATURE”(indicates neither full
nor empty)

40-1206 HB365LC-3
 E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN
40 TROUBLESHOOTING WHITE WHILE ENGINE IS RUNNING

E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE

WHILE ENGINE IS RUNNING (ALL-K-L200-410-30-B)

Failure Hydraulic oil temperature monitor lights up in white while engine is running.
• Signal from hydraulic oil temperature sensor is input to pump controller and then data is
Related
transmitted to machine monitor through CAN communication system.
information
• Hydraulic oil temperature can be checked with monitoring function. (Code: 04401)

No. Cause Procedure, measuring location, criteria and remarks

Insufficient warm-up op- If monitor is lit in white, hydraulic oil temperature may be low (approximately 20°C
eration of machine and below). Warm up engine.
1 • Lights up in white: Hydraulic oil temperature is low.
(When system works
properly) • Lights up in blue: Hydraulic oil temperature is proper.
If no failure is found by preceding checks, hydraulic oil temperature gauge system
may be defective. Perform following troubleshooting:
Defective hydraulic oil • E-mode “HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES
2 temperature gauge sys- NOT MOVE FROM MINIMUM OR MAXIMUM”
tem • E-mode “DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIF-
FERS FROM ACTUAL OIL TEMPERATURE” (indicates neither full nor
empty).

HB365LC-3 40-1207
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW
WHILE ENGINE IS RUNNING 40 TROUBLESHOOTING

E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE

ENGINE IS RUNNING (ALL-K-A966-410-20-B)

Failure Air cleaner clogging monitor lights up in yellow while engine is running.
Related
Signal from air cleaner clogging switch can be checked with monitoring function (Code: 04501).
information

No. Cause Procedure, measuring location, criteria and remarks

Clogged air cleaner Air cleaner may be clogged. Check it for clogging and then clean or replace if clog-
1 (when system works ged.
properly)
Defective air cleaner Perform troubleshooting for failure code [AA10NX].
2
clogging switch system

40-1208 HB365LC-3
 E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE
40 TROUBLESHOOTING IS RUNNING

E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS

RUNNING (ALL-K-AKJ0-410-10-B)

Failure Charge level monitor lights up in red while engine is running.

Related
Generated signal condition of alternator can be checked with monitoring function (Code: 04300)
information

No. Cause Procedure, measuring location, criteria and remarks

Defective alternator sys- Perform troubleshooting for failure code [AB00KE].
1
tem

HB365LC-3 40-1209
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS
RUNNING 40 TROUBLESHOOTING

E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUN-

NING (ALL-K-AD40-410-10-B)

Failure Fuel level monitor lights up in red while engine is running.

Related • Signal voltage of fuel sensor can be checked with monitoring function.
information (Code: 04200)

No. Cause Procedure, measuring location, criteria and remarks

Fuel level reduction Because fuel level may be lowered, check and refill with fuel if level is lowered.
1 (When system works
properly)
If no failure is found by preceding checks, fuel gauge system may be defective.
Perform following troubleshooting:
Defective fuel gauge sys- • E-mode “FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM
2 OR MAXIMUM”
tem
• E-mode “DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL
LEVEL” (indicates neither full nor empty).

40-1210 HB365LC-3
 E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE EN-
40 TROUBLESHOOTING GINE IS RUNNING

E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS

RUNNING (ALL-K-AC00-410-50-B)

Failure Water separator monitor lights up in red while engine is running.

Related infor- • Condition of water detected by fuel filter sensor can be checked with monitoring function.
mation (Code: 18800)

No. Cause Procedure, measuring location, criteria and remarks

Increase of water level in Since water is detected in water separator, check water separator and drain water
water separator in it.
1
(When system works
properly)
Defective fuel filter sen- If failure code is still displayed after above checks, fuel filter system may be defec-
sor system tive. Perform troubleshooting for failure codes [CA428] and [CA429].
2
(Engine controller sys-
tem)
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
3
tor an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1211
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN
RED WHILE ENGINE IS RUNNING 40 TROUBLESHOOTING

E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED

WHILE ENGINE IS RUNNING (ALL-K-AC00-410-10-B)

Failure Engine coolant temperature monitor lights up in red while engine is running.
• Signal voltage of coolant temperature sensor is input to engine controller, and then it is
Related
transmitted to machine monitor through CAN communication system.
information
• Engine coolant temperature can be checked with monitoring function (Code: 04107)

No. Cause Procedure, measuring location, criteria and remarks

If monitor is lit in red, coolant temperature may be high (above approximately
102 °C). Cool down coolant. (Run engine at low idle speed.)
Overheat of engine cool- • Lights up in red: Coolant temperature is high (overheating).
1 ant (when system works
• Lights up in blue: Coolant temperature is proper.
properly)
• Perform troubleshooting S-mode “COOLANT TEMPERATURE RISES
TOO HIGH (OVERHEATING).”
Defective engine coolant If failure code is still displayed after above checks on cause 1, engine coolant tem-
2 temperature sensor sys- perature sensor system may be defective. Perform troubleshooting for failure codes
tem [CA144] and [CA145].
If no failure is found by preceding checks, engine coolant temperature gauge sys-
tem may be defective. Perform following troubleshooting.
Defective engine coolant • E-mode “ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES
3 temperature gauge sys- NOT MOVE FROM MINIMUM OR MAXIMUM”
tem • E-mode “DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIF-
FERS FROM ACTUAL COOLANT TEMPERATURE”(indicates neither full
nor empty)

40-1212 HB365LC-3
 E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE
40 TROUBLESHOOTING ENGINE IS RUNNING

E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE EN-

GINE IS RUNNING (ALL-K-AB00-410-10-B)

Failure Engine oil pressure monitor lights up in red while engine is running.
• Engine oil pressure switch signals are input to engine controller. If engine oil pressure
Related infor-
switch is turned on while engine is running, engine controller sends this failure code
mation
[B@BAZG] to machine monitor.

No. Cause Procedure, measuring location, criteria and remarks

Low engine oil pressure Since engine oil pressure low is sensed, check engine oil pressure.
1 (when system works • Perform troubleshooting S-mode “OIL PRESSURE DROPS.”
properly)
Defective engine oil pres- If failure code is still displayed after above checks on cause 1, engine oil pressure
2
sure system switch system may be defective. Perform troubleshooting for failure codes [CA435].
Defective machine moni- If no failure can be found in causes 1 and 2, machine monitor is defective. (Be-
3
tor cause this is an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1213
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED
WHILE ENGINE IS RUNNING 40 TROUBLESHOOTING

E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED

WHILE ENGINE IS RUNNING (ALL-K-L200-410-20-B)

Failure Hydraulic oil temperature monitor lights up in red while engine is running.
• Signal voltage of hydraulic oil temperature sensor is input to pump controller that transmits
Related infor- information to machine monitor through CAN communication system.
mation • Hydraulic oil temperature can be checked with monitoring function.
(Code: 04401)

No. Cause Procedure, measuring location, criteria and remarks

If monitor is lit in red, hydraulic oil temperature may be high (above approximately
Overheating of hydraulic 102 °C). Cool down hydraulic oil. (Run engine at low idle or stop engine.)
1 oil (when system is nor-
• Lights up in red: Hydraulic oil temperature is high (overheating).
mal)
• Lights up in blue: Hydraulic oil temperature is proper.
If no failure is found by preceding checks, hydraulic oil temperature gauge system
may be defective. Perform following troubleshooting:
Defective hydraulic oil • E-mode “HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES
2 temperature gauge sys- NOT MOVE FROM MINIMUM OR MAXIMUM”
tem • E-mode “DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIF-
FERS FROM ACTUAL OIL TEMPERATURE” (indicates neither full nor
empty).
Defective machine moni- If no failure can be found in causes 1 and 2, machine monitor is defective. (Be-
3
tor cause this is an internal defect, troubleshooting cannot be performed.)

