Komatsu PC360LC-10 PC360NLC-10 Excavator Shop Manual UEN05619-03 PDF  

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Komatsu PC360LC-10 PC360NLC-10 Hydraulic Excavator Shop Manual UEN05619-03 – PDF DOWNLOAD

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Komatsu PC360LC-10 PC360NLC-10 Hydraulic Excavator Shop Manual UEN05619-03 – PDF DOWNLOAD 

Language : English
Pages : 1691
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu PC360LC-10 PC360NLC-10 Hydraulic Excavator Shop Manual UEN05619-03 – PDF DOWNLOAD

00 Index and foreword 3
Index 4
Foreword, safety and general information 16
Important safety notice 16
How to read the shop manual 23
Explanation of terms for maintenance standard 25
Handling equipment of fuel system devices 27
Handling of intake system parts 28
Handling of hydraulic equipment 29
Method of disconnecting and connecting of push-pull type coupler 31
Handling of electrical equipment 34
How to read electric wire code 42
Precautions when performing operation 45
Practical use of KOMTRAX 49
Standard tightening torque table 50
List of abbreviation 54
Conversion table 59
01 Specifications 65
Table of contents 66
Specifications 67
Specification drawings 67
Working range drawings 68
Specifications 69
Weight table 72
Table of fuel, coolant and lubricants 73
10 Structure and function 75
Table of contents 76
Engine and cooling system 77
Engine related parts 77
Cooling system 79
Power train 81
Power train 81
Swing circle 82
Swing machinery 83
Final drive 85
Undercarriage and frame 87
Track frame and idler cushion 87
Hydraulic system 89
Hydraulic component layout 89
Valve control 91
Hydraulic tank 93
CLSS 95
Main pump 100
Control valve 124
Swing motor 179
Travel motor 190
PPC valve 205
Solenoid valve 226
Attachment circuit selector valve 230
Variable pressure compensation valve 233
Center swivel joint 235
Accumulator 237
Hydraulic drift prevention valve 238
ATT EPC valve assembly 243
Return oil filter 245
Quick coupler control valve 246
Work equipment 249
Work equipment shims 249
Bucket play adjustment shim 251
Cab and its attachments 252
Cab mount and cab tipping stopper 252
ROPS cab 253
Electrical system 254
Electrical control system 254
Machine monitor system 299
KOMTRAX system 318
Sensor 321
PPC levers 341
Auto grease system 343
20 Standard value table 357
Table of contents 358
Standard service value table 359
Standard value table for engine related parts 359
Standard value table for machine 361
30 Testing and adjusting 375
Table of contents 376
General information on testing and adjusting 377
Tools for testing and adjusting 377
Sketch of tools for testing and adjusting 382
Engine and cooling system 384
Checking engine speed 384
Measuring boost pressure 385
Measuring exhaust gas color 388
Measuring and adjusting valve clearance 390
Measuring compression pressure 394
Measuring blowby pressure 402
Measuring engine oil pressure 404
Measuring EGR valve and KVGT oil pressure 406
Measuring fuel pressure 407
Measuring fuel delivery, return and leakage 413
Bleeding air from fuel system 419
Checking fuel circuit for leakage 420
Handling cylinder cutout mode operation 421
Handling no injection cranking operation 422
Checking and adjusting air conditioner compressor belt tension 423
Replacing fan belt 424
Replacing alternator belt 425
Power train 426
Testing swing circle bearing clearance 426
Undercarriage and frame 427
Testing and adjusting track shoe tension 427
Hydraulic system 428
Releasing remaining pressure from hydraulic circuit 428
Measuring and adjusting oil pressure in work equipment, swing and travel circuits 429
Measuring oil pressure in control circuit 435
Measuring and adjusting oil pressure in pump PC control circuit 438
Measuring and adjusting oil pressure in pump LS control circuit 448
Measuring solenoid valve output pressure 463
Measuring PPC valve output pressure 467
Adjusting play of work equipment and swing PPC valves 469
Measuring and adjusting quick coupler control valve output pressure 470
