Komatsu PC360LC-11 Hydraulic Excavator Shop Manual SEN06739-08 PDF

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Komatsu PC360LC-11 Hydraulic Excavator Shop Manual SEN06739-08  – PDF DOWNLOAD

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Komatsu PC360LC-11 Hydraulic Excavator Shop Manual SEN06739-08  – PDF DOWNLOAD

Language : English
Pages : 2960
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu PC360LC-11 Hydraulic Excavator Shop Manual SEN06739-08  – PDF DOWNLOAD

• SERIAL NUMBERS 91005 and up

Cover . 1
00 Index and Foreword 3
Index 4
Abbreviation List 21
Foreword, Safety, Basic Information 24
How to Read the Shop Manual 24
Safety Notice for Operation 26
Precautions to Prevent Fire 34
Procedures If Fire Occurs 36
Precautions for Disposing of Waste Materials . 37
Procedures for Exhaust Gas Regulations . 38
Precautions for DEF 39
General Character and Precautions for Handling . 39
Precautions for Adding . 39
Precautions for Storage 39
Precautions for Fire Hazard and Leakage 39
Other Precautions 39
Store DEF 40
Precautions When You Handle Hydraulic Equipment 41
Precautions When You Disconnect and Connect Pipings 44
Precautions When You Handle Electrical Equipment . 51
Precautions When You Handle Fuel System Equipment 53
Precautions When You Handle Intake System Equipment 54
Practical Use of KOMTRAX . 55
Disconnect and Connect Push-Pull Type Coupler 56
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 56
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 57
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 58
Precautions for Disconnection and Connection of Connectors . 60
How to Disconnect and Connect Deutsch Connector 64
How to Disconnect and Connect Slide Lock Type Connector 65
How to Disconnect and Connect Connector with Lock to Pull 67
How to Disconnect and Connect Connector with Lock to Push 68
How to Disconnect and Connect Connector with Housing to Rotate . 70
How to Read the Codes for Electric Cable . 71
Explanation of Terms for Maintenance Standard 75
Standard Tightening Torque Table . 78
Conversion Table . 85
01 Specifications 91
Table of Contents 92
Specifications . 93
Specification Drawing 93
Specification Drawing: PC360LC-11 93
Working Range Drawings . 95
Working Range: PC360LC-11 95
Specifications . 96
Specifications: PC360LC-11 . 96
Weight Table . 99
Weight Table: PC360LC-11 . 99
Table of Fuel, Coolant, and Lubricants . 101
10 Structure and Function 103
Table of Contents 104
Urea SCR System 107
Layout Drawing of Urea SCR System (Applicable Machine: 90156 to 92053) . 107
Layout Drawing of Urea SCR System (Applicable Machine: 92054 and up) . 112
Urea SCR System Diagram 116
Function of Urea SCR System 117
Function of DEF System (Applicable Machine: 90156 to 92053) 117
Function of DEF System (Applicable Machine: 92054 and Up) 119
Inducement Strategy 121
Component Parts of Urea SCR System . 135
DEF Mixing Tube 135
SCR Assembly . 135
DEF Tank . 138
DEF Pump . 140
DEF Injector . 142
DEF Hose . 143
DEF Tank Heating Valve . 144
Boot-up System . 145
Layout Drawing of Boot-up System . 145
System Operating Lamp System . 147
System Diagram of System Operating Lamp System . 147
Function of Operation Lamp System 147
Operation of System Operating Lamp System 147
Battery Disconnect Switch 148
Function of Battery Disconnect Switch 148
Engine System 149
Layout Drawing of Engine System 149
Specifications of Engine System 150
Function of Engine System 150
Engine Control System 151
System Diagram of Engine Control . 151
Operation of Engine Control System . 152
Auto-Deceleration System . 154
System Diagram of Auto-Deceleration System . 154
Function of Auto-Deceleration System . 154
Operation of Auto-Deceleration System 155
Engine Automatic Warm-up System 156
System Diagram of Engine Automatic Warm-up System 156
Function of Engine Automatic Warm-up System 157
Overheat Prevention System . 158
Overheat Prevention System Diagram . 158
Function of Overheat Prevention System . 159
Turbocharger Protection System . 160
System Diagram of Turbocharger Protection System . 160
Function of Turbocharger Protection System . 161
Automatic Idle Stop System . 162
System Diagram of Automatic Idle Stop System . 162
Function of Automatic Idle Stop System . 162
Operation of Automatic Idle Stop System 162
Component Parts of Engine System . 165
VGT 165
EGR System . 168
EGR Valve 170
EGR Cooler . 172
KCCV System 173
KCCV Ventilator 175
KDPF . 176
Cooling System . 181
Layout Drawing of Cooling System . 181
Specifications of Cooling System . 182
Control System . 183
Layout Drawing of Control System . 183
Machine Monitor System . 186
System Diagram of Machine Monitor System . 186
Function of Machine Monitor System . 187
KomVision System . 188
Layout Drawing of KomVision System . 188
System Diagram of KomVision System . 190
Function of KomVision System . 190
KOMTRAX System . 192
System Diagram of KOMTRAX System . 192
Function of KOMTRAX System . 192
Component Parts of Control System 193
Machine Monitor 193
KomVision Camera . 207
Gateway Function Controller 208
Communication Terminal . 211
Pump Controller 213
Resistor for PC-EPC Valve 217
CAN Terminating Resistor . 217
Engine Controller 219
Fuel Control Dial 225
Hydraulic System . 227
Layout Drawing of Hydraulic System . 227
CLSS . 230
Structure of CLSS 230
Operation of Unload Valve and LS Pressure 232
Pump Swash Plate Angle (Oil Flow) Control 233
Pressure Compensation Control 249
Engine and Pump Combined Control System 253
Engine and Pump Combined Control System Diagram 253
Function of Engine and Pump Combined Control System 254
Pump and Valve Control System 259
Pump and Valve Control System Diagram 259
Function of Pump and Valve Control System 260
Component Parts of Hydraulic System 262
Hydraulic Tank . 262
Main Pump 265
Control Valve 291
Work Equipment System 351
Layout Drawing of Work Equipment System 351
Structure of Valve Control . 357
One-Touch Power Maximizing System 359
System Diagram of One-Touch Power Maximizing System 359
Function of One-Touch Power Maximizing System 360
Machine Push-up System . 361
Machine Push-up System Diagram . 361
Function of Machine Push-up System . 362
PPC Lock System 363
System Diagram of PPC Lock . 363
Function of PPC Lock System 363
Work Equipment and Travel Automatic Lock System 364
System Diagram of Lock Lever Automatic Lock System . 364
Function of Work Equipment and Travel Automatic Lock System 364
Operation of Lock Lever Automatic Lock System 365
Attachment Oil Flow Adjuster System 366
Attachment Oil Flow Adjuster System Diagram 366
Function of Attachment Oil Flow Adjuster System 367
Tool Control System 368
Tool Control System Diagram 368
Function of Tool Control System 369
Component Parts of Work Equipment System . 370
Work Equipment and Swing PPC Valve . 370
1st-Line Attachment PPC Valve (with EPC Valve) . 376