40-1214 HB365LC-3
 E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR
40 TROUBLESHOOTING MAXIMUM

E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXI-
MUM (ALL-K-AD40-410-20-B)

Failure Fuel gauge display does not move from minimum or maximum.
Related • Signal voltage of fuel sensor can be checked with monitoring function.
information (Code: 04200)

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective fuel level sen- 2. Disconnect connector P21, and connect T-adapter to male side.
sor
1 Approx.
(Internal open or short Between P21 (male) (1) Fuel level FULL
Resistance 12 Ω
circuit) and ground
Fuel level EMPTY 85 to 110 Ω
1. Turn starting switch to OFF position.
2. Disconnect connector CM01 and connect T-adapter to female side.
Open or short circuit in
2 Approx.
wiring harness Fuel level FULL
Between CM01 (female) 12 Ω
Resistance
(15) and ground
Fuel level EMPTY 85 to 110 Ω

REMARK
Open circuit in wiring har- If check on cause 2 is normal, this check is not required.
ness 1. Turn starting switch to OFF position.
3
(Wire breakage or defec- 2. Disconnect connectors CM01 and P21 and connect T-adapters to each fe-
tive contact of connector) male side.
Resistance Between CM01 (female) (15) and P21 (female) (1) Max. 1 Ω
1. Turn starting switch to OFF position.
Ground fault in wiring
2. Disconnect connectors CM01 and P21, and connect T-adapter to either fe-
harness
4 male side.
(Contact with ground cir-
cuit) Between ground and CM01 (female) (15) or P21 (fe-
Resistance Min. 1 MΩ
male) (1)
1. Turn starting switch to OFF position.
2. Disconnect connector P21.
Hot short circuit in wiring
3. Insert T-adapter into connector CM01, or connect T-adapter to female side
harness
5 of P21.
(Contact with 24 V cir-
4. Turn starting switch to ON position.
cuit)
Approx.
Voltage Between ground and CM01 (15) or P21 (female) (1)
3.3 V
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
6
tor an internal defect, troubleshooting cannot be performed.)

HB365LC-3 40-1215
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR
MAXIMUM 40 TROUBLESHOOTING

Circuit diagram related to fuel level sensor

40-1216 HB365LC-3
 E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEV-
40 TROUBLESHOOTING EL

E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL

(ALL-K-AD40-410-30-B)

Failure Display of fuel gauge differs from actual fuel level.

Related • Signal voltage of fuel sensor can be checked with monitoring function
information (Code: 04200)

No. Cause Procedure, measuring location, criteria and remarks

Defective fuel level sen- See Emode “DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEV-
1
sor EL”.

HB365LC-3 40-1217
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES
NOT MOVE FROM MINIMUM OR MAXIMUM 40 TROUBLESHOOTING

E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT

MOVE FROM MINIMUM OR MAXIMUM (ALL-K-ACA0-410-30-B)

Failure Engine coolant temperature gauge display does not move from minimum or maximum.
• Signal of coolant temperature sensor is input to engine controller, and then it is transmitted
Related to machine monitor through communication system.
information • Coolant temperature can be checked with monitoring function.
(Code: 04107)

No. Cause Procedure, measuring location, criteria and remarks

Defective engine coolant Coolant temperature sensor system may be defective. Perform troubleshooting for
1 temperature sensor sys- failure codes [CA144] and [CA145].
tem
If failure code still displays after above checks on Cause 1, machine monitor may
Defective machine moni- be defective.
2
tor (In case of an internal defect, troubleshooting is impossible as an assembly. Re-
place whole assembly.)

40-1218 HB365LC-3
 E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIF-
40 TROUBLESHOOTING FERS FROM ACTUAL COOLANT TEMPERATURE

E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS

FROM ACTUAL COOLANT TEMPERATURE (ALL-K-ACA0-410-40-B)

Failure Display of engine coolant temperature gauge differs from actual coolant temperature.
• Signal voltage of coolant temperature sensor is input to engine controller, and then it is
Related transmitted to machine monitor through CAN communication system.
information • Coolant temperature can be checked with monitoring function.
(Code: 04107)

No. Cause Procedure, measuring location, criteria and remarks

Defective engine coolant Coolant temperature sensor system may be defective. Perform troubleshooting for
1 temperature sensor sys- failure codes [CA144] and [CA145].
tem

HB365LC-3 40-1219
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT
MOVE FROM MINIMUM OR MAXIMUM 40 TROUBLESHOOTING

E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE

FROM MINIMUM OR MAXIMUM (ALL-K-L200-410-40-B)

Failure Hydraulic oil temperature gauge display does not move from minimum or maximum.
• Signal from hydraulic oil temperature sensor is input to pump controller and then data is
Related transmitted to machine monitor through CAN communication system.
information • Hydraulic oil temperature can be checked with monitoring function.
(Code: 04401)

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector P22 and connect T-adapter to male side.
Approx.
10 °C
90 kΩ
Between P22 (male) (1)
Defective hydraulic oil
and (2) Approx.
temperature sensor 30 °C
1 REMARK 35 kΩ
(Internal open or short
circuit) Resistance Temperature of oil tem- Approx.
80 °C
perature sensor - Resist- 6.5 kΩ
ance characteristics Approx.
100 °C
3.5 kΩ
Between P22 (male) (2) and ground Min. 1 MΩ
1. Turn the starting switch to OFF position.
2. Disconnect the connector CP01, and connect the T-adapter to female side.
Between CP01 (female) (28) and (47).
Open or short circuit in
2 REMARK
wiring harness 3.5 to 90 kΩ
Resistance Resistance accords with thermal characteristics ta-
ble in cause 1.
Between CP01 (female) (28) and ground Min. 1 MΩ
If no failure is found by check on cause 2, this check is not required.
1. Turn the starting switch to OFF position.
Open circuit in wiring har-
ness 2. Disconnect the connectors CP01 and P22, and connect the T-adapter to
3 each female side.
(Wire breakage or defec-
tive contact of connector) Between CP01 (female) (28) and P22 (female) (2) Max. 1 Ω
Resistance
Between CP01 (female) (47) and P22 (female) (1) Max. 1 Ω
If failure code still displays after above checks on cause 2, this check is not re-
quired.
Ground fault in wiring 1. Turn starting switch to OFF position.
harness
4 2. Disconnect connectors CP01 and P13, and connect T-adapter to either fe-
(Contact with ground cir- male side.
cuit)
Between ground and CP01 (female) (28) or P22 (fe-
Resistance Min. 1 MΩ
male) (2)
1. Turn starting switch to OFF position.
2. Disconnect connector P22.
Hot short circuit in wiring
harness 3. Insert T-adapter into connector CP01, or connect T-adapter to female side
5
(Contact with 24 V cir- of P22.
cuit) 4. Turn starting switch to ON position.
Voltage Between ground and CP01 (28) or P22 (female) (2) Approx. 5 V

40-1220 HB365LC-3
 E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT
40 TROUBLESHOOTING MOVE FROM MINIMUM OR MAXIMUM

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by preceding checks, pump controller is defective. (In case of
6 Defective pump controller an internal defect, troubleshooting is impossible as an assembly. Replace whole
assembly).