Testing pump swash plate sensor 471
Isolating the parts causing hydraulic drift in work equipment 472
Measuring oil leakage 473
Bleeding air from hydraulic circuit 475
Cab and its attachments 478
Checking cab tipping stopper 478
Adjusting mirrors 479
Electrical system 482
Special functions of machine monitor 482
Angle adjustment of rear view camera 551
Handling voltage circuit of engine controller 553
Handling battery disconnect switch 554
Testing diodes 555
Pm clinic 556
Pm clinic service 556
40 Troubleshooting 565
Table of contents 566
General information on troubleshooting 573
Troubleshooting points 573
Sequence of events in troubleshooting 575
Checks before troubleshooting 577
Inspection procedure before troubleshooting 579
Classification and procedure for troubleshooting 587
Symptom and troubleshooting numbers 590
Information in troubleshooting table 593
Troubleshooting method for open circuit in wiring harness of pressure sensor system 595
Connector list and layout 597
Connector contact identification 608
T-branch box and T-branch adapter table 644
Fuse location table 650
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement 652
Failure codes table 655
Troubleshooting by failure code (Display of code) 663
Failure code [989L00] Engine Controller Lock Caution 1 663
Failure code [989M00] Engine Controller Lock Caution 2 664
Failure code [989N00] Engine Controller Lock Caution 3 665
Failure code [A1U0N3]: KDPF Dry Request (HC Release) 666
Failure code [A1U0N4] KDPF Dry Request (HC Release) 668
Failure code [AA10NX] Air Cleaner Clogging 670
Failure code [AB00KE] Charge Voltage Low 672
Failure code [B@BAZG] Eng Oil Press Low 674
Failure code [B@BAZK] Eng Oil Level Low 675
Failure code [B@BCNS] Eng Water Overheat 676
Failure code [B@BCZK] Eng Water Level Low 677
Failure code [B@HANS] Hyd Oil Overheat 679
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 680
Failure code [CA122] Chg Air Press Sensor High Error 681
Failure code [CA123] Chg Air Press Sensor Low Error 683
Failure code [CA131] Throttle Sensor High Error 685
Failure code [CA132] Throttle Sensor Low Error 687
Failure code [CA144] Coolant Temp Sens High Error 689
Failure code [CA145] Coolant Temp Sens Low Error 691
Failure code [CA153] Chg Air Temp Sensor High Error 693
Failure code [CA154] Chg Air Temp Sensor Low Error 695
Failure code [CA187] Sens Supply 2 Volt Low Error 697
Failure code [CA221] Ambient Press Sens High Error 699
Failure code [CA222] Ambient Press Sens Low Error 701
Failure code [CA227] Sensor 2 Supply Volt High Error 703
Failure code [CA234] Eng Overspeed 704
Failure code [CA238] Ne Speed Sens Supply Volt Error 705
Failure code [CA239] Ne Speed Sens Supply Volt High Error 706
Failure code [CA271] IMV/PCV1 Short Error 708
Failure code [CA272] IMV/PCV1 Open Error 710
Failure code [CA281] Pump Press Balance Error 711
Failure code [CA295] Ambient Pressure Sensor In Range Error 712
Failure code [CA322] Inj #1(L#1) Open/Short Error 713
Failure code [CA323] Inj #5 (L#5) Open/Short Error 715
Failure code [CA324] Inj #3(L#3) Open/Short Error 717
Failure code [CA325] Inj #6 (L#6) Open/Short Error 719
Failure code [CA331] Inj #2(L#2) Open/Short Error 721
Failure code [CA332] Inj #4(L#4) Open/Short Error 723
Failure code [CA343] ECM Critical Internal Failure 725
Failure code [CA351] Injectors Drive Circuit Error 726
Failure code [CA352] Sensor 1 Supply Volt Low Error 727
Failure code [CA356] Mass Air Flow Sensor High Error 729
Failure code [CA357] Mass Air Flow Sensor Low Error 731
Failure code [CA386] Sensor 1 Supply Volt High Error 733
Failure code [CA428] Water in Fuel Sensor High Error 734
Failure code [CA429] Water in Fuel Sensor Low Error 736
Failure code [CA435] Eng Oil Press Sw Error 738
Failure code [CA441] Battery Voltage Low Error 739
Failure code [CA442] Battery Voltage High Error 741
Failure code [CA449] Rail Press Very High Error 742
Failure code [CA451] Rail Press Sensor High Error 744
Failure code [CA452] Rail Press Sensor Low Error 746
