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Komatsu PC360LC-10 Hydraulic Excavator Shop Manual SEN05619-03 – PDF DOWNLOAD
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Komatsu PC360LC-10 Hydraulic Excavator Shop Manual
SERIAL NUMBERS : 85001 and up
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Description
Komatsu PC360LC-10 Hydraulic Excavator Shop Manual
FILE DETAILS:
Komatsu PC360LC-10 Hydraulic Excavator Shop Manual
Brands: Komatsu
Equipment Type: Hydraulic Excavator
Manuals Type: Shop Manual
Machine Model: PC360LC-10
Serial Number: 70001 and up
Book Code: SEN05619-03
Language: English
Pages: 1726
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu PC360LC-10 Hydraulic Excavator Shop Manual
How to read the shop manual:
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification:
This section explains the specifications of the machine.
10. Structure, function and maintenance standard:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu PC360LC-10 Hydraulic Excavator Shop Manual
COVER ............................................................................................................. 1 00 Index and foreword.............................................................................................. 0 Index.......................................................................................................... 2 Composition of shop manual................................................................................. 3 Table of contents.......................................................................................... 5 Foreword and general information............................................................................... 16 Safety notice.............................................................................................. 17 How to read the shop manual................................................................................ 22 Explanation of terms for maintenance standard.............................................................. 24 Handling of electric equipment and hydraulic component..................................................... 26 Handling of connectors newly used for engines.............................................................. 35 How to read electric wire code............................................................................. 38 Precautions when carrying out operation.................................................................... 41 Method of disassembling and connecting push-pull type coupler.............................................. 44 Standard tightening torque table........................................................................... 47 Conversion table........................................................................................... 51 01 Specification................................................................................................... 0 Specification and technical data............................................................................... 58 Specification dimension drawings........................................................................... 59 Specifications............................................................................................. 60 Weight table............................................................................................... 66 Table of fuel, coolant and lubricants...................................................................... 69 10 Structure, function and maintenance standard.................................................................... 0 Engine and cooling system...................................................................................... 72 Radiator, oil cooler....................................................................................... 73 Engine mount............................................................................................... 80 Cooling fan pump........................................................................................... 81 Cooling fan motor.......................................................................................... 89 Power train, Part 1............................................................................................ 96 Power train skeleton....................................................................................... 97 Overall drawing of power train unit........................................................................ 99 Power train hydraulic piping drawing....................................................................... 101 Damper, universal joint.................................................................................... 103 Torque converter, PTO...................................................................................... 105 Transmission............................................................................................... 113 Transmission ECMV.......................................................................................... 129 Main relief valve and torque converter relief valve........................................................ 135 Lubricating oil relief valve............................................................................... 137 Scavenging pump............................................................................................ 139 Power train and steering lubrication pump.................................................................. 141 Power train, Part 2............................................................................................ 144 Work equipment pump........................................................................................ 145 Work equipment cooler bypass valve......................................................................... 158 Steering, brake control.................................................................................... 159 Steering unit.............................................................................................. 161 Steering control valve..................................................................................... 175 Steering clutch ECMV, steering brake ECMV.................................................................. 177 Parking brake solenoid valve............................................................................... 183 Sudden stop prevention valve............................................................................... 185 Final drive................................................................................................ 188 Sprocket................................................................................................... 193 Undercarriage and frame........................................................................................ 196 Track frame................................................................................................ 197 Recoil spring.............................................................................................. 199 Idler...................................................................................................... 201 Track roller............................................................................................... 203 Carrier roller............................................................................................. 