Circuit diagram related to hydraulic oil temperature sensor

HB365LC-3 40-1221
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS
FROM ACTUAL OIL TEMPERATURE 40 TROUBLESHOOTING

E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS

FROM ACTUAL OIL TEMPERATURE (ALL-K-L200-410-50-B)

Failure Display of hydraulic oil temperature gauge differs from actual oil temperature.
• Signal from hydraulic oil temperature sensor is input to pump controller and then data is
Related
transmitted to machine monitor through CAN communication system.
information
• Hydr. Oil Temperature can be checked with monitoring function. (Code: 04401)

No. Cause Procedure, measuring location, criteria and remarks

Defective hydraulic oil See Emode “HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT
1
temperature sensor MOVE FROM MINIMUM OR MAXIMUM”.

40-1222 HB365LC-3
 E-23 MONITOR TEMPERATURE GAUGE OF HYBRID SYSTEMS
40 TROUBLESHOOTING DOES NOT INDICATE CORRECT TEMPERATURE

E-23 MONITOR TEMPERATURE GAUGE OF HYBRID SYSTEMS DOES NOT

INDICATE CORRECT TEMPERATURE (ALL-K-PQJQ-410-00-B)

Failure Hybrid temperature gauge does not indicate correct temperature.

• Signal from each hydraulic oil temperature sensor is input to hybrid controller, and then
data is transmitted to machine monitor through communication system.
• Each hybrid temperature can be checked with monitoring function.
Related (Code: 09306: Capacitor cell temperature, 09403: Booster IGBT base temperature, 09404:
information Booster IGBT junction temperature, 09402: Booster inductor temperature, 09101: Swing
motor coil temperature, 09600: Motor-generator temperature, 09607: Motor-generator driv-
er IGBT base temperature#0, 09608: Motor-generator IGBT base#1, 09507: Swing driver
IGBT junction temperature)

No. Cause Procedure, measuring location, criteria and remarks

Defective hybrid temper- Defective hybrid temperature sensor system is suspected, perform troubleshooting
1
ature sensor system for failure codes starting with [GA****].
Defective machine moni- Check the temperature of the indicator and hybrid components if the display of the
2
tor machine monitor is correct.

Table for detailed thermal load on hybrid system

Display
position Color of
Thermal Booster Booster Swing
of hybrid the hy- Capaci- Booster Swing Motor- Genera-
load on IGBT IGBT inverter
compo- brid tem- tor cell inductor motor genera- tor driver
hybrid base junction junction
nent perature tempera- tempera- coil tem- tor tem- tempera-
compo- tempera- tempera- tempera-
tempera- caution ture ture perature perature ture
nent ture ture ture
ture lamp (a)
gauge
102 % A1 (red) Red 65 95 130 127 140 180 95 134
A2
100 % Red 63 93 125 122 120 127 85 133
(green)
A3
95 % Blue 60 75 110 110 100 115 75 115
(green)
A4
50 % Blue 40 55 90 90 80 95 55 95
(white)
A5
20 % Blue 0 0 0 0 0 0 0 0
(white)
A6
0% Blue -30 -30 -30 -30 -30 -30 -30 -30
(white)

Hybrid component temperature gauge and hybrid temperature caution lamp

HB365LC-3 40-1223
E-24 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DIS-
PLAYED 40 TROUBLESHOOTING

E-24 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DIS-

PLAYED (ALL-K-Q180-410-20-B)

Failure • Some areas of machine monitor screen are not displayed.

Related
information

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- Perform troubleshooting when starting switch is in ON position.

tor When all the lights of liquid crystal display panel is on (entirely white) by the follow-
1
(Liquid crystal display ing switch operation, machine monitor is normal.
panel part) • Switch operation: [4] + [F2] (Press them simultaneously.)
If failure code still displays after above checks on Cause 1, machine monitor may
Defective machine moni- be defective.
2
tor (In case of an internal defect, troubleshooting is impossible as an assembly. Re-
place whole assembly.)

40-1224 HB365LC-3
40 TROUBLESHOOTING E-25 FUNCTION SWITCH DOES NOT OPERATE

E-25 FUNCTION SWITCH DOES NOT OPERATE (ALL-K-Q1C1-410-00-B)

Failure Function switch does not work.

Related • Signal state of function switch can be checked with monitoring function.
information (Code: 04503)

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- Machine monitor may be defective. (Because this is an internal defect, trouble-
1
tor shooting cannot be performed.)

HB365LC-3 40-1225
E-26 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD
WEATHER) 40 TROUBLESHOOTING

E-26 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD

WEATHER) (ALL-K-AP13-410-00-B)

Failure Automatic warm-up system does not operate (in cold weather).
• Automatic warm-up function increases engine speed to 1200 rpm hen coolant temperature
is below 30 °C.
• With starting switch at ON position or after engine is started, if fuel control dial is kept at
70% or more of full open range for 3 seconds, automatic warm-up operation is canceled.

Related • If machine is equipped with air conditioner, when blower is turned on, ambient temperature
is below 5 °C and engine coolant temperature is below 50 °C, automatic warm-up function
information increases engine speed to 1300 rpm. If engine coolant temperature reaches 60 °C, aut-
matic warm-up function is canceled.
• If engine oil pressure is below 50 kPa {0.51 kg/cm2} , turbocharger protection function
works to keep engine speed below 1000 rpm for up to 20 seconds after engine is started.
• Engine coolant temperature can be checked with monitoring function(code: 04107).

No. Cause Procedure, measuring location, criteria and remarks

Defective engine coolant See E-mode “ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT
1 temperature signal sys- MOVE FROM MINIMUM OR MAXIMUM”
tem
If failure code still displays after above checks on Cause 1, machine monitor may
Defective machine moni- be defective.
2
tor (In case of an internal defect, troubleshooting is impossible as an assembly. Re-
place whole assembly.)

40-1226 HB365LC-3
 E-27 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-
DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO
40 TROUBLESHOOTING OFF

E-27 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECEL-

ERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF
(ALL-K-AF60-410-00-B)

When auto-deceleration switch is operated, auto-deceleration monitor does not light up or does not
Failure
go off.
Related • State of auto-deceleration switch signal can be checked with monitoring function.
information (Code: 04504)

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- Machine monitor may be defective. (Because this is an internal defect, trouble-
1
tor shooting cannot be performed.)