Failure code [CA488] Chg Air Temp High Torque Derate 748
Failure code [CA515] Rail Press Sens Sup Volt High Error 749
Failure code [CA516] Rail Press Sens Sup Volt Low Error 751
Failure code [CA553] Rail Press High Error 753
Failure code [CA555] Crankcase Press High Error 2 754
Failure code [CA556] Crankcase Press High Error 2 755
Failure code [CA559] Rail Pump Press Low Error 756
Failure code [CA595] Turbo Speed High Error 2 760
Failure code [CA687] Turbo Speed Low Error 761
Failure code [CA689] Eng Ne Speed Sensor Error 763
Failure code [CA691] Intake Air Temp Sens High Error 766
Failure code [CA692] Intake Air Temp Sens Low Error 768
Failure code [CA697] ECM Internal Temp Sensor High Error 770
Failure code [CA698] ECM Int Temp Sensor Low Error 771
Failure code [CA731] Eng Bkup Speed Sens Phase Error 772
Failure code [CA778] Eng Bkup Speed Sensor Error 774
Failure code [CA1117] Persistent Data Lost Error 777
Failure code [CA1664] KDOC Malfunction 778
Failure code [CA1691] Regeneration Ineffective 780
Failure code [CA1695] Sens 5 Supply Volt High Error 783
Failure code [CA1696] Sens 5 Supply Volt Low Error 784
Failure code [CA1843] Crankcase Press Sens High Error 786
Failure code [CA1844] Crankcase Press Sens Low Error 788
Failure code [CA1879] KDPF Delta P Sensor High Error 790
Failure code [CA1881] KDPF Delta P Sensor Low Error 792
Failure code [CA1883] KDPF Delta P Sens In Range Error 794
Failure code [CA1921] KDPF Soot Load High Error 1 797
Failure code [CA1922] KDPF Soot Level High Error 2 800
Failure code [CA1942] Crankcase Press Sens In Range Error 804
Failure code [CA1993] KDPF Delta Pressure Low Error 805
Failure code [CA2185] Throt Sens Sup Volt High Error 806
Failure code [CA2186] Throt Sens Sup Volt Low Error 807
Failure code [CA2249] Rail Press Very Low Error 808
Failure code [CA2265] Fuel Feed Pump Open Error 809
Failure code [CA2266] Fuel Feed Pump Short Error 811
Failure code [CA2271] EGR Valve Pos Sens High Error 813
Failure code [CA2272] EGR Valve Pos Sens Low Error 815
Failure code [CA2288] Turbo Speed High Error 1 818
Failure code [CA2311] IMV Solenoid Error 819
Failure code [CA2349] EGR Valve Solenoid Open Error 820
Failure code [CA2353] EGR Valve Solenoid Short Error 822
Failure code [CA2357] EGR Valve Servo Error 824
Failure code [CA2373] Exhaust Manifold Press Sens High error 825
Failure code [CA2374] Exhaust Manifold Press Sens Low error 827
Failure code [CA2375] EGR Orifice Temp Sens High Error 829
Failure code [CA2376] EGR Orifice Temp Sens Low Error 831
Failure code [CA2381] KVGT Pos Sens High Error 833
Failure code [CA2382] KVGT Pos Sens Low Error 835
Failure code [CA2383] KVGT Solenoid Open Error 837
Failure code [CA2386] KVGT Solenoid Short Error 839
Failure code [CA2387] KVGT Servo Error 841
Failure code [CA2554] Exh Manifold Press Sens In Range Error 842
Failure code [CA2555] Grid Htr Relay Open Circuit Error 843
Failure code [CA2556] Grid Htr Relay Short Circuit Error 845
Failure code [CA2637] KDOC Blocked 847
Failure code [CA2639] Manual Stationary Regeneration Request 849
Failure code [CA2961] EGR Orifice Temp High Error 1 851
Failure code [CA2973] Chg Air Press Sensor In Range Error 852
Failure code [CA3133] KDPF Outlet Press Sens High Error 853
Failure code [CA3134] KDPF Outlet Press Sens Low Error 855
Failure code [CA3135] KDPF Outlet Press Sens In Range Error 857
Failure code [CA3251] KDOC Inlet Temp High Error 860
Failure code [CA3253] KDOC Temp Error – Non Regeneration 863
Failure code [CA3254] KDOC Outlet Temp High Error 1 866
Failure code [CA3255] KDPF Temp Error – Non Regeneration 869
Failure code [CA3256] KDPF Outlet Temp High Error 1 870
Failure code [CA3311] KDOC Outlet Temp High Error 2 871
Failure code [CA3312] KDPF Outlet Temp High Error 2 872
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error 875
Failure code [CA3314] KDOC Inlet Temp Sens High Error 878
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error 882
Failure code [CA3316] KDOC Outlet Temp Sens Low Error 886