205 Track shoe................................................................................................. 207 Main frame................................................................................................. 213 Suspension................................................................................................. 215 Hydraulic system............................................................................................... 218 Work equipment hydraulic piping diagram.................................................................... 219 Work equipment control piping diagram...................................................................... 223 Work equipment control..................................................................................... 225 Hydraulic tank and filter.................................................................................. 227 Accumulator................................................................................................ 229 PPC valve.................................................................................................. 230 Work equipment lock valve.................................................................................. 243 Control valve.............................................................................................. 245 Work equipment cylinder.................................................................................... 267 Piston valve............................................................................................... 269 Quick drop valve........................................................................................... 271 Self pressure reducing valve............................................................................... 272 Work equipment................................................................................................. 280 Cylinder stay.............................................................................................. 281 Blade...................................................................................................... 283 Cutting edge, end bit...................................................................................... 285 Ripper..................................................................................................... 287 Cab and its attachments........................................................................................ 292 Cab mount + ROPS pin....................................................................................... 293 ROPS cab................................................................................................... 294 ROPS floor................................................................................................. 295 Air conditioner............................................................................................ 296 Electrical system.............................................................................................. 298 Engine control............................................................................................. 299 Engine control system...................................................................................... 300 Deceleration potentiometer................................................................................. 301 Monitor system............................................................................................. 303 Sensors.................................................................................................... 322 Palm command control system................................................................................ 325 KOMTRAX system............................................................................................. 328 20 Standard value table............................................................................................ 0 Standard service value table................................................................................... 332 Standard value table for engine............................................................................ 333 Standard value table for machine........................................................................... 334 30 Testing and adjusting........................................................................................... 0 Testing and adjusting, Part 1.................................................................................. 344 Tools for testing, adjusting, and troubleshooting.......................................................... 346 Sketches of special tools.................................................................................. 350 Measuring engine speed..................................................................................... 351 Measuring intake air pressure (boost pressure)............................................................. 353 Measuring exhaust temperature.............................................................................. 355 Measuring exhaust gas color................................................................................ 357 Adjusting valve clearance.................................................................................. 358 Measuring compression pressure............................................................................. 359 Measuring blow-by pressure................................................................................. 361 Measuring engine oil pressure.............................................................................. 362 Handling fuel system parts................................................................................. 363 Releasing residual pressure from fuel system............................................................... 363 Measuring fuel pressure.................................................................................... 364 Measuring fuel return rate and fuel leakage................................................................ 365 Bleeding air from fuel circuit............................................................................. 369 Measuring fuel circuit for leakage......................................................................... 371 Testing and adjusting alternator belt tension.............................................................. 372 Testing and adjusting air conditioner compressor belt tension.............................................. 373 Measuring fan speed........................................................................................ 374 Measuring fan circuit oil pressure......................................................................... 376 Bleeding air from fan pump................................................................................. 377 Bleeding air from work equipment pump...................................................................... 378 Adjusting fuel control dial and decelerator pedal.......................................................... 379 Testing and adjusting, Part 2.................................................................................. 382 Measuring power train oil pressure......................................................................... 384 Adjusting transmission output shaft speed sensor........................................................... 392 Simple test procedure for brake performance................................................................ 