HB365LC-3 40-1227
E-28 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED
WITH LEVER 40 TROUBLESHOOTING

E-28 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEV-

ER (ALL-K-AF60-410-10-B)

Failure Auto-deceleration function does not operate or is not canceled while lever is operated.
• Since set engine speed for auto-deceleration is 1000 rpm, auto-deceleration is not actuat-
ed or canceled if engine speed set with fuel control dial is below this speed.
Related • If one-touch power maximizing function does not operate properly, perform troubleshooting
information for Emode “ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE
PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR”.
• Pressure switch signal can be checked with monitoring function.(Code:01900, 01901)

No. Cause Procedure, measuring location, criteria and remarks

1. Start engine and perform troubleshooting (with monitoring function).
2. If display of monitor is incorrect, perform troubleshooting for E-mode
“ MONITORING FUNCTION DOES NOT DISPLAY *** PROPERLY.”
Swing (when lever is operated) ON
Swing (when lever is in NEUTRAL) OFF
Travel (when lever is operated) ON
Travel (when lever is in NEUTRAL) OFF
Boom Lower (when lever is operated) ON
Boom Lower (when lever is in NEUTRAL) OFF
Boom RAISE (when lever is operated) ON
Defective PPC oil pres- Boom RAISE (when lever is in NEUTRAL) OFF
1
sure signal
Monitoring Arm IN (when lever is operated) ON
display Arm IN (when lever is in NEUTRAL) OFF
Arm OUT (when lever is operated) ON
Arm OUT (when lever is in NEUTRAL) OFF
Bucket CURL (when lever is operated) ON
Bucket CURL (when lever is in NEUTRAL) OFF
Bucket DUMP (when lever is operated) ON
Bucket DUMP (when lever is in NEUTRAL) OFF
Service (when lever is operated) ON
Service (when lever is in NEUTRAL) OFF
Defective machine moni- If no failure is found by above checks, machine monitor is defective. (Since this is
2
tor an internal defect, troubleshooting cannot be performed.)
If no failure is found by preceding checks, pump controller is defective. (In case of
3 Defective pump controller an internal defect, troubleshooting is impossible as an assembly. Replace whole
assembly).
Defective engine control- If no failure is found by above checks, engine controller is defective. (Since this is
4
ler an internal defect, troubleshooting cannot be performed.)

40-1228 HB365LC-3
 E-29 WHEN WORKING MODE SWITCH IS OPERATED, WORKING
40 TROUBLESHOOTING MODE SELECTION SCREEN IS NOT DISPLAYED

E-29 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE

SELECTION SCREEN IS NOT DISPLAYED (ALL-K-L010-410-10-B)

Failure When working mode switch is operated, working mode selection screen is not displayed.
Related • Signal state of working mode switch can be checked with monitoring function.
information (Code: 04504)

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- Machine monitor may be defective. (Because this is an internal defect, trouble-
1
tor shooting cannot be performed.)

HB365LC-3 40-1229
E-30 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE
AND HYDRAULIC PUMP IS NOT CHANGED 40 TROUBLESHOOTING

E-30 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND

HYDRAULIC PUMP IS NOT CHANGED (ALL-K-L010-410-20-B)

Failure Setting of engine and hydraulic pump is not changed when working mode is changed.
Related
information

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- Machine monitor may be defective. (Because this is an internal defect, trouble-
1
tor shooting cannot be performed.)
Pump controller may be defective. (In case of an internal defect, troubleshooting is
2 Defective pump controller
impossible as an assembly. Replace whole assembly.)

40-1230 HB365LC-3
 E-31 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED
40 TROUBLESHOOTING MONITOR DOES NOT CHANGE

E-31 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED

MONITOR DOES NOT CHANGE (ALL-K-C130-410-00-B)

Failure Travel speed monitor does not change when travel speed switch is operated.
Related • Signal state of travel speed switch can be checked with monitoring function.
information (Code: 04504)

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- Machine monitor may be defective. (Because this is an internal defect, trouble-
1
tor shooting cannot be performed.)

HB365LC-3 40-1231
E-32 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL
TRAVEL SPEED DOES NOT CHANGE 40 TROUBLESHOOTING

E-32 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL

SPEED DOES NOT CHANGE (ALL-K-C161-410-00-B)

Failure Travel speed does not change after the travel speed is changed.
• If cause 1 occurs, actual travel speed does not lower when travel speed selection is
changed to Lo.
• As T-adapter for pump controller connector is “socket-type box”, operating voltage cannot
Related infor-
be measured at pump controller connector.
mation
• If failure code [DHPAMA], [DHPBMA], [DHSFMA], [DHSGMA], [DHSHMA], [DHSJMA],
[DW43KA], [DW43KB], or [DW43KY] is displayed, perform troubleshooting for these fail-
ure codes first.

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Hot short circuit in wiring
harness 2. Disconnect connector V04, and connect T-adapter to female side.
1
(Contact with 24 V cir- 3. Turn starting switch to ON position.
cuit)
Voltage Between V04 (female) (2) and ground Max. 4.5 V
If failure code still displays after above checks on Cause 1, machine monitor may
Defective machine moni- be defective.
2
tor (In case of an internal defect, troubleshooting is impossible as an assembly. Re-
place whole assembly.)
If failure code still displays after above checks on causes 1 and 2, pump controller
may be defective.
3 Defective pump controller
(In case of an internal defect, troubleshooting is impossible as an assembly. Re-
place whole assembly.)

Circuit diagram related to travel speed solenoid

40-1232 HB365LC-3
40 TROUBLESHOOTING E-33 ALARM BUZZER CANNOT BE CANCELED

E-33 ALARM BUZZER CANNOT BE CANCELED (ALL-K-Q570-410-10-B)

Failure Alarm buzzer does not stop sounding.

Related • Condition of signal of alarm buzzer cancel switch can be checked with monitoring function.
information (Code: 04504)

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- Machine monitor may be defective. (Because this is an internal defect, trouble-
1
tor shooting cannot be performed.)

HB365LC-3 40-1233
E-34 SERVICE METER IS NOT DISPLAYED, WHILE STARTING
SWITCH IS IN OFF POSITION 40 TROUBLESHOOTING

E-34 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS

IN OFF POSITION (ALL-K-Q1M0-410-00-B)

Failure Service meter is not displayed while starting switch is in OFF position.
The following switch operation with the starting switch set to OFF position displays a service meter
Related
in the upper middle of the screen.
information
Operation of switches: [4]+[1] (pressed simultaneously)

No. Cause Procedure, measuring location, criteria and remarks

When starting switch is turned to ON position and machine monitor displays noth-
ing, backup power supply system may be defective and perform the following trou-
Defective backup power
1 bleshooting:
supply system
• E-mode “WHEN STARTING SWITCH IS TURNED TO ON POSITION,
MACHINE MONITOR DISPLAYS NOTHING”
If failure code still displays after above checks on Cause 1, machine monitor may
Defective machine moni- be defective.
2
tor (In case of an internal defect, troubleshooting is impossible as an assembly. Re-
place whole assembly.)

40-1234 HB365LC-3
40 TROUBLESHOOTING E-35 SERVICE MODE CANNOT BE SELECTED

E-35 SERVICE MODE CANNOT BE SELECTED (ALL-K-Q194-410-00-B)

Failure Service mode cannot be selected.

Related
See “TESTING AND ADJUSTING”, “SERVICE MODE”
information

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- Machine monitor may be defective. (Because this is an internal defect, trouble-
1
tor shooting cannot be performed.)

HB365LC-3 40-1235
E-36 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHA-
NISM DO NOT MOVE 40 TROUBLESHOOTING

E-36 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO

NOT MOVE (ALL-K-C001-410-00-B)

Failure None of work equipment, swing or travel works.

