Komatsu PC360LC-11 Excavator Shop Manual SEN06699-00 PDF

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Komatsu PC360LC-11 Hydraulic Excavator Shop Manual SEN06699-00 – PDF DOWNLOAD

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Komatsu PC360LC-11 Hydraulic Excavator Shop Manual SEN06699-00 – PDF DOWNLOAD 

Language : English
Pages : 2678
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu PC360LC-11 Hydraulic Excavator Shop Manual SEN06699-00 – PDF DOWNLOAD 

SERIAL NUMBERS 90001 and up

COVER 1
00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 21
FOREWORD, SAFETY, BASIC INFORMATION 27
HOW TO READ THE SHOP MANUAL 27
SAFETY NOTICE FOR OPERATION 29
PRECAUTIONS TO PREVENT FIRE 37
ACTIONS IF FIRE OCCURS 39
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 40
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 41
PRECAUTIONS FOR DEF 42
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 42
PRECAUTIONS FOR ADDING 42
PRECAUTIONS FOR STORING 42
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 42
THE OTHER PRECAUTIONS 42
STORE AdBlue/DEF 43
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 44
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 47
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 54
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 56
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 57
PRACTICAL USE OF KOMTRAX 58
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 59
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 61
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 63
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 67
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 68
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 70
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 73
HOW TO READ ELECTRICAL WIRE CODE 74
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 78
STANDARD TIGHTENING TORQUE TABLE 81
CONVERSION TABLE 88
01 SPECIFICATIONS 93
CONTENTS 94
ABBREVIATION LIST 95
SPECIFICATIONS 101
SPECIFICATION DRAWING 101
SPECIFICATION DRAWING: PC360LC-11 101
WORKING RANGE DRAWINGS 103
WORKING RANGE: PC360LC-11 103
SPECIFICATIONS 104
SPECIFICATIONS: PC360LC-11 104
WEIGHT TABLE 107
WEIGHT TABLE: PC360LC-11 107
TABLE OF FUEL, COOLANT, AND LUBRICANTS 109
10 STRUCTURE AND FUNCTION 111
CONTENTS 112
ABBREVIATION LIST 115
UREA SCR SYSTEM 121
LAYOUT DRAWING OF UREA SCR SYSTEM 121
UREA SCR SYSTEM DIAGRAM 125
FUNCTION OF UREA SCR SYSTEM 126
FUNCTION OF AdBlue/DEF SYSTEM 126
INDUCEMENT STRATEGY 128
COMPONENT PARTS OF UREA SCR SYSTEM 142
AdBlue/DEF MIXING TUBE 142
SCR ASSEMBLY 143
AdBlue/DEF TANK 145
AdBlue/DEF PUMP 147
AdBlue/DEF INJECTOR 148
AdBlue/DEF HOSE 149
AdBlue/DEF TANK HEATING VALVE 150
BOOT-UP SYSTEM 151
LAYOUT DRAWING OF BOOT-UP SYSTEM 151
SYSTEM OPERATING LAMP SYSTEM 153
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 153
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 153
BATTERY DISCONNECT SWITCH 155
FUNCTION OF BATTERY DISCONNECT SWITCH 155
ENGINE SYSTEM 156
LAYOUT DRAWING OF ENGINE SYSTEM 156
SPECIFICATIONS OF ENGINE SYSTEM 157
FUNCTION OF ENGINE SYSTEM 157
ENGINE CONTROL SYSTEM 158
ENGINE CONTROL SYSTEM DIAGRAM 158
FUNCTION OF ENGINE CONTROL SYSTEM 159
AUTO-DECELERATION SYSTEM 161
AUTO-DECELERATION SYSTEM DIAGRAM 161
FUNCTION OF AUTO-DECELERATION SYSTEM 161
OPERATION OF AUTO-DECELERATION SYSTEM 162
ENGINE AUTOMATIC WARM-UP SYSTEM 163
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 163
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 164
OVERHEAT PREVENTION SYSTEM 165
OVERHEAT PREVENTION SYSTEM DIAGRAM 165
FUNCTION OF OVERHEAT PREVENTION SYSTEM 166
TURBOCHARGER PROTECTION SYSTEM 167
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 167
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 168
AUTOMATIC IDLE STOP SYSTEM 169
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 169
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 169
COMPONENT PARTS OF ENGINE SYSTEM 172
VGT 172
EGR SYSTEM 176
EGR VALVE 178
EGR COOLER 180
KCCV SYSTEM 182
KCCV VENTILATOR 184
KDPF 186
COOLING SYSTEM 190
LAYOUT DRAWING OF COOLING SYSTEM 190
SPECIFICATIONS OF COOLING SYSTEM 191
CONTROL SYSTEM 192
LAYOUT DRAWING OF CONTROL SYSTEM 192
MACHINE MONITOR SYSTEM 195
MACHINE MONITOR SYSTEM DIAGRAM 195
FUNCTION OF MACHINE MONITOR SYSTEM 196
KOMTRAX SYSTEM 197
KOMTRAX SYSTEM DIAGRAM 197
FUNCTION OF KOMTRAX SYSTEM 197
COMPONENT PARTS OF CONTROL SYSTEM 198
MACHINE MONITOR 198
KOMTRAX TERMINAL 213
PUMP CONTROLLER 215
RESISTOR FOR PC-EPC VALVE 219
CAN TERMINATING RESISTOR 220
ENGINE CONTROLLER 221
FUEL CONTROL DIAL 228
HYDRAULIC SYSTEM 230
LAYOUT DRAWING OF HYDRAULIC SYSTEM 230
CLSS 233
STRUCTURE OF CLSS 233
OPERATION OF UNLOAD VALVE AND LS PRESSURE 235
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 237
PRESSURE COMPENSATION CONTROL 250
ENGINE AND PUMP COMBINED CONTROL SYSTEM 254
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 254
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 255
PUMP AND VALVE CONTROL SYSTEM 260
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 260
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 261
COMPONENT PARTS OF HYDRAULIC SYSTEM 263
HYDRAULIC TANK 263
MAIN PUMP 266
CONTROL VALVE 292
WORK EQUIPMENT SYSTEM 355
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 355
STRUCTURE OF VALVE CONTROL 361
ONE-TOUCH POWER MAXIMIZING SYSTEM 363
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 363
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 364
MACHINE PUSH-UP SYSTEM 365
MACHINE PUSH-UP SYSTEM DIAGRAM 365
FUNCTION OF MACHINE PUSH-UP SYSTEM 366
PPC LOCK SYSTEM 367
PPC LOCK SYSTEM DIAGRAM 367
FUNCTION OF PPC LOCK SYSTEM 367
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 368
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 368
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 368
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 369
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 370
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT 370
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 371
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 372
WORK EQUIPMENT AND SWING PPC VALVE 372
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 378
2ND-LINE ATTACHMENT PPC VALVE 383
SOLENOID VALVE 385
ANTI-DROP VALVE FOR BOOM 389
ANTI-DROP VALVE FOR ARM 394
ATTACHMENT CIRCUIT SELECTOR VALVE 399
PILOT CIRCUIT ACCUMULATOR 401
SWING SYSTEM 402
LAYOUT DRAWING OF SWING SYSTEM 402
SWING CONTROL SYSTEM DIAGRAM 405
FUNCTION OF SWING CONTROL SYSTEM 405
COMPONENT PARTS OF SWING SYSTEM 409
SWING MOTOR 409