393 Adjusting brake pedal...................................................................................... 394 Adjusting parking brake lever.............................................................................. 396 Emergency escape method when power train has trouble....................................................... 398 Adjusting idler clearance.................................................................................. 401 Testing and adjusting track shoe tension................................................................... 403 Measuring and adjusting work equipment oil pressure........................................................ 404 Measuring control circuit basic pressure................................................................... 407 Measuring work equipment lock solenoid valve output pressure (PPC valve basic pressure).................... 408 Measuring PPC valve output pressure........................................................................ 409 Adjusting work equipment PPC valve play.................................................................... 411 Measuring ripper pin puller solenoid valve output pressure................................................. 413 Testing parts which cause hydraulic drift of blade and ripper.............................................. 414 Measuring internal leakage of work equipment cylinder...................................................... 415 Releasing residual pressure from work equipment cylinder................................................... 416 Bleeding air from work equipment cylinder.................................................................. 416 Adjusting work equipment lock lever........................................................................ 417 Adjusting blade............................................................................................ 418 Adjusting operator’s cab................................................................................... 420 Testing and adjusting, Part 3.................................................................................. 426 Special functions of machine monitor (EMMS)................................................................ 427 Testing and adjusting, Part 4.................................................................................. 488 Handling of power supply circuit of engine controller...................................................... 489 Preparation work for troubleshooting of electrical system.................................................. 490 Pm Clinic.................................................................................................. 492 40 Troubleshooting................................................................................................. 0 Failure code table and fuse locations.......................................................................... 504 Failure codes table........................................................................................ 505 Fuse locations............................................................................................. 511 General information on troubleshooting......................................................................... 516 Points to remember when troubleshooting.................................................................... 517 Sequence of events in troubleshooting...................................................................... 518 Check before troubleshooting............................................................................... 519 Classification and procedures for troubleshooting.......................................................... 520 Information in troubleshooting table....................................................................... 523 CConnection table for connector pin numbers................................................................ 525 T- branch box and T- branch adapter table.................................................................. 561 Troubleshooting by failure and error codes, Part 1............................................................. 566 Failure code [1500L0] Transmission clutch: Abnormal........................................................ 568 Failure code [15SAL1] Forward clutch: Fill high............................................................ 569 Failure code [15SALH] Forward clutch: Fill low............................................................. 570 Failure code [15SBL1] Reverse clutch: Fill high............................................................ 571 Failure code [15SBLH] Reverse clutch: Fill low............................................................. 572 Failure code [15SEL1] Speed 1st clutch: Fill high.......................................................... 573 Failure code [15SELH] Speed 1st clutch: Fill low........................................................... 574 Failure code [15SFL1] Speed 2nd clutch: Fill high.......................................................... 575 Failure code [15SFLH] Speed 2nd clutch: Fill low........................................................... 576 Failure code [15SGL1] Speed 3rd clutch: Fill high.......................................................... 577 Failure code [15SGLH] Speed 3rd clutch: Fill low........................................................... 578 Failure code [2201L1] When right steering clutch oil pressure command current is OFF, fill signal is ON.... 579 Failure code [2201LH] When right steering clutch oil pressure command current is ON, fill signal is OFF.... 581 Failure code [2202L1] When left steering clutch oil pressure command current is OFF, fill signal is ON..... 583 Failure code [2202LH] When left steering clutch oil pressure command current is ON, fill signal is OFF..... 585 Failure code [2300KM] Stall in 1st gear speed.............................................................. 587 Failure code [2301L1] Right brake: Fill high............................................................... 588 Failure code [2301LH] Right brake: Fill low................................................................ 589 Failure code [2302L1] Left brake: Fill high................................................................ 590 Failure code [2302LH] Left brake: Fill low................................................................. 591 Failure code [7RFAKA] ECM HOLD RELAY: Disconnection........................................................ 593 Failure code [AA10NX] Air Cleaner Clogging................................................................. 595 Failure code [AB00MA] Battery Charge Abnormal.............................................................. 597 Failure code [B@BAZG] Eng Oil Press Low.................................................................... 599 Failure code [B@BCNS] Eng Water Overheat................................................................... 599 Failure code [B@BCZK] Eng Water Level Low.................................................................. 600 Failure code [B@CENS] T/C Oil Overheat..................................................................... 600 Failure code [B@HANS] Hyd Oil Overheat..................................................................... 601 Failure code [CA111] EMC Critical Internal Failure......................................................... 603 Failure code [CA115] Eng Ne and Bkup Speed Sens Error...................................................... 