Related
information

No. Cause Procedure, measuring location, criteria and remarks

If fuse No. 3 of F01 is burnt out, circuit may have ground fault, etc. (See check on
1 Defective fuse
Cause 7.)
1. Turn starting switch to OFF position.
2. Disconnect connector S14 and connect T-adapter to female side.
Defective lock lever
2 switch 3. Operate lock lever and perform troubleshooting.
(Internal open circuit) Lock lever: LOCK Min. 1 MΩ
Between S14 (female) (1)
Resistance
and (2) Lock lever: FREE Max. 1 Ω
1. Turn starting switch to OFF position.
2. Replace PPC lock relay (connector: R48) with light relay (connector: R05).
Defective PPC lock relay 3. Turn starting switch to ON position.
3 (internal open or short
circuit) 4. Set the lock lever to FREE position.
If any of work equipment, swing, and travel is available, the original PPC lock relay
is defective.
1. Turn starting switch to OFF position.
Defective PPC lock sole-
noid 2. Disconnect connector V01 and connect T-adapter to male side.
4
(Internal open, short cir- Between V01 (male) (1) and (2) 20 to 60 Ω
cuit, or ground fault) Resistance
Between V01 (male) (1) and ground Min. 1 MΩ
1. Turn starting switch to OFF position.
Defective diode array 2. Disconnect connector D01 and connect T-adapter to male side.
5 D01 Between D01 (male) (8) (+) and (4) (-) Continuity
(Internal ground fault) Continuity No continui-
Between D01 (male) (4) (+) and (8) (-)
ty
1. Turn starting switch to OFF position.
2. Disconnect connector R48, and connect T-adapter to female side.
3. Turn starting switch to ON position.
Open or short circuit in 4. Set the lock lever to FREE position.
6
wiring harness
Between R48 (female) (5) and ground
Resistance 20 to 60 Ω
(Resistance of PPC lock solenoid)
Voltage Between R48 (female) (3) and ground Min. 20 V

40-1236 HB365LC-3
 E-36 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHA-
40 TROUBLESHOOTING NISM DO NOT MOVE

No. Cause Procedure, measuring location, criteria and remarks

If failure code still displays after above checks on Cause 6, this check is not re-
quired.
1. Turn starting switch to OFF position.
2. Remove fuse No. 3.
3. Disconnect connectors S14, V01, and R48, and connect T-adapters to
Open circuit in wiring har-
7 each female side.
ness
Between V01 (female) (2) and ground Max. 1 Ω
Between V01 (female) (1) and R48 (female) (5) Max. 1 Ω
Resistance
Between R48 (female) (3) and S14 (male) (2) Max. 1 Ω
Between fuse F01-3 outlet and S14 (male) (1) Max. 1 Ω
If failure code is still displayed after above checks on Cause 6, this check is not re-
quired.
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Remove fuse No. 3.
harness 3. Disconnect connectors S14, D01, V01 and then connect T-adapter to male
8
(Contact with ground cir- side of S14 or female side of V01.
cuit)
Between V01 (female) (1) and ground Min. 1 MΩ
Resistance Between S14 (male) (1) and ground Min. 1 MΩ
Between S14 (male) (2) and ground Min. 1 MΩ

Circuit diagram related to PPC lock switch

HB365LC-3 40-1237
E-37 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHA-
NISM DO NOT LOCK 40 TROUBLESHOOTING

E-37 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO

NOT LOCK (ALL-K-PX10-410-00-B)

Failure Any of work equipment, swing, and travel cannot be locked.

Related
information

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector S14 and connect T-adapter to female side.
Defective lock lever
1 switch 3. Operate lock lever and perform troubleshooting.
(internal short circuit) Lock lever: LOCK Min. 1 MΩ
Between S14 (female) (1)
Resistance
and (2) Lock lever: FREE Max. 1 Ω
1. Turn starting switch to OFF position.
Hot short circuit in wiring 2. Disconnect connector V01 and connect T-adapter to female side.
harness
2 3. Turn starting switch to ON position.
(Contact with 24 V cir-
4. Turn lock lever to LOCK position.
cuit)
Voltage Between V01 (female) (2) and (1) Max. 1 V

Circuit diagram related to PPC lock switch

40-1238 HB365LC-3
 E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL
40 TROUBLESHOOTING POSITION, MACHINE CANNOT SWING

E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSI-

TION, MACHINE CANNOT SWING (ALL-K-J6A0-410-00-B)

Failure Upper structure does not swing if swing parking brake cancel switch is set to CANCEL position.
Related • State of swing lock switch signal can be checked with monitoring function.
information (Code: 02200)

No. Cause Procedure, measuring location, criteria and remarks

Defective No.1 in fuse If fuse is blown, circuit probably has ground fault. In this case, perform check on
1
box F01 cause 5 first.
1. Turn starting switch to OFF position.
2. Disconnect connector S25 and connect T-adapter to male side.
Defective swing parking
2 brake cancel switch (in- Swing parking brake can-
Min. 1 MΩ
ternal short circuit) Between S25 (male) (13) cel switch: Normal
Resistance
and (14) Swing parking brake can-
Max. 1 Ω
cel switch: Open
1. Turn starting switch to OFF position.
Defective diode array 2. Remove diode array and connect T-adapter to male side.
3 D01 Continuity Between D01 (male) (7) (+) and (3) (-) Continuity
(internal short circuit)
No continui-
Continuity Between D01 (male) (3) (+) and (7) (-)
ty
1. Turn starting switch to OFF position.
Defective diode array 2. Remove diode array and connect T-adapter to male side.
4 D03 Continuity Between D03 (male) (5) (+) and (1) (-) Continuity
(internal short circuit)
No continui-
Continuity Between D03 (male) (1) (+) and (5) (-)
ty
1. Turn starting switch to OFF position.
2. Disconnect connector V05, and connect T-adapter to female side.
3. Turn starting switch to ON position.
4. Swing lock switch OFF
5 Defective wiring harness
Swing parking brake can-
20 to 30 V
Between V05 (female) (1) cel switch: Open
Voltage
and (2) Swing parking brake can-
Max. 1 V
cel switch: Normal
If failure code is still displayed after above checks on cause 5, this check is not re-
quired.
1. Turn starting switch to OFF position.
Open circuit in wiring har-
ness 2. Disconnect connectors V05 and S25, and connect T-adapters to each fe-
6 male side.
(Wire breakage or defec-
tive contact of connector) 3. Swing lock switch OFF
Between V05 (female) (1) and S25 (female) (14) Max. 1 Ω
Resistance
Between V05 (female) (2) and ground Max. 1 Ω

HB365LC-3 40-1239
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL
POSITION, MACHINE CANNOT SWING 40 TROUBLESHOOTING

No. Cause Procedure, measuring location, criteria and remarks

If failure code is still displayed after above checks on cause 5, this check is not re-
quired.
Ground fault in wiring
harness 1. Turn starting switch to OFF position.
7
(Contact with ground cir- 2. Disconnect connectors S25 and V05 and connect T-adapter to female side
cuit) of V05.
Resistance Between V05 (female) (1) and ground Min. 1 MΩ

40-1240 HB365LC-3
 E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL
40 TROUBLESHOOTING POSITION, MACHINE CANNOT SWING