Failure code [CA3317] KDOC Outlet Temp Sens High Error 889
Failure code [CA3318] KDOC Outlet Temp Sensor In Range Error 893
Failure code [CA3319] KDPF Outlet Temp Sens High Error 897
Failure code [CA3321] KDPF Outlet Temp Sens Low Error 901
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error 904
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error 908
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error 910
Failure code [D110KB] Battery Relay Drive S/C 912
Failure code [CA3741] Rail Press Valve Trip Error 914
Failure code [D19JKZ] Personal Code Relay Abnormality 915
Failure code [D811MC] KOMTRAX Error 918
Failure code [D862KA] GPS Antenna Open Circuit 919
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) 920
Failure code [DA20MC] Pump Controller Malfunction 921
Failure code [DA22KK] Pump Solenoid Power Low Error 922
Failure code [DA25KP] 5V Sensor1 Power Abnormality 924
Failure code [DA29KQ] Model Selection Abnormality 927
Failure code [DA2QKR] CAN2 Discon ( Pump Con) 931
Failure code [DA2RKR] CAN1 Discon ( Pump Con) 934
Failure code [DAF0MB] Monitor ROM Abnormality 935
Failure code [DAF0MC] Monitor Error 936
Failure code [DAF8KB] Camera Power Supply Short Circuit 937
Failure code [DAF9KQ] Model Selection Abnormality 939
Failure code [DAFGMC] GPS Module Error 940
Failure code [DAFQKR] CAN2 Discon 941
Failure code [DAZ9KQ] AC Model Selection Abnormality 942
Failure code [DAZQKR] CAN2 Discon (AC) 943
Failure code [DB2QKR] CAN2 Discon (Engine Con) 948
Failure code [DB2RKR] CAN1 Discon (Engine Con) 953
Failure code [DGH2KB] Hyd Oil Sensor Short 957
Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit 959
Failure code [DHPAMA] Pump Press Sensor Abnormality 960
Failure code [DHPBMA] R Pump Press Sensor Abnormality 963
Failure code [DHS3MA] Arm IN PPC Sen Abnormality 966
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality 968
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality 971
Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality 974
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality 977
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality 980
Failure code [DHSCMA] Arm OUT PPC Press Sensor Abnormality 983
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality 986
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality 989
Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality 992
Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality 995
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality 998
Failure code [DKR0MA] F pump S/P sensor Abnormality 1001
Failure code [DKR1MA] R pump S/P sensor Abnormality 1003
Failure code [DV20KB] Travel alarm short circuit 1005
Failure code [DW43KA] Travel Speed Sol Open Circuit 1007
Failure code [DW43KB] Travel Speed Sol Short Circuit 1009
Failure code [DW45KA] swing holding brake Sol Open Circuit 1011
Failure code [DW45KB] Swing Brake Sol Short Circuit 1014
Failure code [DW91KA] Travel Junction Sol Open Circuit 1017
Failure code [DW91KB] Travel Junction Sol Short Circuit 1019
Failure code [DWA2KA] Attachment Sol Open Circuit 1021
Failure code [DWA2KB] Attachment Sol Short Circuit 1023
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit 1025
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit 1027
Failure code [DWK2KA] Variable Back Pressure Sol Open Circuit 1029
Failure code [DWK2KB] Variable Back Pressure Sol Short Circuit 1031
Failure code [DWK8KA] Swing C/O Solenoid Open Circuit 1033
Failure code [DWK8KB] Swing C/O Solenoid Short Circuit 1035
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit 1037
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit 1039
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit 1041
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit 1043
Failure code [DXE0KA] LS-EPC Sol Open Circuit 1045
Failure code [DXE0KB] LS-EPC Sol Short Circuit 1047
Failure code [DXE4KA] Service Current EPC Disc 1049
Failure code [DXE4KB] Service Current EPC S/C 1051