605 Failure code [CA122] Chg (boost) Air Press Sensor High Error............................................... 607 Failure code [CA123] Chg (boost) Air Press Sensor Low Error................................................ 609 Failure code [CA131] Throttle Sensor High Error............................................................ 611 Failure code [CA132] Throttle Sensor Low Error............................................................. 613 Failure code [CA135] Eng Oil Press Sensor High Error....................................................... 615 Failure code [CA141] Eng Oil Press Sensor Low Error........................................................ 617 Failure code [CA144] Coolant Temp Sens High Error.......................................................... 619 Failure code [CA145] Coolant Temp Sens Low Error........................................................... 621 Failure code [CA153] Chg (boost) Air Temp Sensor High Error................................................ 623 Failure code [CA154] Chg (boost) Air Temp Sensor Low Error................................................. 625 Failure code [CA187] Sens Supply 2 Volt Low Error.......................................................... 625 Failure code [CA221] Ambient Press Sens High Error......................................................... 627 Failure code [CA222] Ambient Press Sens Low Error.......................................................... 629 Failure code [CA227] Sens Supply 2 Volt High Error......................................................... 631 Troubleshooting by failure and error codes, Part 2............................................................. 634 Failure code [CA234] Eng Overspeed......................................................................... 636 Failure code [CA238] Ne Speed Sens Supply Volt Error....................................................... 637 Failure code [CA263] Fuel Temp Sensor High Error........................................................... 639 Failure code [CA265] Fuel Temp Sensor Low Error............................................................ 641 Failure code [CA271] PCV1 Short Error...................................................................... 642 Failure code [CA272] PCV1 Open Error....................................................................... 643 Failure code [CA273] PCV2 Short Error...................................................................... 644 Failure code [CA274] PCV2 Open Error....................................................................... 645 Failure code [CA322] Inj #1 Open/Short Error............................................................... 647 Failure code [CA323] Inj #5 Open/Short Error............................................................... 649 Failure code [CA324] Inj #3 Open/Short Error............................................................... 651 Failure code [CA325] Inj #6 Open/Short Error............................................................... 653 Failure code [CA331] Inj #2 Open/Short Error............................................................... 655 Failure code [CA332] Inj #4 Open/Short Error............................................................... 657 Failure code [CA342] Calibration Code Incompatibility...................................................... 659 Failure code [CA351] Injectors Drive Circuit Error......................................................... 661 Failure code [CA352] Sense Supply 1 Volt Low Error......................................................... 663 Failure code [CA386] Sense Supply 1 Volt High Error........................................................ 665 Failure code [CA441] Battery Voltage Low Error............................................................. 667 Failure code [CA442] Battery Voltage High Error............................................................ 667 Failure code [CA449] Rail Press Very High Error............................................................ 668 Failure code [CA451] Rail Press Sensor High Error.......................................................... 669 Failure code [CA452] Rail Press Sensor Low Error........................................................... 671 Failure code [CA553] Rail Press High Error................................................................. 671 Failure code [CA554] Rail Press Sensor In Range Error...................................................... 672 Failure code [CA559] Rail Press Low Error.................................................................. 673 Failure code [CA689] Eng Ne Speed Sensor Error............................................................. 677 Failure code [CA731] Eng Bkup Speed Sens Phase Error....................................................... 679 Failure code [CA757] All Continuous Data Lost Error........................................................ 679 Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 681 Failure code [CA1633] KOMNET Datalink Timeout Error........................................................ 683 Failure code [CA2185] Throt Sens Sup Volt High Error....................................................... 685 Failure code [CA2186] Throt Sens Sup Volt Low Error........................................................ 687 Failure code [CA2249] Rail Press Very Low Error............................................................ 687 Failure code [CA2555] Grid Htr Relay Volt Low Error........................................................ 688 Failure code [CA2556] Grid Htr Relay Volt High Error....................................................... 689 Failure code [D110KA] Battery relay: Disconnection......................................................... 691 Failure code [D110KB] Battery Relay: Drive Short Circuit................................................... 693 Failure code [D130KA] Neutral relay: Disconnection......................................................... 695 Failure code [D130KB] Neutral relay: Short circuit......................................................... 697 Failure code [D161KA] Back-up alarm relay: Disconnection................................................... 699 Failure code [D161KB] Back-up alarm relay: Short circuit................................................... 701 Failure code [D190KA] ACC signal relay: Disconnection...................................................... 703 Failure code [D190KB] ACC signal relay: Short circuit...................................................... 705 Troubleshooting by failure and error codes, Part 3............................................................. 708 Failure code [D5ZKKX] Throttle Dial: Out of normal range................................................... 711 Failure code [DAFRKR] CAN Disconnection (Monitor).......................................................... 713 Failure code [DB2RKR] CAN Disconnection (Engine controller)................................................ 715 Failure code [DB90KR] PT controller: Can communication lost................................................ 717 Failure code [DBE0KK] PT controller: Source voltage reduction.............................................. 719 Failure code [DBE0KT] PT controller: Abnormality in controller............................................. 721 Failure code [DBE6KK] PT controller: Source voltage reduction.............................................. 723 Failure code [DBE7KK] PT controller: Source voltage reduction.............................................. 