SWING MACHINERY 422
SWING CIRCLE 424
TRAVEL SYSTEM 425
LAYOUT DRAWING OF TRAVEL SYSTEM 425
TRAVEL CONTROL SYSTEM DIAGRAM 429
FUNCTION OF TRAVEL CONTROL SYSTEM 429
COMPONENT PARTS OF TRAVEL SYSTEM 431
TRAVEL MOTOR 431
FINAL DRIVE 443
TRAVEL PPC VALVE 445
CENTER SWIVEL JOINT 449
UNDERCARRIAGE AND FRAME 451
LAYOUT DRAWING OF UNDERCARRIAGE 451
SPECIFICATIONS OF UNDERCARRIAGE 451
WORK EQUIPMENT 452
STRUCTURE OF WORK EQUIPMENT 452
FUNCTION OF WORK EQUIPMENT 453
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 454
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 454
BUCKET CLEARANCE ADJUSTMENT SHIM 455
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 455
CAB AND ITS ATTACHMENTS 456
ROPS CAB 456
STRUCTURE OF ROPS CAB 456
FUNCTION OF ROPS CAB 456
CAB MOUNT 457
STRUCTURE OF CAB MOUNT 457
FUNCTION OF CAB MOUNT 457
CAB TIPPING STOPPER 458
STRUCTURE OF CAB TIPPING STOPPER 458
FUNCTION OF CAB TIPPING STOPPER 458
20 STANDARD VALUE TABLE 459
CONTENTS 460
ABBREVIATION LIST 461
STANDARD VALUE TABLE FOR ENGINE 467
STANDARD VALUE TABLE FOR ENGINE: PC360LC-11 467
STANDARD VALUE TABLE FOR MACHINE 472
STANDARD VALUE TABLE FOR MACHINE: PC360LC-11 472
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 487
STANDARD VALUE TABLE FOR ELECTRICAL 491
STANDARD VALUE TABLE FOR ELECTRICAL 491
30 TESTING AND ADJUSTING 501
CONTENTS 502
ABBREVIATION LIST 505
RELATED INFORMATION ON TESTING AND ADJUSTING 511
TOOLS FOR TESTING AND ADJUSTING 511
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 517
ENGINE AND COOLING SYSTEM 519
TEST ENGINE SPEED 519
METHOD FOR TESTING ENGINE SPEED 519
TEST BOOST PRESSURE 523
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 523
METHOD FOR TESTING BOOST PRESSURE 524
TEST EXHAUST GAS COLOR 525
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 525
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 526
TEST AND ADJUST VALVE CLEARANCE 527
METHOD FOR TESTING VALVE CLEARANCE 527
METHOD FOR ADJUSTING VALVE CLEARANCE 529
TEST COMPRESSION PRESSURE 530
METHOD FOR TESTING COMPRESSION PRESSURE 530
TEST BLOWBY PRESSURE 533
METHOD FOR TESTING BLOWBY PRESSURE 533
TEST ENGINE OIL PRESSURE 535
METHOD FOR TESTING ENGINE OIL PRESSURE 535
TEST EGR VALVE AND VGT OIL PRESSURE 537
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 537
TEST FUEL PRESSURE 539
METHOD FOR TESTING FUEL PRESSURE 540
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 546
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 547
BLEED AIR FROM FUEL SYSTEM 553
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 553
TEST FUEL CIRCUIT FOR LEAKAGE 554
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 554
HANDLE CYLINDER CUT-OUT MODE OPERATION 556
HANDLE NO-INJECTION CRANKING OPERATION 557
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 558
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION 558
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 558
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 559
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 560
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 560
TEST SCR RELATED FUNCTIONS 561
TEST AdBlue/DEF PUMP RAISED PRESSURE 564
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 567
TEST AdBlue/DEF LINE HEATER RELAY 1 571
TEST AdBlue/DEF LINE HEATER RELAY 2 573
TEST AdBlue/DEF PUMP HEATER RELAY 576
TEST AdBlue/DEF TANK HEATER VALVE 579
TEST DENITRATION EFFICIENCY OF SCR 582
CLEAN AdBlue/DEF TANK 586
METHOD FOR CLEANING AdBlue/DEF TANK 586
POWER TRAIN 590
TEST SWING CIRCLE BEARING CLEARANCE 590
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 590
UNDERCARRIAGE AND FRAME 591
TEST AND ADJUST TRACK TENSION 591
METHOD FOR TESTING TRACK TENSION 591
METHOD FOR ADJUSTING TRACK TENSION 591
HYDRAULIC SYSTEM 593
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 593
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 593
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 593
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 597
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 597
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 598
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 599
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 607
TEST OIL PRESSURE OF CONTROL CIRCUIT 611
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 611
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 613
TEST PC VALVE OUTPUT PRESSURE (SERVO PISTON INLET PRESSURE) 613
TEST PC-EPC VALVE OUTPUT PRESSURE 614
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 615
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 616
METHOD FOR TESTING OIL PRESSURE WITH SENSOR ADAPTER (SPECIAL TOOL) 616
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE 617
METHOD FOR TESTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INLET PRESSURE) 619
METHOD FOR TESTING LS-EPC VALVE OUTPUT PRESSURE 619
METHOD FOR ADJUSTING LS VALVE 620
TEST OUTLET PRESSURE OF SOLENOID VALVE 621
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 621
OPERATING CONDITION OF SOLENOID VALVE 622
TEST PPC VALVE OUTPUT PRESSURE 624
METHOD FOR TESTING PPC VALVE OUTPUT PRESSURE 624
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 626
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 626
TEST PUMP SWASH PLATE SENSOR 627
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 627
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 628
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 628
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 628
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 629
TEST OIL LEAKAGE 630
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 630
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 630
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 631
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR 631
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 631
BLEED AIR FROM HYDRAULIC CIRCUIT 633
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 635
CAB AND ITS ATTACHMENTS 638
TEST CAB TIPPING STOPPER 638
METHOD FOR TESTING CAB TIPPING STOPPER 638
METHOD FOR ADJUSTING MIRRORS 639
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 639
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 640
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 641
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 642
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 643
ELECTRICAL SYSTEM 645
SET AND OPERATE MACHINE MONITOR 645
OPERATOR MODE 648
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 649
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 649