2nd-Line Attachment PPC Valve 380
Solenoid Valve . 382
Boom Anti-drop Valve . 385
Arm Anti-Drop Valve 389
Attachment Circuit Selector Valve (For High Pressure) 393
Attachment Circuit Selector Valve (For Low Pressure) . 395
1st-Line Attachment Variable Relief Valve 398
Attachment Bypass Solenoid Valve . 401
Pilot Circuit Accumulator 402
Swing System . 403
Layout Drawing of Swing System . 403
Swing Control System Diagram . 406
Function of Swing Control System . 406
Component Parts of Swing System 410
Swing Motor 410
Swing Machinery 421
Swing Circle . 423
Travel System 424
Layout Drawing of Travel System 424
System Diagram of Travel Control System 428
Function of Travel Control System 428
Component Parts of Travel System . 430
Travel Motor . 430
Final Drive 442
Travel PPC Valve . 443
Center Swivel Joint 448
Undercarriage and Frame 450
Layout Drawing of Undercarriage 450
Specifications of Undercarriage 450
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 Related Parts 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
Table of Contents 460
Standard Value Table for Engine 461
Standard Value Table for Engine: PC360LC-11 461
Standard Value Table for Machine . 466
Standard Value Table for Machine: PC360LC-11 . 466
Machine Posture and Procedures to Measure Performance 481
Standard Value Table for Electricity . 485
Standard Value Table for Electricity . 485
30 Testing and Adjusting . 495
Table of Contents 496
Precautions Before Work 499
Related Information on Testing and Adjusting . 500
Tools for Testing and Adjusting 500
Sketch of Tools for Testing and Adjusting 507
Engine and Cooling System 509
Examine Engine Speed . 509
How to Examine Engine Speed 509
Examine Boost Pressure . 513
How to Examine Boost Pressure on Machine Monitor . 513
How to Examine Boost Pressure by Testing Tool 514
Examine Exhaust Gas Color 515
How to Examine Exhaust Gas Color with the Handy Smoke Checker 515
How to Examine Exhaust Gas Color with Smoke Meter 516
Examine Mass Air Flow and Temperature Sensor . 517
How to Examine Mass Air Flow and Temperature Sensor 517
Examine and Adjust Valve Clearance . 519
How to Examine Valve Clearance . 519
How to Adjust Valve Clearance 521
Examine Compression Pressure . 522
How to Examine Compression Pressure 522
Examine Blowby Pressure 525
How to Examine Blowby Pressure . 525
Examine Engine Oil Pressure 527
How to Examine Engine Oil Pressure . 527
Examine EGR Valve and VGT Oil Pressure . 529
How to Examine EGR Valve and VGT Oil Pressure 529
Examine Fuel Pressure 531
How to Examine Fuel Pressure . 532
Examine Fuel Discharge, Return and Leakage . 538
How to Examine Fuel Discharge, Return, and Leakage . 539
Bleed Air from Fuel System . 545
How to Bleed Air from Fuel System 545
Examine Fuel Circuit for Leakage . 546
How to Examine Fuel System for Leakage . 546
Handle Cylinder Cut-out Mode Operation . 548
Handle No-Injection Cranking Operation . 549
Examine and Adjust Air Conditioner Compressor Belt Tension . 550
How to Examine Air Conditioner Compressor Belt Tension . 550
How to Adjust Air Conditioner Compressor Belt Tension 550
How to Adjust Air Conditioner Compressor Belt 551
Examine Alternator Belt 552
How to Examine Alternator Belt . 552
Examine Automatic Tensioner 553
How to Examine Automatic Tensioner . 553
Write Correction for Ash in Soot Accumulation to Engine Controller . 554
How to Write Correction for Ash in Soot Accumulation to Engine Controller 554
Examine SCR Related Functions 555
Examine DEF Pump Raised Pressure . 558
Examine Injection Volume from DEF Injector . 561
Examine DEF Line Heater Relay 1 565
Examine DEF Line Heater Relay 2 570
Examine DEF Pump Heater Relay 572
Examine DEF Tank Heater Valve 575
Examine SCR Denitration Efficiency . 578
Clean DEF Tank . 582
How to Clean DEF Tank 582
Clean DEF Pump . 586
How to Clean DEF Pump 586
Power Train 592
Examine Swing Circle Bearing Clearance . 592
How to Examine Swing Circle Bearing Clearance 592
Undercarriage and Frame 593
Examine and Adjust Track Tension . 593
How to Examine Track Tension . 593
How to Adjust Track Tension 593
Hydraulic System . 595
Release Remained Pressure in Hydraulic Circuit . 595
How to Release Remained Pressure from Hydraulic Tank . 595
How to Release Remained Pressure in Hydraulic Cylinder Circuit . 595
How to Release Remained Pressure from Swing Motor Circuit 599
How to Release Remained Pressure from Travel Motor Circuit . 599
Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits 600
How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits 601
How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits . 609
Examine Oil Pressure of Control Circuit 612
How to Examine Oil Pressure in Control Circuit . 612
Examine and adjust oil pressure in pump PC control circuit . 614
Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure) . 614
Examine PC-EPC Valve Outlet Pressure . 615
How to Adjust Oil Pressure in Pump PC Control Circuit 616
Examine and Adjust Oil Pressure in Pump LS Control Circuit . 617
How to Examine LS Differential Pressure with Machine Monitor . 617
How to Examine LS Differential Pressure by Testing Tool 618
How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure) 620
How to Examine LS-EPC Valve Outlet Pressure 620
How to Adjust LS Valve . 621
Examine Outlet Pressure of Solenoid Valve 622
How to Examine Outlet Pressure of Solenoid Valve . 622
Operating Condition of Solenoid Valve 623
Examine PPC Valve Outlet Pressure 625
How to Examine Outlet Pressure in PPC Valve 625
Adjust Play of Work Equipment and Swing PPC Valves . 627
How to Adjust Play of Work Equipment and Swing PPC Valves 627
Examine Pump Swash Plate Sensor 628
How to Examine pump swash plate sensor . 628
Examine Parts Which Cause Hydraulic Drift of Work Equipment 629
How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder 629
How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder . 629
How to Examine Parts that Cause Hydraulic Drift of PPC Valve . 630
Examine Oil Leakage 631
How to Examine Oil Leakage from Boom Cylinder 631
How to Examine Oil Leakage from Arm Cylinder . 631
How to Examine Oil Leakage from Bucket Cylinder 632
How to Examine Oil Leakage from Swing Motor 632
How to Examine Oil Leakage from Travel Motor . 633
Bleed Air from Hydraulic System 634
How to Bleed Air from Hydraulic System . 636
Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 639
How to Examine Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side) 639
Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) . 643
How to Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side) . 643
Replace Accumulator Bladder on High Pressure Side for Attachment Piping 647
How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping . 647
CAB Related Parts 654
Examine CAB Tipping Stopper 654
How to Examine Cab Tipping Stopper . 654