725 Failure code [DBE9KQ] PT controller: Type select signal.................................................... 727 Failure code [DD12KA] Shift up Sw: Disconnection........................................................... 729 Failure code [DD12KB] Shift up Sw: Short circuit........................................................... 731 Failure code [DD13KA] Shift down Sw: Disconnection......................................................... 733 Failure code [DD13KB] Shift down Sw: Short circuit......................................................... 735 Failure code [DD14KA] Parking lever Sw: Disconnection...................................................... 737 Failure code [DD14KB] Parking lever Sw: Short circuit...................................................... 739 Failure code [DDDDKA] Back up brake Sw: Disconnection...................................................... 741 Failure code [DDDDKB] Back up brake Sw: Short circuit...................................................... 743 Failure code [DDDDKX] Back up brake Sw: Signal mismatch.................................................... 745 Failure code [DGT1KA] T/C oil temp sensor: Abnormal........................................................ 747 Failure code [DGT1KX] T/C oil temp sensor: Abnormal........................................................ 749 Failure code [DH21KA] Weq pressure sensor: Disconnection................................................... 751 Failure code [DH21KB] Weq pressure sensor: Short circuit................................................... 753 Failure code [DK10KX] Fuel control Dial: Out of normal range............................................... 755 Failure code [DK30KA] ST lever 1: Disconnection............................................................ 757 Failure code [DK30KB] ST lever 1: Short circuit............................................................ 759 Failure code [DK30KX] ST lever 1: Out of normal range...................................................... 761 Failure code [DK30KZ] RL lever: Disconnection or short circuit............................................. 761 Failure code [DK30L8] ST lever: Signal mismatch............................................................ 762 Failure code [DK31KA] ST lever 2: Disconnection............................................................ 763 Failure code [DK31KB] ST lever 2: Short circuit............................................................ 765 Failure code [DK40KA] Brake potentiometer: Disconnection................................................... 767 Failure code [DK40KB] Brake potentiometer: Short circuit................................................... 769 Failure code [DK55KX] FR lever: Out of normal range........................................................ 771 Failure code [DK55KZ] FR lever: Disconnection or short circuit............................................. 771 Failure code [DK55L8] FR lever: Signal mismatch............................................................ 772 Failure code [DK56KA] FR lever 1: Disconnection............................................................ 773 Failure code [DK56KB] FR lever 1: Short circuit............................................................ 775 Troubleshooting by failure and error codes, Part 4............................................................. 778 Failure code [DK57KA] FR lever 2: Disconnection............................................................ 781 Failure code [DK57KB] FR lever 2: Short circuit............................................................ 783 Failure code [DKH1KA] Pitch angle sensor: Disconnection.................................................... 785 Failure code [DKH1KB] Pitch angle sensor: Short circuit.................................................... 787 Failure code [DLT3KA] T/M out-speed sensor: Disconnection.................................................. 789 Failure code [DLT3KB] T/M out-speed sensor: Abnormal....................................................... 790 Failure code [DW7BKA] Fan rev EPC: Disconnection........................................................... 791 Failure code [DW7BKB] Fan rev EPC: Short circuit........................................................... 792 Failure code [DWN3KA] Ssp solenoid: Disconnection.......................................................... 793 Failure code [DWN3KB] Ssp solenoid: Short circuit.......................................................... 795 Failure code [DWN3KY] Ssp solenoid: Short circuit.......................................................... 797 Failure code [DWN5KA] Fan pump solenoid: Disconnection..................................................... 799 Failure code [DWN5KB] Fan pump solenoid: Short circuit..................................................... 800 Failure code [DXH4KA] 1st clutch ECMV: Disconnection....................................................... 801 Failure code [DXH4KB] 1st clutch ECMV: Short circuit....................................................... 802 Failure code [DXH4KY] 1st clutch ECMV: Short circuit....................................................... 803 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection....................................................... 804 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit....................................................... 805 Failure code [DXH5KY] 2nd clutch ECMV: Short circuit....................................................... 806 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection....................................................... 807 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit....................................................... 808 Failure code [DXH6KY] 3rd clutch ECMV: Short circuit....................................................... 809 Failure code [DXH7KA] R clutch ECMV: Disconnection......................................................... 810 Failure code [DXH7KB] R clutch ECMV: Short circuit......................................................... 811 Failure code [DXH7KY] R clutch ECMV: Short circuit......................................................... 812 Failure code [DXH8KA] F clutch ECMV: Disconnection......................................................... 813 Failure code [DXH8KB] F clutch ECMV: Short circuit......................................................... 814 Failure code [DXH8KY] F clutch ECMV: Short circuit......................................................... 815 Failure code [DXH9KA] Right steering clutch ECMV disconnection............................................. 817 Failure code [DXH9KB] Right steering clutch ECMV short circuit............................................. 819 Failure code [DXH9KY] Right steering clutch ECMV hot short................................................. 821 Failure code [DXHAKA] Left steering clutch ECMV disconnection.............................................. 823 Failure code [DXHAKB] Left steering clutch ECMV short circuit.............................................. 825 Failure code [DXHAKY] Left steering clutch ECMV hot short.................................................. 827 Failure code [DXHBKA] Right brake ECMV: Disconnection...................................................... 829 Failure code [DXHBKB] Right brake ECMV: Short circuit...................................................... 