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit 1053
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit 1055
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit 1057
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit 1059
Failure code [DY20KA] Wiper Working Abnormality 1061
Failure code [DY20MA] Wiper Parking Abnormality 1063
Failure code [DY2CKB] Washer Drive Short Circuit 1065
Failure code [DY2DKB] Wiper Drive (For) Short 1067
Failure code [DY2EKB] Wiper Drive (Rev) Short 1069
Troubleshooting of electrical system (E-mode) 1071
E-1 Engine does not start (Engine does not crank) 1071
E-2 Manual preheating does not work 1077
E-3 Automatic preheating system does not work 1080
E-4 While preheating is working, preheating monitor does not light up 1082
E-5 When starting switch is turned to ON position, machine monitor displays nothing 1084
E-6 While starting switch is turned to ON position (with engine stopped), engine oil level monitor lights up in yellow 1087
E-7 While starting switch is turned to ON position (with engine stopped), radiator coolant level monitor lights up in yellow 1088
E-8 Engine coolant temperature monitor lights up in white while engine is running 1089
E-9 Hydraulic oil temperature monitor lights up in white while engine is running 1090
E-10 Charge level monitor lights up while engine is running 1091
E-11 Fuel level monitor lights up in red while engine is running 1092
E-12 Air cleaner clogging monitor lights up in yellow while engine is running 1093
E-13 Engine coolant temperature monitor lights up in red while engine is running 1094
E-14 Hydraulic oil temperature monitor lights up in red while engine is running 1095
E-15 Engine oil pressure monitor lights up in red while engine is running 1096
E-16 Fuel gauge display does not move from minimum or maximum 1097
E-17 Display of fuel gauge differs from actual fuel level 1098
E-18 Engine coolant temperature gauge display does not move from minimum or maximum 1099
E-19 Display of engine coolant temperature gauge differs from actual coolant temperature 1100
E-20 Hydraulic oil temperature gauge display does not move from minimum or maximum 1101
E-21 Display of hydraulic oil temperature gauge differs from actual oil temperature 1103
E-22 Machine monitor does not display partially 1104
E-23 Function switch does not operate 1105
E-24 Automatic warm-up system does not work (in cold weather) 1106
E-25 When auto-decelerator switch is operated, auto-decelerator monitor does not light up or does not go off 1107
E-26 Auto-decelerator is not operated or canceled with lever 1108
E-27 When working mode switch is operated, working mode selection screen is not displayed 1109
E-28 When working mode is changed, setting of engine and hydraulic pump is not changed 1110
E-29 When travel speed switch is operated, travel speed monitor does not change 1111
E-30 When travel speed selection is changed, actual travel speed does not change 1112
E-31 Alarm buzzer cannot be canceled 1113
E-32 When starting switch is turned OFF, service meter is not displayed 1114
E-33 Machine monitor cannot be set in service mode 1115
E-34 Any of work equipment, swing and travel does not work 1116
E-35 Any of work equipment, swing and travel cannot be locked 1118
E-36 Upper structure does not swing while swing brake cancel switch is set to CANCEL position 1120
E-37 Swing brake does not operate while swing brake cancel switch is set to NORMAL position 1122
E-38 One-touch power maximizing function does not work properly or pilot monitor is not displayed 1124
E-39 One-touch power maximizing function cannot be canceled 1126
E-40 Alarm does not sound during travelling 1127
E-41 Alarm does not stop sounding while machine is stopped 1128
E-42 Horn does not sound 1129
E-43 Horn does not stop sounding 1131
E-44 When wiper switch is operated, wiper monitor does not light up or go off 1132
E-45 Wiper does not operate when wiper switch is operated 1133