Circuit diagram related to swing parking brake

HB365LC-3 40-1241
E-39 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL
POSITION, SWING HOLDING BRAKE DOES NOT OPERATE 40 TROUBLESHOOTING

E-39 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSI-

TION, SWING HOLDING BRAKE DOES NOT OPERATE (ALL-K-J6A0-410-10-B)

Failure Swing brake does not operate while swing parking brake cancel switch is set to NORMAL position.
Related
information

No. Cause Procedure, measuring location, criteria and remarks

Defective swing parking
1 brake cancel switch (in-
ternal short circuit)
Hot short circuit in wiring
harness
2 3.
(Contact with 24 V cir-
cuit)
1. Turn starting switch to OFF position.
2. Disconnect connector S25 and connect T-adapter to male side.
Swing parking brake can-
Min. 1 MΩ
Between S25 (male) (13) cel switch: Normal
Resistance
and (14) Swing parking brake can-
Max. 1 Ω
cel switch: Open
1. Turn starting switch to OFF position.
2. Disconnect connector V05, and connect T-adapter to female side.
Turn starting switch to ON position.
4. Swing lock switch: ON
Voltage Between V05 (female) (1) and ground Max. 1 V

40-1242 HB365LC-3
 E-39 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL
40 TROUBLESHOOTING POSITION, SWING HOLDING BRAKE DOES NOT OPERATE

Circuit diagram related to swing parking brake

HB365LC-3 40-1243
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OP-
ERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR 40 TROUBLESHOOTING

E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE

PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR (ALL-K-PT28-410-00-B)

One-touch power maximizing function does not operate properly, or indicator not displayed on moni-
Failure
tor
• One-touch power maximizing function does not operate when working mode is other than
Related power mode (P) or economy mode (E).
information • Condition of L.H.knob switch signal can be checked with monitoring function.
(Code: 02200)

No. Cause Procedure, measuring location, criteria and remarks

If work equipment power is increased when L.H. knob switch is pressed but not dis-
Defective machine moni-
1 played on the monitor, machine monitor may be defective. (In case of an internal
tor
defect, troubleshooting is impossible as an assembly. Replace whole assembly.)
If fuse is burnt out, circuit may have ground fault. (See ground fault in wiring har-
2 Defective No.8 fuse
ness(Contact with ground circuit).)
1. Turn starting switch to OFF position.
Defective L.H.knob 2. Disconnect connector S11 and connect T-adapter to male side.
3 switch
Between S11 (male) (1) L.H.knob switch: Release Min. 1 MΩ
(Internal open circuit) Resistance
and (2) L.H. knob switch: Press Max. 1 Ω
1. Turn starting switch to OFF position.
Defective 2-stage relief
solenoid 2. Disconnect connector V08, and connect T-adapter to male side.
4
(Internal short circuit or Between V08 (male) (1) and (2) 20 to 60 Ω
ground fault) Resistance
Between V08 (male) (1) and ground Min. 1 MΩ
1. Turn starting switch to OFF position.
2. Disconnect connector CP01 and connect T-adapter to female side.
Open circuit or ground 3. Turn starting switch to ON position.
5
fault in wiring harness
Between CP01 (female) L.H.knob switch: Release Max. 1 V
Voltage
(42) and ground L.H. knob switch: Press 20 to 30 V
If failure code is still displayed after above checks on short circuit or ground fault in
wiring harness, this check is not required.
1. Turn starting switch to OFF position.
Open circuit in wiring har-
ness 2. Remove fuse F01-8.
6
(Wire breakage or defec- 3. Disconnect connectors CP01 and S11 and connect T-adapters to each fe-
tive contact of connector) male side.
Between F01-8 and S11 (female) (1) Max. 1 Ω
Resistance
Between S11 (female) (2) and CP01 (female) (42) Max. 1 Ω
If failure code is still displayed after above checks on Short circuit or ground fault in
wiring harness, this check is not required.
1. Turn starting switch to OFF position.
Ground fault in wiring 2. Remove fuse F01-8.
harness
7 3. Disconnect connectors CP01 and S11, and connect T-adapter to female
(Contact with ground cir- side of S11.
cuit)
Between ground and F01-8 or S11 (female) (1) Min. 1 MΩ
Resistance Between ground and S11 (female) (2) or CP01 (fe-
Min. 1 MΩ
male) (42)

40-1244 HB365LC-3
 E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OP-
40 TROUBLESHOOTING ERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR

No. Cause Procedure, measuring location, criteria and remarks

If no failure is found by preceding checks, pump controller is defective. (In case of
8 Defective pump controller an internal defect, troubleshooting is impossible as an assembly. Replace whole
assembly).

Circuit diagram related to 2-stage relief solenoid system

Circuit diagram related to one-touch power maximizing system

HB365LC-3 40-1245
E-41 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCEL-
LED 40 TROUBLESHOOTING

E-41 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED

(ALL-K-PT28-410-10-B)

Failure One-touch power maximizing function is not cancelled.

Related • Condition of L.H.knob switch signal can be checked with monitoring function.
information (Code: 02200)

No. Cause Procedure, measuring location, criteria and remarks

Hot short circuit in wiring
harness
1
(Contact with 24 V cir-
cuit)
2 Defective pump controller
1. Turn starting switch to OFF position.
2. Disconnect connector V08, and connect T-adapter to female side.
3. Turn starting switch to ON position.
Voltage Between V08 (female) (1) and (2) Max. 4.5 V
If failure code still displays after above checks on cause 1, pump controller is de-
fective.
(In case of an internal defect, troubleshooting is impossible as an assembly. Re-
place whole assembly.)

Circuit diagram related to 2-stage relief solenoid system

40-1246 HB365LC-3
40 TROUBLESHOOTING E-42 ALARM DOES NOT SOUND DURING TRAVEL

E-42 ALARM DOES NOT SOUND DURING TRAVEL (ALL-K-Q520-410-00-B)

Failure Alarm does not sound during travel.

• Work in pairs.

Related • Travel signal can be checked with monitoring function.

(Code: 01900)
information
• Travel differential pressure signal can be checked with monitoring function.
(Code: 01901)

No. Cause Procedure, measuring location, criteria and remarks

Perform troubleshooting when starting switch is at OFF position and engine is run-
ning.
If monitoring data is not displayed normally, perform troubleshooting for E-mode
“TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING
FUNCTION”.