How to Adjust Mirrors 655
Procedure to Adjust Machine Left Front Mirror (A) 655
Procedure to Adjust Regular Position of Machine Left Front Mirror (A) 656
Procedure to Adjust Machine Right Front Mirror (B) . 657
Procedure to Adjust Regular Position of Machine Right Front Mirror (B) . 658
Procedure to Adjust Machine Right Side Mirror (C) 659
Electrical System 661
Set and Operate Machine Monitor 661
Operator Mode 664
Function to Show Technician Identification Status Screen . 665
Function to Show Operator Identification Input Screen 665
Examine Function by LCD (Liquid Crystal Display) . 666
Examine Function of Service Meter 666
Usage Limitation and Maintenance Password Change Function 666
Service Mode . 669
How to Operate Service Mode 669
How to See Pre-defined Monitoring Information 671
How to Examine Self-Define Monitor Information . 678
Abnormality Record Menu 688
How to See Maintenance Record 693
Maintenance Mode Setting . 694
How to Set Phone Number Entry 698
Default Menu . 699
Diagnostic Tests Menu 711
Adjustment Menu 721
No-Injection Cranking Operation 738
KOMTRAX Settings Menu 739
How to Show Service Message 741
How to Start Up KOMTRAX System . 743
Adjust Rearview Camera Angle . 748
How to Adjust Rearview Camera Angle 748
Adjust KomVision Camera Angle 751
Adjust KomVision Related Function 753
Setting of KomVision (Main Setting) 753
Setting of KomVision (Camera Setting) 755
Setting of KomVision (Camera Calibration) 757
KomVision screen – Check 12 m visibility . 770
Set Region of Bluetooth(R) Compatible Radio 773
How to Set Region of Bluetooth(R) Compatible Radio . 773
Handle Voltage Circuit of Engine Controller 775
Handle Battery Disconnect Switch . 776
Examine Diodes . 777
How to Examine Diodes by Digital Tester 777
How to Examine Diodes by Analog Tester . 777
Pm Clinic 778
Pm Clinic Service 778
Pm Clinic Check Sheet 779
40 Troubleshooting . 797
Table of Contents 798
Precautions Before Work 809
Related Information to Troubleshooting . 810
General Troubleshooting Points . 810
Troubleshooting Points for Urea SCR System . 811
Sequence of Events in Troubleshooting 825
Checks Before Troubleshooting 827
Inspection Procedure Before Troubleshooting 829
Walk-Around Check 829
Test in Accordance with Testing Procedure 831
Examine Fuel Level and Type 831
Examine for Impure Ingredient in Fuel 831
Examine Fuel Prefilter . 832
Examine Water Separator, Drain Water and Sediment 832
How to Replace Fuel Prefilter Cartridge 833
Examine Fuel Main Filter . 834
Examine Engine Oil Level (Oil Quantity in Oil Pan) . 836
Examine Coolant Level (Expansion Tank) . 837
Examine Air Cleaner Clogging . 838
Clean Outer Element 838
Replace Element 841
Examine Hydraulic Oil Level 842
Examine Hydraulic Oil Strainer . 843
Examine Hydraulic Oil Filter . 844
Examine Oil Level in Swing Machinery Case 844
Examine Oil Level in Damper Case . 845
Examine Oil Level in Final Drive Case 846
Bleed Air from Fuel System . 846
Bleed Air from Hydraulic System 846
How to Examine Electric Equipment 846
Preparation for Troubleshooting of Electrical System . 851
Procedure for Troubleshooting 864
Symptom and Troubleshooting Numbers 867
Information Shown in Troubleshooting Table . 871
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 873
Connector List and Layout 876
Connector Contact Connection Table . 893
T-Branch Box and T-Branch Adapter Table 933
Fuse Location Table 939
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 941
Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135]) . 945
Failure Code Table . 947
Troubleshooting by Failure Code (Display of Code) 966
Failure Code [879AKA] 966
Failure Code [879AKB] 967
Failure Code [879BKA] 968
Failure Code [879BKB] 970
Failure Code [879CKA] 972
Failure Code [879CKB] 973
Failure Code [879DKZ] 974
Failure Code [879EMC] 976
Failure Code [879FMC] 977
Failure Code [879GKX] 978
Failure Code [989L00] 980
Failure Code [989M00] 981
Failure Code [989N00] 982
Failure Code [A1U0N3] 983
Failure Code [A1U0N4] 985
Failure Code [A900FR] 987
Failure Code [A900N6] 988
Failure Code [A900NY] 989
Failure Code [AA10NX] 990
Failure Code [AB00KE] 992
Failure Code [AQ10N3] 995
Failure Code [AS00N3] 997
Failure Code [AS00R2] 999
Failure Code [AS00R3] 1000
Failure Code [AS00R4] 1001
Failure Code [AS00R5] 1002
Failure Code [AS00R6] 1003
Failure Code [AS00ZK] 1004
Failure Code [AS10KM] 1005
Failure Code [AS10NR] 1006
Failure Code [AS10NT] 1007
Failure Code [B@BAZG] 1008
Failure Code [B@BAZK] 1009
Failure Code [B@BCNS] 1011
Failure Code [B@BCQA] 1012
Failure Code [B@BCZK] 1014
Failure Code [B@HANS] 1016
Failure Code [CA115] .1017
Failure Code [CA122] .1018
Failure Code [CA123] .1020
Failure Code [CA131] .1022
Failure Code [CA132] .1024
Failure Code [CA144] .1026
Failure Code [CA145] .1028
Failure Code [CA153] .1030
Failure Code [CA154] .1033
Failure Code [CA187] .1036
Failure Code [CA221] .1038
Failure Code [CA222] .1040
Failure Code [CA227] .1042
Failure Code [CA234] .1043
Failure Code [CA238] .1044
Failure Code [CA239] .1046
Failure Code [CA249] .1048
Failure Code [CA256] .1050
Failure Code [CA271] .1052
Failure Code [CA272] .1054
Failure Code [CA281] .1056
Failure Code [CA322] .1057
Failure Code [CA323] .1059
Failure Code [CA324] .1061
Failure Code [CA325] .1063
Failure Code [CA331] .1065
Failure Code [CA332] .1067
Failure Code [CA343] .1069
Failure Code [CA351] .1070
Failure Code [CA352] .1071
Failure Code [CA356] .1074
Failure Code [CA357] .1076
Failure Code [CA386] .1078
Failure Code [CA428] .1079
Failure Code [CA429] .1081
Failure Code [CA435] .1083
Failure Code [CA441] .1085
Failure Code [CA442] .1087
Failure Code [CA449] .1088
Failure Code [CA451] .1093
Failure Code [CA452] .1096
Failure Code [CA488] .1098
Failure Code [CA515] .1099
Failure Code [CA516] .1101
Failure Code [CA553] .1103
Failure Code [CA555] .1104
Failure Code [CA556] .1105
Failure Code [CA559] .1106
Failure Code [CA595] .1110
Failure Code [CA687] .1111
Failure Code [CA689] .1113
Failure Code [CA691] .1118
Failure Code [CA692] .1120
Failure Code [CA697] .1122
Failure Code [CA698] .1123
Failure Code [CA731] .1124
Failure Code [CA778] .1126
Failure Code [CA1117] 1131
Failure Code [CA1664] 1132
Failure Code [CA1669] 1134
Failure Code [CA1673] 1135
Failure Code [CA1677] 1136
Failure Code [CA1678] 1137
Failure Code [CA1682] 1138
Failure Code [CA1683] 1140
Failure Code [CA1684] 1142
Failure Code [CA1686] 1144
Failure Code [CA1691] 1145
Failure Code [CA1694] 1148
Failure Code [CA1695] 1151
Failure Code [CA1696] 1152
Failure Code [CA1712] 1154
Failure Code [CA1713] 1157
Failure Code [CA1714] 1159
Failure Code [CA1715] 1160
Failure Code [CA1776] 1161
Failure Code [CA1777] 1164
Failure Code [CA1843] 1167
Failure Code [CA1844] 1169
Failure Code [CA1879] 1172
Failure Code [CA1881] 1175
Failure Code [CA1883] 1177
Failure Code [CA1885] 1180