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 650
CHECKING FUNCTION OF SERVICE METER 650
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 650
SERVICE MODE 653
METHOD FOR OPERATING SERVICE MODE 653
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 655
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 662
ABNORMALITY RECORD MENU 672
METHOD FOR CONFIRMING MAINTENANCE RECORD 677
METHOD FOR OPERATING MAINTENANCE MODE SETTING 678
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 682
DEFAULT MENU 683
DIAGNOSTIC TESTS MENU 690
ADJUSTMENT MENU 699
METHOD FOR PERFORMING NO-INJECTION CRANKING 716
KOMTRAX SETTINGS MENU 717
METHOD FOR DISPLAYING SERVICE MESSAGE 719
METHOD FOR STARTING UP KOMTRAX TERMINAL 721
ADJUST REARVIEW CAMERA ANGLE 726
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 726
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 729
HANDLE BATTERY DISCONNECT SWITCH 730
TEST DIODES 731
METHOD FOR TESTING DIODE USING DIGITAL TESTER 731
METHOD FOR TESTING DIODE USING ANALOG TESTER 731
Pm CLINIC 732
Pm CLINIC SERVICE 732
Pm CLINIC CHECK SHEET 734
40 TROUBLESHOOTING 749
CONTENTS 750
ABBREVIATION LIST 760
RELATED INFORMATION ON TROUBLESHOOTING 766
GENERAL TROUBLESHOOTING POINTS 766
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 767
SEQUENCE OF EVENTS IN TROUBLESHOOTING 779
CHECKS BEFORE TROUBLESHOOTING 781
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 783
WALK-AROUND CHECK 783
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 785
CHECK FUEL LEVEL AND TYPE 785
CHECK IMPURE INGREDIENT IN FUEL 785
CHECK FUEL PREFILTER 786
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 786
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE 787
CHECK MAIN FILTER 788
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 790
CHECK COOLANT LEVEL (RESERVOIR TANK) 791
CHECK CLOGGING OF AIR CLEANER 792
OUTER ELEMENT – CLEAN 792
ELEMENTS – REPLACE 794
CHECK HYDRAULIC OIL LEVEL 795
CHECK HYDRAULIC OIL STRAINER 796
CHECK HYDRAULIC FILTER 797
CHECK OIL LEVEL IN SWING MACHINERY CASE 798
CHECK OIL LEVEL IN DAMPER CASE 798
CHECK OIL LEVEL IN FINAL DRIVE CASE 799
BLEED AIR FROM FUEL SYSTEM 799
BLEED AIR FROM HYDRAULIC SYSTEM 799
ELECTRICAL EQUIPMENT – CHECK METHOD 799
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 805
PROCEDURE FOR TESTING AND TROUBLESHOOTING 815
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 818
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 822
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 824
Connector list and layout 827
CONNECTOR CONTACT IDENTIFICATION 840
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 880
FUSE LOCATION TABLE 886
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 888
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 892
FAILURE CODES TABLE 894
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 911
FAILURE CODE [879AKA] 911
FAILURE CODE [879AKB] 912
FAILURE CODE [879BKA] 913
FAILURE CODE [879BKB] 915
FAILURE CODE [879CKA] 917
FAILURE CODE [879CKB] 918
FAILURE CODE [879DKZ] 919
FAILURE CODE [879EMC] 921
FAILURE CODE [879FMC] 922
FAILURE CODE [879GKX] 923
FAILURE CODE [989L00] 925
FAILURE CODE [989M00] 926
FAILURE CODE [989N00] 927
FAILURE CODE [A1U0N3] 928
FAILURE CODE [A1U0N4] 930
FAILURE CODE [A900FR] 932
FAILURE CODE [A900N6] 933
FAILURE CODE [A900NY] 934
FAILURE CODE [AA10NX] 935
FAILURE CODE [AB00KE] 937
FAILURE CODE [AQ10N3] 940
FAILURE CODE [AS00N3] 942
FAILURE CODE [AS00R2] 944
FAILURE CODE [AS00R3] 945
FAILURE CODE [AS00R4] 946
FAILURE CODE [AS00R5] 947
FAILURE CODE [AS00R6] 948
FAILURE CODE [AS00ZK] 949
FAILURE CODE [AS10KM] 950
FAILURE CODE [AS10NR] 951
FAILURE CODE [AS10NT] 952
FAILURE CODE [B@BAZG] 953
FAILURE CODE [B@BAZK] 954
FAILURE CODE [B@BCNS] 956
FAILURE CODE [B@BCQA] 957
FAILURE CODE [B@BCZK] 959
FAILURE CODE [B@HANS] 961
FAILURE CODE [CA115] 962
FAILURE CODE [CA122] 963
FAILURE CODE [CA123] 965
FAILURE CODE [CA131] 967
FAILURE CODE [CA132] 969
FAILURE CODE [CA144] 971
FAILURE CODE [CA145] 973
FAILURE CODE [CA153] 975
FAILURE CODE [CA154] 978
FAILURE CODE [CA187] 981
FAILURE CODE [CA221] 983
FAILURE CODE [CA222] 985
FAILURE CODE [CA227] 987
FAILURE CODE [CA234] 988
FAILURE CODE [CA238] 989
FAILURE CODE [CA239] 991
FAILURE CODE [CA249] 993
FAILURE CODE [CA256] 995
FAILURE CODE [CA271] 997
FAILURE CODE [CA272] 999
FAILURE CODE [CA281] 1001
FAILURE CODE [CA322] 1002
FAILURE CODE [CA323] 1004
FAILURE CODE [CA324] 1006
FAILURE CODE [CA325] 1008
FAILURE CODE [CA331] 1010
FAILURE CODE [CA332] 1012
FAILURE CODE [CA343] 1014
FAILURE CODE [CA351] 1015
FAILURE CODE [CA352] 1016
FAILURE CODE [CA356] 1019
FAILURE CODE [CA357] 1021
FAILURE CODE [CA386] 1023
FAILURE CODE [CA428] 1024
FAILURE CODE [CA429] 1026
FAILURE CODE [CA435] 1028
FAILURE CODE [CA441] 1030
FAILURE CODE [CA442] 1032
FAILURE CODE [CA449] 1033
FAILURE CODE [CA451] 1037
FAILURE CODE [CA452] 1040
FAILURE CODE [CA488] 1042
FAILURE CODE [CA515] 1043
FAILURE CODE [CA516] 1045
FAILURE CODE [CA553] 1047
FAILURE CODE [CA555] 1048
FAILURE CODE [CA556] 1049
FAILURE CODE [CA559] 1050
FAILURE CODE [CA595] 1054
FAILURE CODE [CA687] 1055
FAILURE CODE [CA689] 1057
FAILURE CODE [CA691] 1062
FAILURE CODE [CA692] 1064
FAILURE CODE [CA697] 1066
FAILURE CODE [CA698] 1067
FAILURE CODE [CA731] 1068
FAILURE CODE [CA778] 1070
FAILURE CODE [CA1117] 1075
FAILURE CODE [CA1664] 1076
FAILURE CODE [CA1669] 1078
FAILURE CODE [CA1673] 1079
FAILURE CODE [CA1677] 1080
FAILURE CODE [CA1678] 1081
FAILURE CODE [CA1682] 1082
FAILURE CODE [CA1683] 1084
FAILURE CODE [CA1684] 1086
FAILURE CODE [CA1686] 1088
FAILURE CODE [CA1691] 1089
FAILURE CODE [CA1694] 1092
FAILURE CODE [CA1695] 1095
FAILURE CODE [CA1696] 1096
FAILURE CODE [CA1712] 1098
FAILURE CODE [CA1713] 1101
FAILURE CODE [CA1714] 1103
FAILURE CODE [CA1715] 1104
FAILURE CODE [CA1776] 1105
FAILURE CODE [CA1777] 1108
FAILURE CODE [CA1843] 1111
FAILURE CODE [CA1844] 1113
FAILURE CODE [CA1879] 1116
FAILURE CODE [CA1881] 1119
FAILURE CODE [CA1883] 1121
FAILURE CODE [CA1885] 1124
FAILURE CODE [CA1887] 1126
FAILURE CODE [CA1921] 1128
FAILURE CODE [CA1922] 1131
FAILURE CODE [CA1942] 1136
FAILURE CODE [CA1993] 1137
FAILURE CODE [CA2185] 1140
FAILURE CODE [CA2186] 1142
FAILURE CODE [CA2249] 1144
FAILURE CODE [CA2265] 1145
FAILURE CODE [CA2266] 1147
FAILURE CODE [CA2271] 1149
FAILURE CODE [CA2272] 1152
FAILURE CODE [CA2288] 1155
FAILURE CODE [CA2311] 1156
FAILURE CODE [CA2349] 1157
FAILURE CODE [CA2353] 1160
FAILURE CODE [CA2357] 1162
FAILURE CODE [CA2381] 1163
FAILURE CODE [CA2382] 1166
FAILURE CODE [CA2383] 1169
FAILURE CODE [CA2386] 1172
FAILURE CODE [CA2387] 1174
FAILURE CODE [CA2555] 1175