1 Defective travel signal Travel differential pressure signal (When lever is in

OFF
NEUTRAL)

Monitoring Travel differential pressure signal (When one lever op-

ON
display erated)
Travel signal (When lever is in NEUTRAL) OFF
Travel signal (When both levers are operated) ON
1. Turn starting switch to OFF position.
2. Disconnect connector M14, and connect T-adapter to female side.
3. Start engine and control travel lever.
k Never enter under the machine when operating travel lever.
Defective travel alarm REMARK
2
(Internal defect)
• When travel lever is set to the travel position, voltage is applied usually to
the travel alarm connector before machine starts moving.
• If the following voltage is normal but travel alarm does not sound, travel
alarm is defective.
Voltage Between M14 (female) (1) and (2) 20 to 30 V
1. Turn starting switch to OFF position.
Open circuit in wiring har- 2. Disconnect connectors M14 and CP02 and connect T-adapters to each fe-
ness male side.
3
(Wire breakage or defec-
Between CP02 (female) (107) and M14 (female) (1) Max. 1 Ω
tive contact of connector) Resistance
Between M14 (female) (2) and ground Max. 1 Ω
1. Turn starting switch to OFF position.
Ground fault in wiring
2. Disconnect connectors CP02 and M14, and connect T-adapter to either fe-
harness
4 male side.
(Contact with ground cir-
cuit) Between CP02 (female) (107) and ground, or M14 (fe-
Resistance Min. 1 MΩ
male) (1) and ground

HB365LC-3 40-1247
E-42 ALARM DOES NOT SOUND DURING TRAVEL 40 TROUBLESHOOTING

Circuit related to travel signal system

40-1248 HB365LC-3
 E-43 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS
40 TROUBLESHOOTING STOPPED

E-43 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED

(ALL-K-Q520-410-10-B)

Failure Alarm does not stop sounding while machine is stopped.

Related
information

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Hot short circuit in wiring
harness 2. Disconnect connector M14, and connect T-adapter to female side.
1
(Contact with 24 V cir- 3. Turn starting switch to ON position.
cuit)
Voltage Between M14 (female) (1) and ground Max. 1 V

Circuit related to travel signal system

HB365LC-3 40-1249
E-44 HORN DOES NOT SOUND 40 TROUBLESHOOTING

E-44 HORN DOES NOT SOUND (ALL-K-Q530-410-00-B)

Failure Horn does not sound.

Related
information

No. Cause Procedure, measuring location, criteria and remarks

If fuse F01-5 is blown out, the circuit probably has ground fault. In this case, per-
1 Defective fuse
form check on cause 7 first.
1. Turn starting switch to OFF position.
Defective horn relay 2. Replace horn relay (connector: R08) with another relay.
2 (Internal open or short 3. Turn starting switch to ON position.
circuit) 4. Press R.H. knob switch.
If horn sounds, original horn relay is defective.
1. Turn starting switch to OFF position.
Defective horn switch 2. Disconnect connector S10 and connect T-adapter to male side.
3 (Internal open or short
Between S10 (male) (1) Switch: OFF Min. 1 MΩ
circuit) Resistance
and (2) Switch: ON Max. 1 Ω
1. Turn starting switch to OFF position.
Defective treble tone 2. Disconnect connectors M07 and M08, and connect T-adapters to male
horn (M07) or bass tone side.
4
horn (M08) (internal open
or short circuit) Continuity Between M07 (male) (1) and (2) Continuity
Continuity Between M08 (male) (1) and (2) Continuity
1. Turn the starting switch to OFF position.
2. Disconnect the connector R08, and connect the T-adapter to female side.
3. Turn the starting switch to ON position.
5 Defective wiring harness
4. Press R.H. knob switch.
Between R08 (female) (1) and (2) 20 to 30 V
Voltage
Between R08 (female) (3) and (2) 20 to 30 V

40-1250 HB365LC-3
40 TROUBLESHOOTING
No. Cause
Open circuit in wiring har-
6 ness (wire breakage or
defective contact)
Ground fault in wiring
7 harness (contact with
ground circuit)
Defective horn (internal
8
defect)
HB365LC-3
E-44 HORN DOES NOT SOUND
Procedure, measuring location, criteria and remarks
1. Turn the starting switch to OFF position.
2. Disconnect the connector R08, and connect the T-adapter to female side.
Between R08 (female) (5) and ground Continuity
Continuity
Between R08 (female) (2) and ground Continuity
1. Turn the starting switch to OFF position.
2. Remove the fuse F01-5.
3. Disconnect the connectors R08, S10, M07 and M08, and connect the T-
adapter to each female side.
Between F01-5 and R08 (female) (3) Max. 1 Ω
Between F01-5 and S10 (female) (1) Max. 1 Ω
Between R08 (female) (1) and S10 (female) (2) Max. 1 Ω
Between R08 (female) (5) and M07 (female) (2) Max. 1 Ω
Resistance
Between R08 (female) (5) and M08 (female) (2) Max. 1 Ω
Between R08 (female) (2) and ground Max. 1 Ω
Between M07 (female) (1) and ground Max. 1 Ω
Between M08 (female) (1) and ground Max. 1 Ω
If the fuse is not blown out, this check is not required.
1. Turn the starting switch to OFF position.
2. Remove the fuse F01-5.
3. Disconnect connectors S10, M07, M08, R08 and K04, and connect T-
adapter to female side of R08.
Between R08 (female) (1) and ground Min. 1 MΩ
Resistance Between R08 (female) (3) and ground Min. 1 MΩ
Between R08 (female) (5) and ground Min. 1 MΩ
If failure code is still displayed after above checks, horn may be defective.
40-1251
E-44 HORN DOES NOT SOUND 40 TROUBLESHOOTING

Circuit diagram related to horn

40-1252 HB365LC-3
40 TROUBLESHOOTING E-45 HORN DOES NOT STOP SOUNDING

E-45 HORN DOES NOT STOP SOUNDING (ALL-K-Q530-410-10-B)

Failure Horn does not stop sounding.

Related
information

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
Defective horn relay
(R08) 2. Remove horn relay (connector R08).
1
(Internal open or short 3. Turn starting switch to ON position.
circuit)
If horn stops sounding, the original horn relay is defective.
1. Turn starting switch to OFF position.
2. Disconnect connectors M07 and M08, and connect T-adapters to female
Hot short circuit in wiring side.
2 harness (contact with 24 3. Turn starting switch to ON position.
V circuit)
Between M07 (female) (2) and (1) Max. 1 V
Voltage
Between M08 (female) (2) and (1) Max. 1 V

HB365LC-3 40-1253
E-45 HORN DOES NOT STOP SOUNDING 40 TROUBLESHOOTING

Circuit diagram related to horn

40-1254 HB365LC-3
 E-46 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES
40 TROUBLESHOOTING NOT LIGHT UP OR GO OFF

E-46 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT

LIGHT UP OR GO OFF (ALL-K-K710-410-10-B)

Failure Wiper monitor does not light up, or does not go out, while wiper switch is operated.
Related • Condition of wiper switch signal can be checked with monitoring function.
information (Code: 04504)

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- Machine monitor may be defective. (Because this is an internal defect, trouble-
1
tor shooting cannot be performed.)

HB365LC-3 40-1255
E-47 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER
DOES NOT OPERATE 40 TROUBLESHOOTING

E-47 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES

NOT OPERATE (ALL-K-K710-410-20-B)

Failure Windshield wiper does not operate while wiper switch is operated.
• State of window rear limit switch signal can be checked with monitoring function.
Related (Code: 02204)
information • Failures in wiper motor are expressed by failure codes [DY20KA], [DY20MA], [DY2DKB],
and [DY2EKB].