Failure Code [CA1887] 1182
Failure Code [CA1921] 1184
Failure Code [CA1922] 1187
Failure Code [CA1942] 1192
Failure Code [CA1993] 1193
Failure Code [CA2185] 1196
Failure Code [CA2186] 1198
Failure Code [CA2249] 1200
Failure Code [CA2265] 1201
Failure Code [CA2266] 1203
Failure Code [CA2271] 1205
Failure Code [CA2272] 1208
Failure Code [CA2288] 1211
Failure Code [CA2311] 1212
Failure Code [CA2349] 1213
Failure Code [CA2353] 1216
Failure Code [CA2357] 1218
Failure Code [CA2381] 1219
Failure Code [CA2382] 1222
Failure Code [CA2383] 1225
Failure Code [CA2386] 1228
Failure Code [CA2387] 1230
Troubleshooting Flowchart 1234
Failure Code [CA2555] 1235
Failure Code [CA2556] 1238
Failure Code [CA2637] 1241
Failure Code [CA2639] 1243
Failure Code [CA2771] 1246
Failure Code [CA2777] 1252
Failure Code [CA2976] 1255
Failure Code [CA3133] 1257
Failure Code [CA3134] 1259
Failure Code [CA3135] 1261
Failure Code [CA3142] 1264
Failure Code [CA3143] 1265
Failure Code [CA3144] 1266
Failure Code [CA3146] 1268
Failure Code [CA3147] 1269
Failure Code [CA3148] 1270
Failure Code [CA3151] 1272
Failure Code [CA3165] 1278
Failure Code [CA3229] 1280
Failure Code [CA3231] 1282
Failure Code [CA3232] 1284
Failure Code [CA3235] 1288
Failure Code [CA3239] 1290
Failure Code [CA3241] 1293
Failure Code [CA3242] 1296
Failure Code [CA3251] 1299
Failure Code [CA3253] 1301
Failure Code [CA3254] 1304
Failure Code [CA3255] 1307
Failure Code [CA3256] 1311
Failure Code [CA3311] 1313
Failure Code [CA3312] 1315
Failure Code [CA3313] 1318
Failure Code [CA3314] 1319
Failure Code [CA3315] 1320
Failure Code [CA3316] 1322
Failure Code [CA3317] 1323
Failure Code [CA3318] 1324
Failure Code [CA3319] 1326
Failure Code [CA3321] 1327
Failure Code [CA3322] 1329
Failure Code [CA3419] 1331
Failure Code [CA3421] 1333
Failure Code [CA3497] 1335
Failure Code [CA3498] 1336
Failure Code [CA3543] 1337
Failure Code [CA3545] 1344
Failure Code [CA3547] 1346
Failure Code [CA3558] 1347
Failure Code [CA3559] 1349
Failure Code [CA3562] 1351
Failure Code [CA3563] 1353
Failure Code [CA3567] 1356
Failure Code [CA3568] 1359
Failure Code [CA3571] 1363
Failure Code [CA3572] 1365
Failure Code [CA3574] 1367
Failure Code [CA3575] 1369
Failure Code [CA3577] 1371
Failure Code [CA3578] 1373
Failure Code [CA3582] 1375
Failure Code [CA3583] 1381
Failure Code [CA3596] 1383
Failure Code [CA3649] 1385
Failure Code [CA3681] 1387
Failure Code [CA3682] 1392
Failure Code [CA3713] 1398
Failure Code [CA3717] 1401
Failure Code [CA3718] 1402
Failure Code [CA3725] 1403
Failure Code [CA3741] 1406
Failure Code [CA3748] 1407
Failure Code [CA3751] 1409
Failure Code [CA3755] 1411
Failure Code [CA3866] 1413
Failure Code [CA3867] 1417
Failure Code [CA3868] 1420
Failure Code [CA3899] 1424
Failure Code [CA3911] 1426
Failure Code [CA3912] 1430
Failure Code [CA3932] 1432
Failure Code [CA3933] 1434
Failure Code [CA3934] 1436
Failure Code [CA3935] 1439
Failure Code [CA3936] 1441
Failure Code [CA4151] 1443
Failure Code [CA4152] 1447
Failure Code [CA4155] 1451
Failure Code [CA4156] 1453
Failure Code [CA4157] 1456
Failure Code [CA4158] 1458
Failure Code [CA4159] 1459
Failure Code [CA4161] 1460
Failure Code [CA4162] 1463
Failure Code [CA4163] 1466
Failure Code [CA4164] 1468
Failure Code [CA4165] 1470
Failure Code [CA4166] 1472
Failure Code [CA4168] 1474
Failure Code [CA4169] 1477
Failure Code [CA4171] 1479
Failure Code [CA4249] 1482
Failure Code [CA4251] 1484
Failure Code [CA4259] 1486
Failure Code [CA4261] 1489
Failure Code [CA4277] 1492
Failure Code [CA4281] 1496
Failure Code [CA4459] 1499
Failure Code [CA4461] 1501
Failure Code [CA4658] 1504
Failure Code [CA4731] 1508
Failure Code [CA4732] 1509
Failure Code [CA4739] 1510
Failure Code [CA4768] 1511
Failure Code [CA4769] 1513
Failure Code [CA4842] 1516
Failure Code [CA4952] 1520
Failure Code [CA5115] 1522
Failure Code [CA5179] 1525
Failure Code [CA5181] 1527
Failure Code [CA5383] 1529
Failure Code [D110KB] 1531
Failure Code [D19JKZ] 1533
Failure Code [D811MC] 1536
Failure Code [D862KA] 1537
Failure Code [D8ALKA] 1539
Failure Code [D8ALKB] 1542
Failure Code [D8AQKR] 1544
Failure Code [D8G1KT] 1551
Failure Code [D8G6KT] 1552
Failure Code [DA20MC] 1553
Failure Code [DA22KK] 1554
Failure Code [DA25KP] 1557
Failure Code [DA29KQ] 1560
Failure Code [DA2LKA] 1562
Failure Code [DA2LKB] 1565
Failure Code [DA2QKR] 1567
Failure Code [DA2RKR] 1576
Failure Code [DAF0MB] 1577
Failure Code [DAF0MC] 1578
Failure Code [DAF8KB] 1579
Failure Code [DAF9KQ] 1581
Failure Code [DAFGMC] 1582
Failure Code [DAFLKA] 1583
Failure Code [DAFLKB] 1586
Failure Code [DAFQKR] 1588
Failure Code [DAZ9KQ] 1596
Failure Code [DAZQKR] 1597
Failure Code [DB2QKR] 1604
Failure Code [DB2RKR] 1612
Failure Code [DBP0KM] 1617
Failure Code [DBP0KT] 1618
Failure Code [DBP5KB] 1619
Failure Code [DBP5KY] 1622
Failure Code [DBPQKR] 1625
Failure Code [DDNRKA] 1633
Failure Code [DDNRKY] 1635
Failure Code [DDNS00] 1637
Failure Code [DGH2KB] 1639
Failure Code [DHA4KA] 1641
Failure Code [DHAAMA] 1643
Failure Code [DHACMA] 1645
Failure Code [DHPAMA] 1647
Failure Code [DHPBMA] 1650
Failure Code [DHS3MA] 1653
Failure Code [DHS4MA] 1656
Failure Code [DHS8MA] 1659
Failure Code [DHS9MA] 1662
Failure Code [DHSAMA] 1665
Failure Code [DHSBMA] 1668
Failure Code [DHSCMA] 1671
Failure Code [DHSDMA] 1674
Failure Code [DHSFMA] 1677
Failure Code [DHSGMA] 1680
Failure Code [DHSHMA] 1683
Failure Code [DHSJMA] 1686
Failure Code [DHZAMA] 1689
Failure Code [DHZCL8] 1693
Failure Code [DKR0MA] 1694
Failure Code [DKR1MA] 1697
Failure Code [DKULKA] 1700
Failure Code [DKULKB] 1702
Failure Code [DKULKY] 1704
Failure Code [DR10KA] 1706
Failure Code [DR12KA] 1709
Failure Code [DR20KA] 1711
Failure Code [DR21KX] 1713
Failure Code [DR30KA] 1715
Failure Code [DR31KX] 1717
Failure Code [DR40KA] 1719
Failure Code [DUMBKA] 1721
Failure Code [DUMBKB] 1724
Failure Code [DV20KB] 1726
Failure Code [DW43KA] 1728
Failure Code [DW43KB] 1730
Failure Code [DW43KY] 1732
Failure Code [DW45KA] 1734
Failure Code [DW45KB] 1737
Failure Code [DW45KY] 1740
Failure Code [DW4CKY] 1742
Failure Code [DW91KA] 1743
Failure Code [DW91KB] 1745
Failure Code [DW91KY] 1747
Failure Code [DWA2KA] 1749
Failure Code [DWA2KB] 1751
Failure Code [DWA2KY] 1753
Failure Code [DWK0KA] 1755
Failure Code [DWK0KB] 1757
Failure Code [DWK0KY] 1759
Failure Code [DWK2KA] 1761
Failure Code [DWK2KB] 1763
Failure Code [DWK2KY] 1765
Failure Code [DWK8KA] 1767
Failure Code [DWK8KB] 1769
Failure Code [DWK8KY] 1771
Failure Code [DWPUKA] 1773
Failure Code [DWPUKB] 1775
Failure Code [DWPUKY] 1777
Failure Code [DXA8KA] 1779
Failure Code [DXA8KB] 1782
Failure Code [DXA9KA] 1784
Failure Code [DXA9KB] 1787
Failure Code [DXE0KA] 1789
Failure Code [DXE0KB] 1791
Failure Code [DXE4KA] 1793
Failure Code [DXE4KB] 1795
Failure Code [DXE4KY] 1797
Failure Code [DXE5KA] 1798
Failure Code [DXE5KB] 1800