FAILURE CODE [CA2556] 1178
FAILURE CODE [CA2637] 1181
FAILURE CODE [CA2639] 1183
FAILURE CODE [CA2771] 1186
FAILURE CODE [CA2777] 1192
FAILURE CODE [CA2976] 1195
FAILURE CODE [CA3133] 1197
FAILURE CODE [CA3134] 1199
FAILURE CODE [CA3135] 1201
FAILURE CODE [CA3142] 1204
FAILURE CODE [CA3143] 1205
FAILURE CODE [CA3144] 1206
FAILURE CODE [CA3146] 1208
FAILURE CODE [CA3147] 1209
FAILURE CODE [CA3148] 1210
FAILURE CODE [CA3151] 1212
FAILURE CODE [CA3165] 1218
FAILURE CODE [CA3229] 1220
FAILURE CODE [CA3231] 1222
FAILURE CODE [CA3232] 1224
FAILURE CODE [CA3235] 1228
FAILURE CODE [CA3239] 1230
FAILURE CODE [CA3241] 1233
FAILURE CODE [CA3242] 1236
FAILURE CODE [CA3251] 1239
FAILURE CODE [CA3253] 1241
FAILURE CODE [CA3254] 1244
FAILURE CODE [CA3255] 1247
FAILURE CODE [CA3256] 1251
FAILURE CODE [CA3311] 1253
FAILURE CODE [CA3312] 1255
FAILURE CODE [CA3313] 1258
FAILURE CODE [CA3314] 1259
FAILURE CODE [CA3315] 1260
FAILURE CODE [CA3316] 1262
FAILURE CODE [CA3317] 1263
FAILURE CODE [CA3318] 1264
FAILURE CODE [CA3319] 1266
FAILURE CODE [CA3321] 1267
FAILURE CODE [CA3322] 1269
FAILURE CODE [CA3419] 1271
FAILURE CODE [CA3421] 1273
FAILURE CODE [CA3497] 1275
FAILURE CODE [CA3498] 1276
FAILURE CODE [CA3543] 1277
FAILURE CODE [CA3545] 1283
FAILURE CODE [CA3547] 1285
FAILURE CODE [CA3558] 1286
FAILURE CODE [CA3559] 1288
FAILURE CODE [CA3562] 1290
FAILURE CODE [CA3563] 1292
FAILURE CODE [CA3567] 1295
FAILURE CODE [CA3568] 1298
FAILURE CODE [CA3571] 1302
FAILURE CODE [CA3572] 1304
FAILURE CODE [CA3574] 1306
FAILURE CODE [CA3575] 1308
FAILURE CODE [CA3577] 1310
FAILURE CODE [CA3578] 1312
FAILURE CODE [CA3582] 1314
FAILURE CODE [CA3583] 1320
FAILURE CODE [CA3596] 1322
FAILURE CODE [CA3649] 1324
FAILURE CODE [CA3681] 1326
FAILURE CODE [CA3682] 1331
FAILURE CODE [CA3713] 1337
FAILURE CODE [CA3717] 1340
FAILURE CODE [CA3718] 1341
FAILURE CODE [CA3725] 1342
FAILURE CODE [CA3741] 1345
FAILURE CODE [CA3748] 1346
FAILURE CODE [CA3751] 1348
FAILURE CODE [CA3755] 1350
FAILURE CODE [CA3866] 1352
FAILURE CODE [CA3867] 1355
FAILURE CODE [CA3868] 1358
FAILURE CODE [CA3899] 1362
FAILURE CODE [CA3911] 1364
FAILURE CODE [CA3912] 1368
FAILURE CODE [CA3932] 1370
FAILURE CODE [CA3933] 1372
FAILURE CODE [CA3934] 1374
FAILURE CODE [CA3935] 1377
FAILURE CODE [CA3936] 1379
FAILURE CODE [CA4151] 1381
FAILURE CODE [CA4152] 1385
FAILURE CODE [CA4155] 1389
FAILURE CODE [CA4156] 1391
FAILURE CODE [CA4157] 1394
FAILURE CODE [CA4158] 1396
FAILURE CODE [CA4159] 1397
FAILURE CODE [CA4161] 1398
FAILURE CODE [CA4162] 1401
FAILURE CODE [CA4163] 1404
FAILURE CODE [CA4164] 1406
FAILURE CODE [CA4165] 1408
FAILURE CODE [CA4166] 1410
FAILURE CODE [CA4168] 1412
FAILURE CODE [CA4169] 1415
FAILURE CODE [CA4171] 1417
FAILURE CODE [CA4249] 1420
FAILURE CODE [CA4251] 1422
FAILURE CODE [CA4259] 1424
FAILURE CODE [CA4261] 1427
FAILURE CODE [CA4277] 1430
FAILURE CODE [CA4281] 1433
FAILURE CODE [CA4459] 1436
FAILURE CODE [CA4461] 1439
FAILURE CODE [CA4658] 1442
FAILURE CODE [CA4731] 1446
FAILURE CODE [CA4732] 1447
FAILURE CODE [CA4739] 1448
FAILURE CODE [CA4768] 1449
FAILURE CODE [CA4769] 1451
FAILURE CODE [CA4842] 1454
FAILURE CODE [CA4952] 1457
FAILURE CODE [CA5115] 1459
FAILURE CODE [CA5179] 1462
FAILURE CODE [CA5181] 1464
FAILURE CODE [CA5383] 1466
FAILURE CODE [D110KB] 1468
FAILURE CODE [D19JKZ] 1470
FAILURE CODE [D811MC] 1473
FAILURE CODE [D862KA] 1474
FAILURE CODE [D8ALKA] 1475
FAILURE CODE [D8ALKB] 1477
FAILURE CODE [D8AQKR] 1479
FAILURE CODE [DA20MC] 1481
FAILURE CODE [DA22KK] 1482
FAILURE CODE [DA25KP] 1485
FAILURE CODE [DA29KQ] 1488
FAILURE CODE [DA2LKA] 1490
FAILURE CODE [DA2LKB] 1492
FAILURE CODE [DA2QKR] 1494
FAILURE CODE [DA2RKR] 1497
FAILURE CODE [DAF0MB] 1498
FAILURE CODE [DAF0MC] 1499
FAILURE CODE [DAF8KB] 1500
FAILURE CODE [DAF9KQ] 1502
FAILURE CODE [DAFGMC] 1503
FAILURE CODE [DAFLKA] 1504
FAILURE CODE [DAFLKB] 1506
FAILURE CODE [DAFQKR] 1508
FAILURE CODE [DAZ9KQ] 1509
FAILURE CODE [DAZQKR] 1510
FAILURE CODE [DB2QKR] 1515
FAILURE CODE [DB2RKR] 1520
FAILURE CODE [DDNRKA] 1525
FAILURE CODE [DDNRKY] 1527
FAILURE CODE [DDNS00] 1529
FAILURE CODE [DGH2KB] 1531
FAILURE CODE [DHA4KA] 1533
FAILURE CODE [DHAAMA] 1535
FAILURE CODE [DHACMA] 1537
FAILURE CODE [DHPAMA] 1539
FAILURE CODE [DHPBMA] 1542
FAILURE CODE [DHS3MA] 1545
FAILURE CODE [DHS4MA] 1548
FAILURE CODE [DHS8MA] 1551
FAILURE CODE [DHS9MA] 1554
FAILURE CODE [DHSAMA] 1557
FAILURE CODE [DHSBMA] 1560
FAILURE CODE [DHSCMA] 1563
FAILURE CODE [DHSDMA] 1566
FAILURE CODE [DHSFMA] 1569
FAILURE CODE [DHSGMA] 1572
FAILURE CODE [DHSHMA] 1575
FAILURE CODE [DHSJMA] 1578
FAILURE CODE [DKR0MA] 1581
FAILURE CODE [DKR1MA] 1584
FAILURE CODE [DKULKA] 1587
FAILURE CODE [DKULKB] 1589
FAILURE CODE [DKULKY] 1591
FAILURE CODE [DR21KX] 1592
FAILURE CODE [DR31KX] 1594
FAILURE CODE [DV20KB] 1596
FAILURE CODE [DW43KA] 1598
FAILURE CODE [DW43KB] 1600
FAILURE CODE [DW43KY] 1602
FAILURE CODE [DW45KA] 1604
FAILURE CODE [DW45KB] 1607
FAILURE CODE [DW45KY] 1610
FAILURE CODE [DW4CKY] 1612
FAILURE CODE [DW91KA] 1613
FAILURE CODE [DW91KB] 1615
FAILURE CODE [DW91KY] 1617
FAILURE CODE [DWA2KA] 1619
FAILURE CODE [DWA2KB] 1621
FAILURE CODE [DWA2KY] 1623
FAILURE CODE [DWK0KA] 1625
FAILURE CODE [DWK0KB] 1627
FAILURE CODE [DWK0KY] 1629
FAILURE CODE [DWK2KA] 1631
FAILURE CODE [DWK2KB] 1633
FAILURE CODE [DWK2KY] 1635
FAILURE CODE [DWK8KA] 1637
FAILURE CODE [DWK8KB] 1639
FAILURE CODE [DWK8KY] 1641
FAILURE CODE [DXA8KA] 1643
FAILURE CODE [DXA8KB] 1646
FAILURE CODE [DXA9KA] 1648
FAILURE CODE [DXA9KB] 1651
FAILURE CODE [DXE0KA] 1653
FAILURE CODE [DXE0KB] 1655
FAILURE CODE [DXE4KA] 1657
FAILURE CODE [DXE4KB] 1659
FAILURE CODE [DXE4KY] 1661
FAILURE CODE [DXE5KA] 1662
FAILURE CODE [DXE5KB] 1664
FAILURE CODE [DXE6KA] 1666
FAILURE CODE [DXE6KB] 1668
FAILURE CODE [DXE7KA] 1670
FAILURE CODE [DXE7KB] 1672
FAILURE CODE [DXE7KY] 1674
FAILURE CODE [DXE8KA] 1676
FAILURE CODE [DXE8KB] 1678
FAILURE CODE [DXE8KY] 1680
FAILURE CODE [DXE9KA] 1682
FAILURE CODE [DXE9KB] 1684
FAILURE CODE [DXE9KY] 1686
FAILURE CODE [DXEAKA] 1688
FAILURE CODE [DXEAKB] 1690
FAILURE CODE [DXEAKY] 1692
FAILURE CODE [DY20KA] 1694
FAILURE CODE [DY20MA] 1697
FAILURE CODE [DY2CKB] 1699
FAILURE CODE [DY2DKB] 1702
FAILURE CODE [DY2EKB] 1704
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 1706
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 1706
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1712
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 1715
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 1717
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 1719
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1722