E-46 When window washer switch is operated, window washer does not operate 1135
E-47 Boom LOWER indicator is not displayed properly with monitoring function 1136
E-48 Arm OUT indicator is not displayed properly with monitoring function 1137
E-49 Arm IN indicator is not displayed properly with monitoring function 1138
E-50 Boom RAISE indicator is not displayed properly with monitoring function 1139
E-51 Bucket CURL indicator is not displayed properly with monitoring function 1140
E-52 Bucket DUMP indicator is not displayed properly with monitoring function 1141
E-53 Swing indication is not displayed properly with monitoring function 1142
E-54 Travel indication is not displayed properly with monitoring function 1143
E-55 Service indication is not displayed properly with monitoring function 1144
E-56 Attachment circuit is not switched 1146
E-57 KOMTRAX system does not operate properly 1147
E-58 Machine push-up function is not canceled 1148
E-59 Machine push-up function does not work 1150
Troubleshooting of hydraulic and mechanical system (H-mode) 1151
Information described in troubleshooting table (H-mode) 1151
List of Failure Mode and Cause 1152
H-1 All of work equipment, swing and travel operation lacks speed or power 1157
H-2 Engine speed lowers significantly or engine stalls 1161
H-3 Any of work equipment, swing and travel does not work 1164
H-4 Unusual sound is heard from around hydraulic pump 1165
H-5 Fine control performance or response is poor　 1166
H-6 Speed or power of boom is low 1168
H-7 Speed or power of arm is low 1172
H-8 Speed or power of bucket is low 1177
H-9 Work equipment does not move in single operation 1181
H-10 Hydraulic drift of boom is large 1182
H-11 Hydraulic drift of arm is large 1183
H-12 Hydraulic drift of bucket is large 1185
H-13 Time lag of work equipment is large 1186
H-14 When part of work equipment is relieved singly, other parts of work equipment move 1188
H-15 One-touch power maximizing function does not work 1189
H-16 Machine push up function does not work 1190
H-17 In combined operation of work equipment, equipment having heavier load moves slower 1191
H-18 In combined operations of swing and boom RAISE, boom rising speed is low 1192
H-19 In combined operations of swing and travel, travel speed drops largely 1193
H-20 Machine does not travel straight 1194
H-21 Travel speed is too low 1197
H-22 Machine is hard to steer or travel power is low 1199
H-23 Travel speed does not change, or travel speed is too low or high 1202
H-24 One of tracks does not run 1203
H-25 Upper structure does not swing in both right and left directions 1205
H-26 Upper structure does not swing in only one direction 1206
H-27 Swing acceleration or swing speed is low in both directions (right and left) 1207
H-28 Swing acceleration performance is poor or swing speed is slow in only one direction 1208
H-29 Upper structure overruns remarkably when it stops swinging in both directions (right and left) 1209
H-30 Upper structure overruns excessively when it stops swinging in only one direction 1210
H-31 Shock is large when upper structure stops swinging 1211
H-32 Large unusual noise is heard when upper structure stops swinging 1212
H-33 When swing holding brake is applied, hydraulic drift of swing is large 1213
H-34 When swing holding brake is released, hydraulic drift of swing is large 1214
H-35 When additional attachment is installed, attachment circuit is not switched 1215
H-36 Oil flow in attachment circuit cannot be controlled 1216
H-37 Quick coupler cylinder will not extend 1217
H-38 Quick coupler cylinder will not extend (but buzzer does not sound) 1219
H-39 Buzzer does not sound (but quick coupler cylinder does retract) 1221
H-40 Quick coupler cylinder extends and retracts slowly 1223
Troubleshooting of engine (S-mode) 1224
Information contained in troubleshooting table (S mode) 1224
S-1 Engine does not crank when starting switch is turned to “START” position 1225
S-2 The engine cranks but exhaust smoke does not come out 1226