Failure Code [DXE6KA] 1802
Failure Code [DXE6KB] 1804
Failure Code [DXE7KA] 1806
Failure Code [DXE7KB] 1808
Failure Code [DXE7KY] 1810
Failure Code [DXE8KA] 1812
Failure Code [DXE8KB] 1814
Failure Code [DXE8KY] 1816
Failure Code [DXE9KA] 1818
Failure Code [DXE9KB] 1820
Failure Code [DXE9KY] 1822
Failure Code [DXEAKA] 1824
Failure Code [DXEAKB] 1826
Failure Code [DXEAKY] 1828
Failure Code [DXEKKA] 1830
Failure Code [DXEKKB] 1832
Failure Code [DXEKKY] 1834
Failure Code [DXELKA] 1836
Failure Code [DXELKB] 1838
Failure Code [DXELKY] 1840
Failure Code [DY20KA] 1842
Failure Code [DY20MA] 1845
Failure Code [DY2CKB] 1847
Failure Code [DY2DKB] 1850
Failure Code [DY2EKB] 1852
Failure Code [F311KA] 1854
Failure Code [F311KB] 1856
Failure Code [F312KA] 1858
Failure Code [F312KB] 1860
Failure Code [F313KA] 1862
Failure Code [F313KB] 1864
Failure Code [F314KA] 1867
Failure Code [F314KB] 1869
Failure Code [F315KB] 1871
Failure Code [F315KY] 1873
Failure Code [F316KB] 1875
Failure Code [F316KY] 1877
Failure Code [F318KB] 1879
Failure Code [F318KY] 1882
Failure Code [F31AKB] 1884
Failure Code [F31AKY] 1886
Failure Code [F31BKB] 1888
Failure Code [F31BKY] 1890
Failure Code [F31CKB] 1892
Failure Code [F31CKY] 1894
Failure Code [F31DKB] 1896
Failure Code [F31DKY] 1898
Failure Code [F31EKB] 1900
Failure Code [F31EKY] 1902
Troubleshooting of Electrical System (E-Mode) 1904
E-1 Engine Does Not Start (Engine Does Not Crank) 1904
E-2 Manual Preheating System Does Not Operate 1910
E-3 Automatic Preheating System Does Not Operate .1913
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1915
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing .1917
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow 1920
E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1921
E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation .1922
E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs 1923
E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs .1924
E-11 Charge Level Monitor Comes On in Red While Engine is in Operation .1925
E-12 Fuel Level Monitor Comes On in Red While Engine Runs 1926
E-13 Water Separator Monitor Comes On in Red While Engine Runs .1927
E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation .1928
E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1929
E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1930
E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum 1931
E-18 Display of Fuel Gauge is Different from Actual Fuel Level .1933
E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum .1934
E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature .1935
E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum .1936
E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature .1938
E-23 Some Areas of Machine Monitor Screen are Not Shown 1939
E-24 Function Switch Does Not Operate 1940
E-25 Automatic Warm-up System Does Not Work (in Cold Weather) 1941
E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out 1942
E-27 Auto-Decelerator is Not Operated or Canceled with Lever .1943
E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown 1944
E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed .1945
E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change 1946
E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change .1947
E-32 Alarm Buzzer Cannot be Canceled .1949
E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position 1950
E-34 Service Mode Cannot be Selected .1951
E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move 1952
E-36 All Work Equipment, Swing and Travel Do Not Lock 1954
E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing 1955
E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate 1958
E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show .1960
E-40 One-Touch Power Maximizing Function is Not Cancelled 1962
E-41 Alarm Does Not Sound During Travel 1963
E-42 Alarm Does Not Stop When Machine Stops 1965
E-43 Horn Does Not Sound .1966
E-44 Horn Does Not Stop 1970
E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out .1972
E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate 1973
E-47 Window Washer Does Not Operate When Window Washer Switch is Operated 1975
E-48 “Boom RAISE” is Not Shown Correctly with Monitoring Function 1976
E-49 “Boom LOWER” is Not Shown Correctly with Monitoring Function 1977
E-50 “Arm OUT” is Not Shown Correctly with Monitoring Function .1978
E-51 “Arm IN” is Not Shown Correctly with Monitoring Function 1979
E-52 “Bucket DUMP” is Not Shown Correctly with Monitoring Function .1980
E-53 “Bucket CURL” is Not Shown Correctly with Monitoring Function .1981
E-54 “Swing” is Not Shown Correctly with Monitoring Function .1982
E-55 “Travel” is Not Shown Correctly with Monitoring Function 1983
E-56 Service is Not Shown Correctly with Monitoring Function .1984
E-57 Attachment Hydraulic Circuit Cannot be Changed 1986
E-58 KOMTRAX System Does Not Operate Correctly .1987
R-55 Machine Push-Up Function is Not Canceled 1988
E-60 Machine Push-Up Function Does Not Operate .1990
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 1991
Information Shown in Troubleshooting Table (H-Mode) 1991
System Chart of Hydraulic and Mechanical Systems .1992
Failure Mode and Cause Table .1994
H-1 All Work Equipment, Swing and Travel Do Not Work .2005
H-2 All Work Equipment, Swing and Travel Lack Speed and Power 2006
H-3 Fine Control Performance or Response is Unsatisfactory .2009
H-4 Unusual Noise is Heard from Around Hydraulic Pump 2010
H-5 Engine Speed Drops Largely or Engine Stops .2011
H-6 Speed or Power of Boom is Low 2013
H-7 Arm Speed or Power is Low 2019
H-8 Bucket Speed or Power is Low .2024
H-9 Work Equipment Does Not Move in Single Operation .2028
H-10 Hydraulic Drift of Boom is Large 2029
H-11 Hydraulic Drift of Arm is Large .2031
H-12 Hydraulic Drift of Bucket is Large 2033
H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves 2034
H-14 Time Lag of Work Equipment is Large .2035
H-15 One-Touch Power Maximizing Function Does Not Operate 2036
H-16 Machine Push-Up Function Does Not Operate .2037
H-17 Attachment Circuit Cannot be Changed 2038
H-18 Oil Flow in Attachment Circuit Cannot be Changed 2039
H-19 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower .2040
H-20 In Mixed Operation of Swing and Travel, Travel Speed Drops Largely 2041
H-21 In Mixed Operation of Swing and Boom RAISE, Boom RAISE Speed is Low .2042
H-22 Machine Does Not Travel Straight 2043
H-23 Machine is Not Steered Correctly or Steering Power is Low .2045
H-24 Travel Speed is Low .2048
H-25 One of Tracks Does Not Run 2050
H-26 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast .2052
H-27 Machine Does Not Swing to Right or Left .2053
H-28 Upper Structure Swings Only to Right or Left 2054
H-29 Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left 2055