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1723
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1724
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1725
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 1726
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1727
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1728
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1729
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1730
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1731
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1732
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1733
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 1735
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1736
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1737
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1738
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE 1740
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 1741
E-24 FUNCTION SWITCH DOES NOT OPERATE 1742
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) 1743
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1744
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1745
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED 1746
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1747
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE 1748
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1749
E-32 ALARM BUZZER CANNOT BE CANCELED 1751
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 1752
E-34 SERVICE MODE CANNOT BE SELECTED 1753
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1754
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 1756
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING 1757
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE 1760
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR 1762
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED 1764
E-41 ALARM DOES NOT SOUND DURING TRAVEL 1765
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1767
E-43 HORN DOES NOT SOUND 1768
E-44 HORN DOES NOT STOP SOUNDING 1772
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF 1774
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 1775
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1777
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1778
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1779
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1780
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1781
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1782
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1783
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1784
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1785
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1786
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED 1788
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 1789
E-59 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED 1790
E-60 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1792
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 1793
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 1793
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1794
FAILURE MODE AND CAUSE TABLE 1796
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1805
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER 1806
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1809
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 1810
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1811
H-6 SPEED OR POWER OF BOOM IS LOW 1813
H-7 ARM SPEED OR POWER IS LOW 1819
H-8 BUCKET SPEED OR POWER IS LOW 1824
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1827
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE 1828
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1830
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE 1832
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 1833
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1834
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE 1835
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1836
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED 1837
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 1838
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1839
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1840
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1841
H-22 MACHINE DOES NOT TRAVEL STRAIGHT 1842
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 1844
H-24 TRAVEL SPEED IS LOW 1847
H-25 ONE OF TRACKS DOES NOT RUN 1849
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 1851
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 1852
H-28 SWINGS ONLY IN ONE DIRECTION 1853
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 1854
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 1855
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 1856
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 1857
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 1858
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 1859
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 1860
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 1861
TROUBLESHOOTING OF ENGINE (S-MODE) 1862
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 1862
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 1863
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 1864
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 1865
S-4 ENGINE STARTABILITY IS POOR 1867
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 1869
S-6 ENGINE STOPS DURING OPERATION 1871
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 1873
S-8 ENGINE LACKS POWER 1874
S-9 KDPF GETS CLOGGED IN A SHORT TIME 1876
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 1878
S-11 OIL BECOMES CONTAMINATED QUICKLY 1879
S-12 FUEL CONSUMPTION IS EXCESSIVE 1880
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 1881
S-14 OIL PRESSURE DROPS 1882
S-15 FUEL MIXES INTO ENGINE OIL 1884
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 1885
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 1886
S-18 UNUSUAL NOISE IS HEARD 1887
S-19 VIBRATION IS EXCESSIVE 1888
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 1889
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 1890
S-22 ACTIVE REGENERATION TAKES TIME 1892
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 1893
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 1894
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 1896
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 1897