831 Failure code [DXHBKY] Right brake ECMV: Short circuit...................................................... 833 Failure code [DXHCKA] Left brake ECMV: Disconnection....................................................... 835 Failure code [DXHCKB] Left brake ECMV: Short circuit....................................................... 837 Failure code [DXHCKY] Left brake ECMV: Short circuit....................................................... 839 Failure code [DXJ4KA] Weq lock Sol.: Disconnection......................................................... 841 Failure code [DXJ4KB] Weq lock Sol.: Short circuit......................................................... 842 Troubleshooting of electrical system (E-mode).................................................................. 844 Before carrying out troubleshooting for electrical system.................................................. 846 Information in troubleshooting table....................................................................... 850 E-1 When starting switch turned ON, machine monitor displays nothing....................................... 851 E-2 When starting switch turned ON (before starting engine), basic check item lights up.................... 853 E-3 Engine does not start (Engine does not turn)........................................................... 855 E-4 Preheater does not operate............................................................................. 858 E-5 Precaution item lights up while engine is running...................................................... 861 E-6 Emergency stop item lights up while engine is running.................................................. 863 E-7 Engine coolant temperature gauge does not indicate normally............................................ 865 E-8 Fuel level gauge does not indicate normally............................................................ 866 E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally............................. 868 E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally.................................. 869 E-11 Contents of display by machine monitor are different from applicable machine.......................... 871 E-12 Machine monitor does not display some items........................................................... 871 E-13 Function switch does not work......................................................................... 871 E-14 Operation mode does not change........................................................................ 872 E-15 Gearshift mode does not change........................................................................ 872 E-16 Customize function does not operate normally.......................................................... 873 E-17 Customize memory function does not normally........................................................... 873 E-18 Alarm buzzer cannot be stopped........................................................................ 874 E-19 Air conditioner does not operate normally (including air conditioner fault history)................... 875 E-20 When starting switch is turned OFF, service meter is not displayed.................................... 889 E-21 Machine monitor cannot be set in service mode......................................................... 889 E-22 Ripper pin puller cylinder does not operate........................................................... 891 E-23 Backup alarm does not sound or does not stop.......................................................... 893 E-24 Headlamp, rear lamp, and ripper point lamp do not light up............................................ 895 E-25 Windshield wiper and window washer do not operate..................................................... 900 E-26 KOMTRAX terminal does not operate normally............................................................ 916 E-27 Fan does not reverse.................................................................................. 917 E-28 Gear cannot be shifted................................................................................ 919 E-29 Electric priming pump does not operate or does not stop automatically................................. 921 Troubleshooting of hydraulic and mechanical system (H-mode).................................................... 924 Information in troubleshooting table....................................................................... 926 H-1 Power is low (Drawbar pull is low)..................................................................... 927 H-2 Machine does not travel (at 2nd or 3rd gear speed)..................................................... 928 H-3 Machine does not start at any gear speed............................................................... 929 H-4 Machine can travel only forward or in reverse.......................................................... 930 H-5 When gear speed or travel direction is changed, time lag is large...................................... 931 H-6 Steering is not possible............................................................................... 932 H-7 Steering is possible only on one side.................................................................. 933 H-8 Steering overrun occurs................................................................................ 934 H-9 Brake does not work.................................................................................... 935 H-10 Power train oil is overheated......................................................................... 936 H-11 Speed of all work equipment is low.................................................................... 937 H-12 No work equipment moves............................................................................... 938 H-13 Blade lift speed or power is low...................................................................... 939 H-14 Blade tilt speed or power is low...................................................................... 940 H-15 Ripper lift speed or power is low..................................................................... 941 H-16 Ripper tilt speed or power is low..................................................................... 942 H-17 Hydraulic drift of blade lift is large................................................................ 942 H-18 Hydraulic drift of blade tilt is large................................................................ 943 H-19 Hydraulic drift of ripper lift is large............................................................... 943 H-20 Ripper pin puller cylinder does not operate........................................................... 944 H-21 Abnormal sound comes out from around work equipment pump.............................................. 945 H-22 Fan speed is abnormal (Sound and/or vibration are abnormally large or engine over heats).............. 946 Troubleshooting of engine (S-mode)............................................................................. 948 Method of using troubleshooting chart...................................................................... 950 S-1 Starting performance of engine is poor................................................................ 953 S-2 Engine does not start................................................................................. 954 S-3 Engine does not pick up smoothly...................................................................... 957 S-4 Engine stops during operation......................................................................... 