H-30 Swing Acceleration or Swing Speed is Low in Only One Direction 2056
H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left) 2057
H-32 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction) 2058
H-33 Shock is Large When Upper Structure Stops Swing Operation .2059
H-34 There is Large Unusual Noise When It Stops Swing Operation 2060
H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied) 2061
H-36 Swing Drift on a Slope is Large (While Swing Parking Brake is Released) .2062
Troubleshooting of Engine (S-Mode) .2063
Information Shown in Troubleshooting Table (S-Mode) 2063
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position .2064
S-2 Engine Cranks but No Exhaust Smoke Comes Out .2065
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) .2066
S-4 Engine Startability is Unsatisfactory 2068
S-5 Engine Does Not Pick Up Smoothly .2070
S-6 Engine Stops During Operation 2072
S-7 Engine Runs Rough or is Not Stable .2074
S-8 Engine Lacks Power .2075
S-9 KDPF Becomes Clogged in a Short Time .2077
S-10 Engine Oil Consumption is Excessive .2079
S-11 Oil Becomes Dirty Quickly .2080
S-12 Fuel Consumption is Excessive .2081
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 2082
S-14 Oil Pressure Drops 2083
S-15 Fuel Mixes Into Engine Oil 2085
S-16 Water Mixes Into Engine Oil (Milky) .2086
S-17 Coolant Temperature Increases Too High (Overheating) 2087
S-18 Unusual Noise is Heard 2088
S-19 Vibration is Excessive 2089
S-20 Air Cannot be Bled from Fuel Circuit 2090
S-21 Active Regeneration is Done Frequently 2091
S-22 Active Regeneration Continues Long 2093
S-23 White Smoke is Exhausted During Active Regeneration .2094
S-24 DEF Consumption is Excessive 2095
S-25 There is Unusual Smell (Irritating Odor) 2097
S-26 Foreign Materials Enter DEF (DEF Increases) .2098
50 Disassembly and Assembly 2099
Table of Contents 2100
Precautions Before Work 2105
Related Information on Disassembly and Assembly 2106
How to Read This Manual 2106
Coating Materials List .2107
Special Tool List 2112
Sketches of Special Tools 2127
Engine and Cooling System 2135
Remove and Install Supply Pump Assembly 2135
How to Remove Supply Pump Assembly .2135
How to Install Supply Pump Assembly 2140
Remove and Install Injector Assembly .2148
How to Remove Injector Assembly 2148
How to Install Injector Assembly .2155
Remove and Install Cylinder Head Assembly 2167
How to Remove Cylinder Head Assembly .2167
How to Install Cylinder Head Assembly 2176
Remove and Install EGR Valve Assembly 2194
How to Remove EGR Valve Assembly .2194
How to Install EGR Valve Assembly 2195
Remove and Install EGR Cooler Assembly .2197
How to Remove EGR Cooler Assembly 2197
How to Install EGR Cooler Assembly .2198
Remove and Install Starter Assembly 2201
How to Remove Starting Motor Assembly 2201
How to Install Starting Motor Assembly .2202
Remove and Install Alternator Belt .2203
How to Remove Alternator Belt 2203
How to Install Alternator Belt .2206
Remove and Install Radiator Assembly .2209
How to Remove Radiator Assembly 2209
How to Install Radiator Assembly .2211
Remove and Install Hydraulic Oil Cooler Assembly .2213
How to Remove Hydraulic Oil Cooler Assembly 2213
How to Install Hydraulic Oil Cooler Assembly .2215
Remove and Install Aftercooler Assembly 2219
How to Remove Aftercooler Assembly .2219
How to Install Aftercooler Assembly 2220
Remove and Install Engine and Main Pump Assembly .2222
How to Remove Engine and Main Pump Assembly 2223
How to Install Engine and Main Pump Assembly .2235
Remove and Install Engine Front Oil Seal .2250
How to Remove Engine Front Oil Seal 2250
How to Install Engine Front Oil Seal .2254
Remove and Install Engine Rear Oil Seal 2258
How to Remove Engine Rear Oil Seal .2259
How to Install Engine Rear Oil Seal 2260
Remove and Install Engine Hood Assembly 2267
How to Remove Engine Hood Assembly .2267
How to Install Engine Hood Assembly 2268
Remove and Install Fuel Tank Assembly 2271
How to Remove Fuel Tank Assembly .2271
How to Install Fuel Tank Assembly 2274
Remove and Install DEF Tank Assembly .2277
How to Remove DEF Tank Assembly 2277
How to Install DEF Tank Assembly .2283
Remove and Install DEF Tank Sensor Flange Assembly .2289
How to Remove DEF Tank Sensor Flange Assembly 2289
How to Install DEF Tank Sensor Flange Assembly .2296
Remove and Install DEF Tank Sensor .2301
How to Remove DEF Tank Sensor 2301
How to Install DEF Tank Sensor .2301
Remove and Install DEF Tank Strainer .2308
How to Remove DEF Tank Strainer 2308
How to Install DEF Tank Strainer .2308
Remove and Install DEF Tank Filler Port Filter .2309
How to Remove DEF Tank Filler Port Filter 2309
How to Install DEF Tank Filler Port Filter .2311
Remove and Install KDPF Assembly .2314
How to Remove KDPF Assembly 2314
How to Install KDPF Assembly .2317
Disassemble and Assemble KDPF Assembly .2322
How to Disassemble KDPF Assembly .2323
How to Assemble KDPF Assembly 2326
Remove and Install SCR Assembly 2331
How to Remove SCR Assembly .2331
How to Install SCR Assembly 2334
Remove and Install KDPF and SCR Assembly .2337
How to Remove KDPF and SCR Assembly 2338
How to Install KDPF and SCR Assembly .2345
Remove and Install KDPF and SCR Assembly Bracket .2352
How to Remove KDPF and SCR Assembly Bracket 2352
How to Install KDPF and SCR Assembly Bracket .2355
Remove and Install Bellows Pipe Assembly .2360
How to Remove Bellows Pipe Assembly 2360
How to Install Bellows Pipe Assembly .2363
Remove and Install KCCV Assembly .2367
How to Remove KCCV Assembly 2367
How to Install KCCV Assembly .2368
Remove and Install DEF Mixing Tube .2370
How to Remove DEF Mixing Tube 2371
How to Install DEF Mixing Tube .2374
Remove and Install DEF Injector 2378
How to Remove DEF Injector .2378
How to Install DEF Injector 2381
Remove and Install DEF Pump 2385
How to Remove DEF Pump (Applicable Machine Model: 90156 to 92053) 2385
How to Install DEF Pump (Applicable Machine Model: 90156 to 92053) .2388
How to Remove DEF Pump (Applicable Machine Model: 92054 and up) 2390
How to Install DEF Pump (Applicable Machine Model: 92054 and up) .2393
Remove and Install DEF Hose 2396
How to Remove DEF Hose (Applicable Machine Model: 90156 to 92053) 2397
How to Install DEF Hose (Applicable Machine Model: 90156 to 92053) .2403
How to Remove DEF Hose (Applicable Machine Model: 92054 and up) 2410
How to Install DEF Hose (Applicable Machine Model: 92054 or Later) .2417
Remove and Install Air Cleaner Assembly 2425
How to Remove Air Cleaner Assembly .2425
How to Install Air Cleaner Assembly 2427
Remove and Install Air Conditioner Compressor Assembly .2429
How to Remove Air Conditioner Compressor Assembly 2429
How to Install Air Conditioner Compressor Assembly .2430
Remove and Install Air Conditioner Condenser Assembly 2432
How to Remove Air Conditioner Condenser Assembly .2432