50 DISASSEMBLY AND ASSEMBLY 1899
CONTENTS 1900
ABBREVIATION LIST 1905
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 1911
HOW TO READ THIS MANUAL 1911
COATING MATERIALS LIST 1913
SPECIAL TOOLS LIST 1917
SKETCHES OF SPECIAL TOOLS 1932
ENGINE AND COOLING SYSTEM 1940
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 1940
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 1940
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 1945
REMOVE AND INSTALL INJECTOR ASSEMBLY 1953
METHOD FOR REMOVING INJECTOR ASSEMBLY 1953
METHOD FOR INSTALLING INJECTOR ASSEMBLY 1960
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 1972
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 1973
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 1982
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2000
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2000
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2001
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2003
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2003
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2004
REMOVE AND INSTALL STARTER ASSEMBLY 2007
METHOD FOR REMOVING STARTER ASSEMBLY 2007
METHOD FOR INSTALLING STARTER ASSEMBLY 2008
REMOVE AND INSTALL ALTERNATOR BELT 2009
METHOD FOR REMOVING ALTERNATOR BELT 2009
METHOD FOR INSTALLING ALTERNATOR BELT 2012
REMOVE AND INSTALL RADIATOR ASSEMBLY 2015
METHOD FOR REMOVING RADIATOR ASSEMBLY 2015
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2017
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2019
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2019
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2021
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2024
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2024
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2025
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2027
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY 2028
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY 2039
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2054
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2054
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2058
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2062
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2063
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2064
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2071
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2071
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2072
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2075
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2075
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2079
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2082
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2082
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2088
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2094
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2094
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2100
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2105
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2105
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2105
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2107
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2107
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2107
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2108
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2108
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2110
REMOVE AND INSTALL KDPF ASSEMBLY 2113
METHOD FOR REMOVING KDPF ASSEMBLY 2113
METHOD FOR INSTALLING KDPF ASSEMBLY 2116
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2120
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2121
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2124
REMOVE AND INSTALL SCR ASSEMBLY 2129
METHOD FOR REMOVING SCR ASSEMBLY 2129
METHOD FOR INSTALLING SCR ASSEMBLY 2132
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2135
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2136
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2142
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET 2149
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2149
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2152
REMOVE AND INSTALL KCCV ASSEMBLY 2157
METHOD FOR REMOVING KCCV ASSEMBLY 2157
METHOD FOR INSTALLING KCCV ASSEMBLY 2158
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2160
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2161
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2164
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2168
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2168
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2171
REMOVE AND INSTALL AdBlue/DEF PUMP 2175
METHOD FOR REMOVING AdBlue/DEF PUMP 2175
METHOD FOR INSTALLING AdBlue/DEF PUMP 2178
REMOVE AND INSTALL AdBlue/DEF HOSE 2180
METHOD FOR REMOVING AdBlue/DEF HOSE 2181
METHOD FOR INSTALLING AdBlue/DEF HOSE 2187
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2195
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2195
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2197
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2199
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2199
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2200
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2202
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2202
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2203
POWER TRAIN 2204
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2204
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2204
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2205
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2207
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2208
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2212
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 2220
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2220
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2221
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 2223
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 2223
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2226
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2233
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 2233
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 2233
UNDERCARRIAGE AND FRAME 2235
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 2235