S-3 Fuel is being injected but engine does not start (incomplete combustion: engine cranks but does not start) 1227
S-4 Startability is poor 1228
S-5 Engine does not pick up smoothly 1230
S-6 Engine stops during operation 1232
S-7 Engine runs rough or is unstable 1234
S-8 Engine lacks power 1235
S-9 Exhaust smoke is black (KDPF gets clogged in a short time) 1237
S-10 Engine oil consumption is excessive 1239
S-11 Engine oil becomes contaminated early 1240
S-12 Fuel consumption is excessive 1241
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) 1242
S-14 Oil pressure drops 1243
S-15 Fuel mixes into engine oil 1244
S-16 Water mixes into engine oil (milky) 1245
S-17 Coolant temperature rises too high (overheating) 1246
S-18 Unusual noise is heard 1247
S-19 Vibration is excessive 1248
S-20 Air cannot be bled from fuel circuit 1249
S-21 Frequent active regeneration 1250
S-22 Active regeneration takes time 1251
S-23 White smoke is exhausted during active regeneration 1252
Auto grease system 1253
Finding malfunctions 1253
Malfunction finding procedures 1256
50 Disassembly and assembly 1259
Table of contents 1260
General information on disassembly and assembly 1262
How to read this manual 1262
Coating materials list 1264
Special tools list 1268
Sketches of special tools 1273
Engine and cooling system 1276
Removal and installation of supply pump assembly 1276
Removal and installation of injector assembly 1286
Removal and installation of cylinder head assembly 1302
Removal and installation of radiator assembly 1324
Removal and installation of hydraulic oil cooler assembly 1327
Removal and installation of aftercooler assembly 1330
Removal and installation of engine and main pump assembly 1331
Removal and installation of engine front seal 1343
Removal and installation of engine rear seal 1348
Removal and installation of fuel tank assembly 1355
Removal and installation of engine hood assembly 1357
Removal and installation of KDPF assembly 1360
Disassembly and assembly of KDPF 1367
Removal and installation of KCCV assembly 1376
Removal and installation of air cleaner assembly 1377
Removal and installation of air conditioner compressor assembly 1379
Removal and installation of air conditioner condenser assembly 1381
Power train system 1383
Removal and installation of travel motor and final drive assembly 1383
Disassembly and assembly of final drive 1384
Removal and installation of swing motor and swing machinery assembly 1393
Disassembly and assembly of swing machinery 1395
Removal and installation of swing circle assembly 1402
Undercarriage and frame 1403
Separation and connection of track shoe assembly 1403
Removal and installation of sprocket 1406
Removal and installation of idler and idler cushion assembly 1407
Disassembly and assembly of idler 1408
Disassembly and assembly of idler cushion 1411
Disassembly and assembly of track roller 1413
Disassembly and assembly of carrier roller 1415
Removal and installation of revolving frame assembly 1418
Removal and installation of counterweight assembly 1420
Hydraulic system 1423
Removal and installation of center swivel joint assembly 1423
Disassembly and assembly of center swivel joint 1425
Removal and installation of hydraulic tank assembly 1426
Removal and installation of main pump assembly 1429
Removal and installation of control valve assembly 1433
Disassembly and assembly of control valve 1439
Disassembly and assembly of work equipment PPC valve 1444
Disassembly and assembly of travel PPC valve 1446
Removal and installation of quick coupler valve 1448
Work equipment 1449
Removal and installation of bucket assembly 1449
Removal and installation of arm assembly 1450
Removal and installation of work equipment assembly 1452
Disassembly and assembly of work equipment cylinder 1455
Cab and its attachments 1461
Removal and installation of operator’s cab assembly 1461
Removal and installation of operator cab glass (adhered glass) 1466
Removal and installation of front window assembly 1476