How to Install Air Conditioner Condenser Assembly 2433
Power Train 2434
Remove and Install Travel Motor and Final Drive Assembly .2434
How to Remove Travel Motor and Final Drive Assembly 2434
How to Install Travel Motor and Final Drive Assembly .2435
Disassemble and Assemble Final Drive Assembly 2437
How to Disassemble Final Drive Assembly 2438
How to Assemble Final Drive Assembly .2442
Remove and Install Swing Motor and Swing Machinery Assembly 2450
How to Remove Swing Motor and Swing Machinery Assembly .2450
How to Install Swing Motor and Swing Machinery Assembly 2451
Disassemble and Assemble Swing Machinery Assembly 2453
How to Disassemble Swing Machinery Assembly 2453
How to Assemble Swing Machinery Assembly .2456
Remove and Install Swing Circle Assembly .2464
How to Remove Swing Circle Assembly 2464
How to Install Swing Circle Assembly .2464
Undercarriage and Frame 2466
Separate and Connect Track Assembly 2466
How to Separate Track Assembly .2466
How to Install Track Assembly 2468
Remove and Install Sprocket 2471
How to Remove Sprocket .2471
How to Install Sprocket 2471
Remove and Install Idler and Idler Cushion Assembly 2473
How to Remove Idler and Idler Cushion Assembly .2473
How to Install Idler and Idler Cushion Assembly 2474
Disassemble and Assemble Idler Assembly 2475
How to Disassemble Idler Assembly 2475
How to Assemble Idler Assembly .2476
Disassemble and Assemble Idler Cushion Assembly 2480
How to Disassemble Idler Cushion Assembly 2481
How to Assemble Idler Cushion Assembly .2481
Disassemble and Assemble Track Roller Assembly .2483
How to Disassemble Track Roller Assembly .2484
How to Assemble Track Roller Assembly 2485
Disassemble and Assemble Carrier Roller Assembly .2487
How to Disassemble Carrier Roller Assembly .2487
How to Assemble Carrier Roller Assembly 2488
Remove and Install Revolving Frame Assembly 2491
How to Remove Revolving Frame Assembly .2491
How to Install Revolving Frame Assembly 2493
Remove and Install Counterweight Assembly 2496
How to Remove Counterweight Assembly .2496
How to Install Counterweight Assembly 2497
Hydraulic System .2500
Remove and Install Center Swivel Joint Assembly 2500
How to Remove Center Swivel Joint Assembly .2500
How to Install Center Swivel Joint Assembly 2501
Disassemble and Assemble Center Swivel Joint Assembly 2504
How to Disassemble Center Swivel Joint Assembly 2505
How to Assemble Center Swivel Joint Assembly .2506
Remove and Install Hydraulic Tank Assembly .2507
How to Remove Hydraulic Tank Assembly 2507
How to Install Hydraulic Tank Assembly .2511
Remove and Install Main Pump Assembly 2515
How to Remove Main Pump Assembly .2515
How to Install Main Pump Assembly 2518
Remove and Install Control Valve Assembly 2521
How to Remove Control Valve Assembly .2521
How to Install Control Valve Assembly 2528
Disassemble and Assemble Control Valve Assembly 2535
How to Replace Pressure Compensation Valve Seal Ring .2536
How to Assemble Control Valve Assembly .2537
Remove and Install ATT Bypass Solenoid .2542
How to Remove ATT Bypass Solenoid 2542
How to Install ATT Bypass Solenoid .2545
Disassemble and Assemble Work Equipment PPC Valve Assembly .2547
How to Disassemble Work Equipment PPC Valve Assembly .2547
How to Assemble Work Equipment PPC Valve Assembly 2548
Disassemble and Assemble Travel PPC Valve Assembly .2550
How to Disassemble Travel PPC Valve Assembly .2550
How to Assemble Travel PPC Valve Assembly 2551
Work Equipment .2553
Remove and Install Bucket Assembly .2553
How to Remove Bucket Assembly 2553
How to Install Bucket Assembly .2553
Remove and Install Arm Assembly 2555
How to Remove Arm Assembly .2555
How to Install Arm Assembly 2556
Remove and Install Work Equipment Assembly .2558
How to Remove Work Equipment Assembly 2558
How to Install Work Equipment Assembly .2561
Remove and Install Boom Anti-drop Valve Assembly .2564
How to Remove Boom Anti-drop Valve Assembly 2564
How to Install Boom Anti-drop Valve Assembly .2566
Remove and Install Arm Anti-Drop Valve Assembly 2567
How to Remove Arm Anti-Drop Valve Assembly .2567
How to Install Arm Anti-Drop Valve Assembly 2569
Disassemble and Assemble Anti-Drop Valve Assembly 2570
How to Disassemble Anti-Drop Valve Assembly 2570
How to Assemble Anti-Drop Valve Assembly .2570
Disassemble and Assemble Work Equipment Cylinder Assembly 2571
How to Disassemble Work Equipment Cylinder Assembly 2571
How to Assemble Work Equipment Cylinder Assembly .2574
CAB Related Parts 2581
Remove and Install Operator Cab Assembly .2581
How to Remove Operator Cab Assembly 2581
How to Install Operator Cab Assembly .2589
Remove and Install Operator Cab Glass (Adhered Glass) 2596
How to Remove Operator Cab Glass (Adhered Glass) .2598
How to Install Operator Cab Glass (Adhered Glass) 2598
Remove and Install Front Window Assembly .2608
How to Remove Front Window Assembly 2608
How to Install Front Window Assembly .2611
Remove and Install Floor Frame Assembly 2617
How to Remove Floor Frame Assembly .2618
How to Install Floor Frame Assembly 2624
Remove and Install Air Conditioner Unit Assembly .2632
How to Remove Air Conditioner Unit Assembly 2632
How to Install Air Conditioner Unit Assembly .2637
Remove and Install Operator Seat .2643
How to Remove Operator Seat 2643
How to Install Operator Seat .2645
How to Remove and Install Seat Belt 2648
How to Remove Seat Belt 2648
How to Install Seatbelt 2649
Remove and Install Work Equipment Control Lever Assembly .2650
How to Remove Work Equipment Control Lever Assembly 2650
How to Install Work Equipment Control Lever Assembly .2656
Remove and Install Front Wiper Assembly 2665
How to Remove Front Wiper Assembly .2665
How to Install Front Wiper Assembly 2670
Electrical System 2679
Remove and Install Engine Controller Assembly 2679
How to Remove Engine Controller Assembly .2679
How to Install Engine Controller Assembly 2681
Remove and Install Pump Controller Assembly 2685
How to Remove Pump Controller Assembly .2685
How to Install Pump Controller Assembly 2688
Remove and Install Machine Monitor Assembly 2692
How to Remove Machine Monitor Assembly .2692
How to Install Machine Monitor Assembly 2695
Remove and Install KomVision Controller Assembly .2699
How to Remove KomVision Controller Assembly 2699
How to Install KomVision Controller Assembly .2700
Remove and Install Pump Swash Plate Sensor .2701
How to Remove Pump Swash Plate Sensor 2701
How to Install Pump Swash Plate Sensor .2701
Remove and Install Mass Air Flow and Temperature Sensor 2703
How to Remove Mass Air Flow and Temperature Sensor .2703
How to Install Mass Air Flow and Temperature Sensor 2704
Remove and Install KCCV Crankcase Pressure Sensor 2705
How to Remove KCCV Crankcase Pressure Sensor .2705
How to Install KCCV Crankcase Pressure Sensor 2706
Remove and Install SCR Temperature Sensor 2707