METHOD FOR SEPARATING TRACK ASSEMBLY 2235
METHOD FOR INSTALLING TRACK ASSEMBLY 2237
REMOVE AND INSTALL SPROCKET 2240
METHOD FOR REMOVING SPROCKET 2240
METHOD FOR INSTALLING SPROCKET 2240
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 2242
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2242
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2243
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2244
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2244
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2245
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2249
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY 2249
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2250
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2252
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2253
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2254
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 2256
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2256
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2257
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 2260
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2260
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2262
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 2265
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2265
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2266
HYDRAULIC SYSTEM 2269
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 2269
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2269
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2270
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 2273
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2274
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2275
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2276
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2276
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2279
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 2283
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2283
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2286
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2289
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2289
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2296
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 2303
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2304
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2305
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2310
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2310
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2311
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2313
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2313
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2314
WORK EQUIPMENT 2316
REMOVE AND INSTALL BUCKET ASSEMBLY 2316
METHOD FOR REMOVING BUCKET ASSEMBLY 2316
METHOD FOR INSTALLING BUCKET ASSEMBLY 2316
REMOVE AND INSTALL ARM ASSEMBLY 2318
METHOD FOR REMOVING ARM ASSEMBLY 2318
METHOD FOR INSTALLING ARM ASSEMBLY 2319
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2321
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 2321
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 2324
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR BOOM 2327
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR BOOM 2327
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR BOOM 2329
REMOVE AND INSTALL ANTI-DROP VALVE ASSEMBLY FOR ARM 2330
METHOD FOR REMOVING ANTI-DROP VALVE ASSEMBLY FOR ARM 2330
METHOD FOR INSTALLING ANTI-DROP VALVE ASSEMBLY FOR ARM 2332
DISASSEMBLE AND ASSEMBLE ANTI-DROP VALVE ASSEMBLY 2333
METHOD FOR DISASSEMBLING ANTI-DROP VALVE ASSEMBLY 2333
METHOD FOR ASSEMBLING ANTI-DROP VALVE ASSEMBLY 2333
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 2334
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2334
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2337
CAB AND ITS ATTACHMENTS 2344
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2344
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY 2344
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY 2350
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 2357
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2359
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2359
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2369
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 2369
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 2372
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 2378
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2379
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2385
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2393
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2393
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2398
REMOVE AND INSTALL OPERATOR’S SEAT 2404
METHOD FOR REMOVING OPERATOR’S SEAT 2404
METHOD FOR INSTALLING OPERATOR’S SEAT 2406
REMOVE AND INSTALL SEAT BELT 2409
METHOD FOR REMOVING SEAT BELT 2409
METHOD FOR INSTALLING SEAT BELT 2410
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 2411
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2411
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2416
ELECTRICAL SYSTEM 2425
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2425
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2425
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2427
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 2431
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2431
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2434
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2438
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2438
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2441
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2445
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR 2445
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR 2445
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2447
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2447
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2448
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2449
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2449
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2450
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2451
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2451
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2452
REMOVE AND INSTALL REARVIEW CAMERA 2454