No. Cause Procedure, measuring location, criteria and remarks

1. Turn starting switch to OFF position.
2. Disconnect connector W03.
Defective rear limit switch
1 for window (internal short Front window: Front
Min. 1 MΩ
circuit) Between W03 (male) (1) equipment
Resistance
and (2) Front window: Rear rest-
Max. 1 Ω
ing
1. Turn starting switch to OFF position.
Defective wiper motor
2 2. Disconnect connector M05, and connect T-adapter to female side.
(Internal open circuit)
Continuity Between M05 (female) (1) and (3) Continuity
• Wiper motor system
See troubleshooting for failure codes [DY20KA], [DY20MA], [DY2DKB],
and [DY2EKB]
Open circuit in wiring har-
• Rear limit switch system
ness
3 1. Turn starting switch to OFF position.
(Wire breakage or defec-
tive contact of connector) 2. Disconnect connector CP01 and connect T-adapter to female side.
3. Rear resting of front window
Resistance Between CP01 (female) (76) and ground Max. 1 Ω
1. Turn starting switch to OFF position.
Ground fault in wiring
harness 2. Disconnect connector CP01 and connect T-adapter to female side.
4
(Contact with ground cir- 3. Front equipment of front window
cuit)
Resistance Between CP01 (female) (76) and ground Min. 1 MΩ
If no failure is found by preceding checks, pump controller is defective. (In case of
5 Defective pump controller an internal defect, troubleshooting is impossible as an assembly. Replace whole
assembly).

40-1256 HB365LC-3
 E-47 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER
40 TROUBLESHOOTING DOES NOT OPERATE

Circuit diagram related to wiper

HB365LC-3 40-1257
E-48 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW
WASHER DOES NOT OPERATE 40 TROUBLESHOOTING

E-48 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASH-

ER DOES NOT OPERATE (ALL-K-K7A0-410-10-B)

Failure Window washer does not operate while window washer switch is operated.
• State of window washer switch signal can be checked with monitoring function.
Related infor- (Code: 04504)
mation
• Failure in window washer is expressed by failure codes [DY2CKB].

No. Cause Procedure, measuring location, criteria and remarks

Defective machine moni- Machine monitor may be defective. (Because this is an internal defect, trouble-
1
tor shooting cannot be performed.)

40-1258 HB365LC-3
 E-49 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH
40 TROUBLESHOOTING MONITORING FUNCTION

E-49 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH

MONITORING FUNCTION (ALL-K-L6WF-410-10-B)

Failure "Boom RAISE" is not displayed correctly with monitoring function.

Related
• Monitoring code: 01900
information

No. Cause Procedure, measuring location, criteria and remarks

Defective boom raise Perform troubleshooting for failure code [DHS8MA].
PPC oil pressure sensor
1 system
(Internal open or short
circuit)

HB365LC-3 40-1259
E-50 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY
WITH MONITORING FUNCTION 40 TROUBLESHOOTING

E-50 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH

MONITORING FUNCTION (ALL-K-L6WL-410-10-B)

Failure "Boom LOWER" is not displayed correctly with monitoring function.

Related
• Monitoring code: 01900
information

No. Cause Procedure, measuring location, criteria and remarks

Defective boom LOWER Perform troubleshooting for failure code [DHS9MA].
PPC oil pressure sensor
1 system
(Internal open or short
circuit)

40-1260 HB365LC-3
 E-51 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH
40 TROUBLESHOOTING MONITORING FUNCTION

E-51 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONI-

TORING FUNCTION (ALL-K-L9UE-410-10-B)

Failure "Arm OUT" is not displayed correctly with monitoring function.

Related
• Monitoring code: 01900
information

No. Cause Procedure, measuring location, criteria and remarks

Defective arm OUT PPC Perform troubleshooting for failure code [DHSCMA].
oil pressure sensor sys-
1
tem (internal open or
short circuit)

HB365LC-3 40-1261
E-52 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MON-
ITORING FUNCTION 40 TROUBLESHOOTING

E-52 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITOR-

ING FUNCTION (ALL-K-L9U8-410-10-B)

Failure "Arm IN" is not displayed correctly with monitoring function.

Related
• Monitoring code: 01900
information

No. Cause Procedure, measuring location, criteria and remarks

Defective arm IN PPC oil Perform troubleshooting for failure code [DHS3MA].
pressure sensor system
1
(internal open or short
circuit)

40-1262 HB365LC-3
 E-53 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY
40 TROUBLESHOOTING WITH MONITORING FUNCTION

E-53 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH

MONITORING FUNCTION (ALL-K-LEN6-410-10-B)

Failure "Bucket DUMP" is not displayed correctly with monitoring function.

Related
• Monitoring code: 01901
information

No. Cause Procedure, measuring location, criteria and remarks

Defective Bucket DUMP Perform troubleshooting for failure code [DHSDMA].
1 PPC pressure sensor
system

HB365LC-3 40-1263
E-54 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY
WITH MONITORING FUNCTION 40 TROUBLESHOOTING

E-54 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH

MONITORING FUNCTION (ALL-K-LEN5-410-10-B)

Failure "Bucket CURL" is not displayed correctly with monitoring function.

Related
• Monitoring code: 01901
information

No. Cause Procedure, measuring location, criteria and remarks

Defective bucket CURL Perform troubleshooting for failure code [DHS4MA].
1 PPC oil pressure sensor
system

40-1264 HB365LC-3
 E-55 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MON-
40 TROUBLESHOOTING ITORING FUNCTION

E-55 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITOR-

ING FUNCTION (ALL-K-JA0A-410-00-B)

Failure "Swing" is not displayed correctly with monitoring function.

Related
• Monitoring code: 01901
information

No. Cause Procedure, measuring location, criteria and remarks

Defective swing PPC oil Perform troubleshooting for failure codes [DHSAMA] and [DHSBMA].
pressure sensor system
1
(Internal open or short
circuit)

HB365LC-3 40-1265
E-56 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH
MONITORING FUNCTION 40 TROUBLESHOOTING

E-56 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITOR-

ING FUNCTION (ALL-K-C6T8-410-00-B)

Failure "Travel" is not displayed correctly with monitoring function.

Related
• Monitoring code: 01901
information

No. Cause Procedure, measuring location, criteria and remarks

Defective travel PPC oil Perform troubleshooting for failure codes [DHSFMA], [DHSGMA], [DHSHMA], and
pressure sensor system [DHSJMA].
1
(Internal open or short
circuit)

40-1266 HB365LC-3
 E-57 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH
40 TROUBLESHOOTING MONITORING FUNCTION

E-57 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONI-

TORING FUNCTION (ALL-K-PT0K-410-00-B)

Failure Service is not displayed correctly with monitoring function.

• Monitoring code: 01901
Related • For safety, use “short socket adapter”: 799-601-7230 for 2-pin X connector in tests for
information causes 1 and 2.
k While the engine is running, do not check oil pressure switch connector.

No. Cause Procedure, measuring location, criteria and remarks

If monitoring function does not indicate that attachment control pedal is operated
when engine is started and attachment control pedal is depressed at front end:
1. Turn starting switch to OFF position.
2. Disconnect connector P14 and connect “short socket adapter” to female
side.
3. Turn starting switch to ON position.
4. If monitoring function indicates that “Service” is “ON”, PPC oil pressure
Defective pre-service
1 PPC oil pressure switch switch (P14) for front end of attachment control pedal is defective.
(P14) If monitoring function indicates that attachment control pedal is operated when
starting switch is turned to ON position:
1. Turn starting switch to OFF position.
2. Disconnect connector P14.
3. Turn starting switch to ON position.
4. If monitoring function indicates that “Service” is “OFF”, PPC oil pressure