How to Remove SCR Temperature Sensor .2707
How to Install SCR Temperature Sensor 2708
Remove and Install KomVision Camera 2710
How to Remove KomVision Camera .2710
How to Install KomVision Camera 2711
Remove and Install Rearview Camera .2713
How to Remove Rearview Camera 2713
How to Install Rearview Camera .2714
Remove and Install Gateway Function Controller Assembly 2716
How to Remove Gateway Function Controller Assembly .2716
How to Install Gateway Function Controller Assembly 2721
Remove and Install Communication Terminal Wiring Harness .2726
How to Remove Communication Terminal Wiring Harness 2726
How to Install Communication Terminal Wiring Harness .2734
Remove and Install Communication Terminal 2743
How to Remove Communication Terminal .2743
How to Install Communication Terminal 2745
60 Maintenance Standard 2749
Table of Contents 2750
Engine and Cooling System 2751
Maintenance Standard for Engine Mount 2751
Maintenance Standard for Cooling System 2753
Power Train 2754
Maintenance Standard for Swing Circle 2754
Maintenance Standard for Swing Machinery .2755
Maintenance Standard for Final Drive .2757
Maintenance Standard for Sprocket 2759
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing .2760
Undercarriage and Frame 2761
Maintenance Standard for Track Frame and Idler Cushion .2761
Maintenance Standard for Idler .2763
Maintenance Standard for Track Roller 2765
Maintenance Standard for Carrier Roller 2767
Maintenance Standard for Track Shoes .2768
Maintenance Standard for Triple Shoes 2771
Hydraulic System .2772
Maintenance Standard for Hydraulic Tank 2772
Maintenance Standard for Main Pump .2773
Maintenance Standard for Swing Motor .2775
Maintenance Standard for Travel Motor 2778
Maintenance Standard for Control Valve .2781
Maintenance Standard for Boom Anti-Drop Valve 2791
Maintenance Standard for Arm Anti-Drop Valve .2793
Maintenance Standard for Work Equipment and Swing PPC Valve 2795
Maintenance Standard for Travel PPC Valve 2798
Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve) 2801
Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve 2802
Maintenance Standard for 2nd-Line Attachment PPC Valve .2804
Maintenance Standard for Solenoid Valve 2806
Maintenance Standard for Attachment Circuit Selector Valve .2807
Maintenance Standard for Center Swivel Joint .2808
Work Equipment .2809
Maintenance Standard for Work Equipment Linkage 2809
Dimensions of Arm 2814
Dimensions of Bucket .2816
Maintenance Standard for Boom Cylinder .2818
Maintenance Standard for Arm Cylinder 2819
Maintenance Standard for Bucket Cylinder .2820
80 Appendix 2821
Table of Contents 2822
Precautions Before Work 2824
Air Conditioner System .2825
Precautions for Refrigerant 2825
Air Conditioner Component 2826
Specifications of Air Conditioner 2828
Structure and Function of Refrigeration Cycle 2829
Outline of Refrigeration Cycle .2830
Component Parts of Air Conditioner System 2832
Air Conditioner Unit .2832
Configuration Diagram of Air Conditioner Unit 2832
Function of Air Conditioner Unit .2834
Component Parts of Air Conditioner Unit 2836
Function of Evaporator as Air Conditioner Unit Component .2837
Function of Heater Core as Air Conditioner Unit Component 2837
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 2837
Function of Servo Motor as Air Conditioner Unit Component 2837
Structure of Expansion Valve as Air Conditioner Unit Component .2838
Function of Expansion Valve as Air Conditioner Unit Component 2838
Operate Expansion Valve as Air Conditioner Unit Component 2838
Function of Dual Pressure Switch .2839
Air Conditioner Controller .2840
Structure of Air Conditioner Controller 2840
Compressor .2841
Structure of Compressor 2841
Specifications of Compressor .2841
Function of Compressor .2841
Condenser 2842
Structure of Condenser .2842
Specifications of Condenser 2842
Function of Condenser 2842
Receiver Drier .2843
Structure of Receiver Dryer 2843
Specifications of Receiver Dryer .2843
Function of Receiver Dryer .2843
Air Conditioner Related Sensors 2844
Structure of Sunlight Sensor .2844
Function of Sunlight Sensor 2844
Structure of Outside Temperature Sensor 2844
Function of Outside Air Temperature Sensor .2844
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 2846
Circuit Diagram and Configuration of Connector Pins of Air Conditioner .2848
System Diagram of Air Conditioner 2850
Input and Output Signals of Air Conditioner Controller .2851
Function of Air Conditioner Controller .2852
Locations of Air Conditioner Parts and Layout of Connectors 2853
Examine Air Leakage (Duct) .2857
How to Examine Air Leakage (Duct) 2857
Examine Air Conditioner with Self-Diagnosis Function .2859
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 2860
Examine Vent (Mode) Changeover .2861
How to Examine Vent (Mode) Changeover 2861
Examine Fresh/Recirc Air Changeover 2863
How to Examine Fresh/Recirc Air Changeover .2863
Examine Sunlight Sensor 2864
How to Examine Sunlight Sensor .2864
Examine Refrigerant (Dual) Pressure Switch .2865
How to Examine Refrigerant (Dual) Pressure Switch 2865
Examine Relay 2866
How to Examine Relay .2866
Air Conditioner Troubleshooting Chart 1 2867
Air Conditioner Troubleshooting Chart 2 2868
Information Shown in Troubleshooting Table .2871
Failure Code [879AKA] 2872
Failure Code [879AKB] 2873
Failure Code [879BKA] 2874
Failure Code [879BKB] 2876
Failure Code [879CKA] 2878
Failure Code [879CKB] 2879
Failure Code [879DKZ] 2880
Failure Code [879EMC] 2882
Failure Code [879FMC] 2883
Failure Code [879GKX] 2884
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) .2886
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 2888
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) .2891
A-4 Troubleshooting for Fresh/Recirc Air Changeover 2893
Troubleshooting by Gauge Pressure 2895
Connect Service Tool .2898
How to Connect Service Tool 2898
Precautions for Disconnection and Connection of Air Conditioner Piping .2900
Handle Compressor Oil 2902
90 Circuit Diagrams 2905
Table of Contents 2906
Hydraulic Circuit Diagram 2907
Symbols Used in Hydraulic Circuit Diagram 2907
Hydraulic Circuit Diagram 2911
Electrical Circuit Diagram .2913
Symbols Used in Electric Circuit Diagram .2913
Electrical Circuit Diagram (1/12) 2917
Electrical Circuit Diagram (2/12) 2919
Electrical Circuit Diagram (3/12) 2921
Electrical Circuit Diagram (4/12) 2923
Electrical Circuit Diagram (5/12) 2925
Electrical Circuit Diagram (6/12) 2927
Electrical Circuit Diagram (7/12) 2929
Electrical Circuit Diagram (8/12) 2931
Electrical Circuit Diagram (9/12) 2933
Electrical Circuit Diagram (10/12) .2935
Electrical Circuit Diagram (11/12) .2937
Electrical Circuit Diagram (12/12) .2939
Index .2941

DESCRIPTION:

Komatsu PC360LC-11 Hydraulic Excavator Shop Manual SEN06739-08  – PDF DOWNLOAD

• SERIAL NUMBERS 91005 and up

G.B 28/12/24