958 S-5 Engine does not rotate smoothly....................................................................... 959 S-6 Engine lack output (or lacks power)................................................................... 960 S-7 Exhaust gas is black (incomplete combustion).......................................................... 961 S-8 Oil consumption is excessive (or exhaust gas is blue)................................................. 962 S-9 Oil becomes dirty quickly............................................................................. 963 S-10 Fuel consumption is excessive........................................................................ 964 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)................................ 965 S-12 Oil pressure drops................................................................................... 966 S-13 Oil level rises (Entry of coolant or fuel)........................................................... 967 S-14 Coolant temperature becomes too high (Overheating)................................................... 968 S-15 Abnormal noise is made............................................................................... 969 S-16 Vibration is excessive............................................................................... 970 S-17 Air cannot be bled from fuel circuit................................................................. 971 50 Disassembly and assembly........................................................................................ 0 General information on disassembly and assembly................................................................ 974 How to read this manual.................................................................................... 975 Coating materials list..................................................................................... 977 Special tool list.......................................................................................... 980 Sketches of special tools.................................................................................. 986 Engine and cooling system...................................................................................... 996 Removal and installation of fuel supply pump assembly...................................................... 997 Removal and installation of fuel injector assembly.........................................................1002 Removal and installation of cylinder head assembly.........................................................1008 Removal and installation of radiator assembly..............................................................1019 Removal and installation of aftercooler assembly...........................................................1022 Removal and installation of engine assembly................................................................1025 Removal and installation of engine hood assembly...........................................................1030 Removal and installation of engine front seal..............................................................1032 Removal and installation of engine rear seal...............................................................1036 Removal and installation of fuel tank assembly.............................................................1041 Removal and installation of fan drive assembly.............................................................1043 Removal and installation of fan motor assembly.............................................................1044 Power train, Part 1............................................................................................1046 Removal and installation of damper assembly................................................................1047 Disassembly and assembly of damper assembly................................................................1050 Removal and installation of power train unit assembly......................................................1056 Disconnection and connection of power train unit assembly..................................................1061 Power train, Part 2............................................................................................1068 Disassembly and assembly of PTO assembly...................................................................1069 Disassembly and assembly of torque converter assembly......................................................1076 Disassembly and assembly of transmission assembly..........................................................1081 Disassembly and assembly of steering case assembly.........................................................1098 Power train, Part 3............................................................................................1114 Removal and installation of final drive assembly...........................................................1115 Disassembly and assembly of final drive assembly...........................................................1117 Undercarriage and frame........................................................................................1132 Removal and installation of track frame assembly...........................................................1134 Removal and installation of idler assembly.................................................................1137 Disassembly and assembly of idler assembly.................................................................1138 Removal and installation of recoil spring assembly.........................................................1142 Disassembly and assembly of recoil spring assembly.........................................................1143 Removal and installation of track roller assembly..........................................................1148 Disassembly and assembly of track roller assembly..........................................................1149 Removal and installation of carrier roller assembly........................................................1151 Disassembly and assembly of carrier roller assembly........................................................1152 Removal and installation of pivot shaft assembly...........................................................1156 Spreading and installation of track shoe assembly..........................................................1158 General disassembly and assembly of track shoe.............................................................1161 Disassembly and assembly of 1 link in field................................................................1175 Disassembly and assembly of master link....................................................................1179 Removal and installation of equalizer bar assembly.........................................................1182 Disassembly and assembly of equalizer bar assembly.........................................................1184 Removal and installation of segment teeth..................................................................1186 Hydraulic system...............................................................................................1188 Removal and installation of hydraulic tank assembly........................................................1189 Removal and installation of hydraulic pump assembly........................................................1191 Disassembly and assembly of hydraulic cylinder