Removal and installation of floor frame assembly 1482
Removal and installation of air conditioner unit assembly 1488
Removal and installation of operator’s seat 1492
Removal and installation of seat belt 1494
Removal and installation of front wiper assembly 1496
Electrical system 1503
Removal and installation of engine controller assembly 1503
Removal and installation of pump controller assembly 1506
Removal and installation of machine monitor assembly 1509
Removal and installation of pump swash plate sensor 1511
Removal and installation of mass air flow and temperature sensor 1512
Removal and installation of KOMTRAX terminal assembly 1513
60 Maintenance standard 1515
Table of contents 1516
Engine and cooling system 1517
Engine mount 1517
Cooling system 1518
Power train system 1519
Swing circle 1519
Swing machinery 1520
Final drive 1522
Undercarriage and frame 1524
Sprocket 1524
Track frame and idler cushion 1526
Idler 1528
Track roller 1530
Carrier roller 1532
Track shoe 1533
Hydraulic system 1536
Hydraulic tank 1536
Main pump 1537
Control valve 1538
Swing motor 1548
Travel motor 1550
PPC valve 1553
Solenoid valve 1563
Attachment circuit selector valve 1564
Hydraulic drift prevention valve 1565
Center swivel joint 1567
Work equipment 1568
Work equipment cylinder 1577
80 Appendix 1581
Table of contents 1582
Air conditioner components 1583
Precautions for refrigerant 1583
Air conditioner component 1584
Configuration and function of refrigeration cycle 1587
Outline of refrigeration cycle 1588
Air conditioner unit 1590
Dual pressure switch 1596
Air conditioner controller 1597
Compressor 1598
Condenser 1599
Receiver drier 1600
Sunlight sensor 1601
Outer temperature sensor (outside air temperature sensor) 1602
Procedure for testing and troubleshooting 1603
Circuit diagram and arrangement of connector pins 1605
System diagram 1607
Input and output signals of the air conditioner controller 1608
Parts and connectors layout 1610
Layout of air conditioner related parts and connectors 1611
Testing air leakage (duct) 1614
Testing with self-diagnosis function 1617
How to enter air conditioner “Electrical Systems” screen in service mode of the machine monitor 1618
Testing vent (mode) changeover 1620
Testing FRESH/RECIRC air changeover 1622
Testing sunlight sensor 1623
Testing (dual) pressure switch for refrigerant 1624
Testing relays 1625
Troubleshooting chart 1 1626
Troubleshooting chart 2 1627
Information in troubleshooting table 1630
Failure code list related to air conditioner 1631
Failure code [879AKA] A/C Inner sensor Open Circuit 1632
Failure code [879AKB] A/C Inner sensor Short Circuit 1633
Failure code [879BKA] A/C Outer sensor Open Circuit 1634
Failure code [879BKB] A/C Outer sensor Short Circuit 1636
Failure code [879CKA] Ventilating sensor Open Circuit 1638
Failure code [879CKB] Ventilating sensor Short Circuit 1639
Failure code [879DKZ] Sunlight sensor Open or Short Circuit 1640
Failure code [879EMC] Ventilating Damper Abnormality 1642
Failure code [879FMC] Air Mix Damper Abnormality 1643
Failure code [879GKX] Refrigerant Abnormality 1644
A-1 Troubleshooting for power supply system (Air conditioner does not operate) 1645
A-2 Troubleshooting of compressor system (Air is not cooled) 1647
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) 1650
A-4 Troubleshooting for FRESH/RECIRC air changeover 1652
Troubleshooting with gauge pressure 1654
Connection of service tool 1657
Precautions for disconnecting and connecting air conditioner piping 1659
Handling of compressor oil 1661
90 Diagrams and drawings 1663
Table of contents 1664
Hydraulic circuit diagram 1665
Symbols in hydraulic circuit diagram 1665
Hydraulic circuit diagram 0
Electric circuit diagram 1669
Symbols in electric circuit diagram 1669
Electric circuit diagram 0
Electric circuit diagram for air conditioner unit 0

DESCRIPTION:

Komatsu PC360LC-10 PC360NLC-10 Hydraulic Excavator Shop Manual UEN05619-03 – PDF DOWNLOAD 

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