METHOD FOR REMOVING REARVIEW CAMERA 2454
METHOD FOR INSTALLING REARVIEW CAMERA 2455
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2457
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY 2457
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY 2460
60 MAINTENANCE STANDARD 2463
CONTENTS 2464
ABBREVIATION LIST 2465
ENGINE AND COOLING SYSTEM 2471
MAINTENANCE STANDARD OF ENGINE MOUNT 2471
MAINTENANCE STANDARD OF COOLING SYSTEM 2473
POWER TRAIN 2475
MAINTENANCE STANDARD OF SWING CIRCLE 2475
MAINTENANCE STANDARD OF SWING MACHINERY 2476
MAINTENANCE STANDARD OF FINAL DRIVE 2478
MAINTENANCE STANDARD OF SPROCKET 2480
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING 2481
UNDERCARRIAGE AND FRAME 2483
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2483
MAINTENANCE STANDARD OF IDLER 2485
MAINTENANCE STANDARD OF TRACK ROLLER 2487
MAINTENANCE STANDARD OF CARRIER ROLLER 2489
MAINTENANCE STANDARD OF TRACK SHOE 2490
MAINTENANCE STANDARD OF TRIPLE SHOE 2493
HYDRAULIC SYSTEM 2494
MAINTENANCE STANDARD OF HYDRAULIC TANK 2494
MAINTENANCE STANDARD OF MAIN PUMP 2495
MAINTENANCE STANDARD OF SWING MOTOR 2497
MAINTENANCE STANDARD OF TRAVEL MOTOR 2500
MAINTENANCE STANDARD OF CONTROL VALVE 2503
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR BOOM 2513
MAINTENANCE STANDARD OF ANTI-DROP VALVE FOR ARM 2515
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2517
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2520
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2523
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2525
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE 2526
MAINTENANCE STANDARD OF SOLENOID VALVE 2528
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE 2529
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 2530
WORK EQUIPMENT 2531
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2531
DIMENSION OF ARM 2536
DIMENSIONS OF BUCKET 2538
MAINTENANCE STANDARD OF BOOM CYLINDER 2540
MAINTENANCE STANDARD OF ARM CYLINDER 2541
MAINTENANCE STANDARD OF BUCKET CYLINDER 2542
80 APPENDIX 2543
CONTENTS 2544
ABBREVIATION LIST 2546
AIR CONDITIONER SYSTEM 2552
PRECAUTIONS FOR REFRIGERANT 2552
AIR CONDITIONER COMPONENT 2553
SPECIFICATIONS OF AIR CONDITIONER 2555
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2556
OUTLINE OF REFRIGERATION CYCLE 2557
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2559
AIR CONDITIONER UNIT 2559
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2559
FUNCTION OF AIR CONDITIONER UNIT 2561
COMPONENT PARTS OF AIR CONDITIONER UNIT 2563
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2564
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2564
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 2564
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 2564
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2565
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2565
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2565
FUNCTION OF DUAL PRESSURE SWITCH 2566
AIR CONDITIONER CONTROLLER 2567
STRUCTURE OF AIR CONDITIONER CONTROLLER 2567
COMPRESSOR 2568
STRUCTURE OF COMPRESSOR 2568
SPECIFICATIONS OF COMPRESSOR 2568
FUNCTION OF COMPRESSOR 2568
CONDENSER 2569
STRUCTURE OF CONDENSER 2569
SPECIFICATIONS OF CONDENSER 2569
FUNCTION OF CONDENSER 2569
RECEIVER DRIER 2570
STRUCTURE OF RECEIVER DRIER 2570
SPECIFICATIONS OF RECEIVER DRIER 2570
FUNCTION OF RECEIVER DRIER 2570
SENSORS FOR AIR CONDITIONER SYSTEM 2571
STRUCTURE OF SUNLIGHT SENSOR 2571
FUNCTION OF SUNLIGHT SENSOR 2571
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 2571
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2571
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2573
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 2575
AIR CONDITIONER SYSTEM DIAGRAM 2577
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2578
FUNCTION OF AIR CONDITIONER CONTROLLER 2579
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2580
TESTING AIR LEAKAGE (DUCT) 2584
METHOD FOR TESTING AIR LEAKAGE (DUCT) 2584
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 2586
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2587
TEST VENT (MODE) CHANGEOVER 2588
METHOD FOR TESTING VENT (MODE) CHANGEOVER 2588
TESTING FRESH/RECIRC AIR CHANGEOVER 2590
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2590
TEST SUNLIGHT SENSOR 2591
METHOD FOR TESTING SUNLIGHT SENSOR 2591
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2592
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2592
TEST RELAYS 2593
METHOD FOR TESTING RELAYS 2593
AIR CONDITIONER TROUBLESHOOTING CHART 1 2594
AIR CONDITIONER TROUBLESHOOTING CHART 2 2595
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2598
FAILURE CODE [879AKA] 2600
FAILURE CODE [879AKB] 2601
FAILURE CODE [879BKA] 2602
FAILURE CODE [879BKB] 2604
FAILURE CODE [879CKA] 2606
FAILURE CODE [879CKB] 2607
FAILURE CODE [879DKZ] 2608
FAILURE CODE [879EMC] 2610
FAILURE CODE [879FMC] 2611
FAILURE CODE [879GKX] 2612
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2614
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 2616
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2619
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 2621
TROUBLESHOOTING USING GAUGE PRESSURE 2623
CONNECTION OF SERVICE TOOL 2626
METHOD FOR CONNECTING SERVICE TOOL 2626
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 2628
HANDLE COMPRESSOR OIL 2630
90 CIRCUIT DIAGRAMS 2633
CONTENTS 2634
ABBREVIATION LIST 2635
HYDRAULIC CIRCUIT DIAGRAM 2641
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 2641
HYDRAULIC CIRCUIT DIAGRAM 2645
ELECTRICAL CIRCUIT DIAGRAM 2646
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2646
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(1/11) 2650
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(2/11) 2651
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(3/11) 2652
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(4/11) 2653
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(5/11) 2654
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(6/11) 2655
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(7/11) 2656
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(8/11) 2657
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(9/11) 2658
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(10/11) 2659
ELECTRICAL CIRCUIT DIAGRAM (FOR OCEANIA)(11/11) 2660
INDEX 2661

DESCRIPTION:

Komatsu PC360LC-11 Hydraulic Excavator Shop Manual SEN06699-00 – PDF DOWNLOAD 

SERIAL NUMBERS 90001 and up

Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams.

IMAGES PREVIEW OF THE MANUAL:

S.V 28/12/24