assembly....................................................1194 Work equipment.................................................................................................1204 Removal and installation of blade assembly.................................................................1205 Disassembly and assembly of multi-shank ripper.............................................................1207 Cab and its attachments........................................................................................1212 Removal and installation of operator’s cab assembly........................................................1213 Removal and installation of operator’s cab glass (Stuck glass).............................................1215 Removal and installation of operator’s cab and floor frame assembly........................................1224 Electrical system..............................................................................................1230 Removal and installation of air conditioner unit assembly..................................................1231 Removal and installation of engine controller assembly.....................................................1233 Removal and installation of power train controller assembly................................................1234 Removal and installation of KOMTRAX assembly...............................................................1234 60 Air conditioner................................................................................................. 0 Structure, function, testing, adjusting, and troubleshooting...................................................1236 Structure and function.....................................................................................1238 Air conditioner component..............................................................................1238 Configuration and function of refrigerating cycle......................................................1239 Outline of refrigerating cycle.........................................................................1240 Air conditioner unit...................................................................................1242 Functions of major components in the air conditioner unit..............................................1244 Control plate..........................................................................................1246 Compressor.............................................................................................1248 Condenser..............................................................................................1249 Receiver drier.........................................................................................1250 Testing, adjusting and troubleshooting.....................................................................1252 Caution about refrigerant..............................................................................1252 Troubleshooting procedure..............................................................................1253 Block diagram..........................................................................................1254 Circuit diagram and arrangement of connector pins......................................................1255 Detail of air conditioner unit.........................................................................1257 Part and connector locations...........................................................................1259 Testing air leakage (duct).............................................................................1266 Testing with self-diagnosis function...................................................................1268 Testing temperature control............................................................................1271 Testing vent (mode) changeover.........................................................................1274 Testing Recirc/Fresh changeover........................................................................1277 Testing inner sensor...................................................................................1279 Testing evaporator temperature sensor..................................................................1280 Testing sunlight sensor................................................................................1283 Testing (dual) pressure switch for refrigerant.........................................................1284 Testing relays and diodes..............................................................................1286 Troubleshooting chart 1................................................................................1288 Troubleshooting chart 2................................................................................1289 Troubleshooting for electrical system (E mode).........................................................1292 E-1 Power supply system (Air conditioner does not operate).........................................1293 E-2 Compressor system (Air is not cooled)..........................................................1297 E-3 Blower motor system (No air comes out or air flow is abnormal).................................1300 E-4 Temperature cannot be controlled...............................................................1305 E-5 Vent (mode) cannot be changed over.............................................................1307 E-6 Recirc/Fresh air cannot be changed over........................................................1309 Troubleshooting with gauge pressure....................................................................1311 Connection of service tool.............................................................................1313 Precautions for connecting air conditioner piping......................................................1314 Handling of compressor oil.............................................................................1315 1. Control of compressor oil.......................................................................1315 2. Adding of compressor oil........................................................................1315 3. Compressor replacement..........................................................................1316 4. Applying compressor oil for O-ring..............................................................1316 90 Diagrams and drawings........................................................................................... 0 Hydraulic diagrams and drawings................................................................................1318 Power train hydraulic circuit diagram......................................................................1320 Hydraulic circuit diagram Serial No.: 85001 - 85024........................................................1321 Hydraulic circuit diagram Serial No.: 85025 and up.........................................................1322 Electrical diagrams and drawings...............................................................................1325 Electrical circuit diagram.................................................................................1327 Electrical circuit diagram for inside cab..................................................................1341 Connectors table and arrangement drawing .................................................................1342
KOMATSU PC360LC-10 HYDRAULIC EXCAVATOR SHOP MANUAL SEN05619-03 – PDF DOWNLOAD:
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