Komatsu PC360LC-11E0 PC360NLC-11E0 PC390HRD-11E0 Excavator Shop Manual – PDF DOWNLOAD

Description

Komatsu PC360LC-11E0 PC360NLC-11E0 PC390HRD-11E0 Excavator Shop Manual – PDF DOWNLOAD

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DESCRIPTION:

Komatsu PC360LC-11E0 PC360NLC-11E0 PC390HRD-11E0 Excavator Shop Manual – PDF DOWNLOAD

SERIAL NUMBERS K75001 and up

FOREWORD, SAFETY, BASIC INFORMATION:
HOW TO READ THE SHOP MANUAL:
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual:
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “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.

Questions? Email us: [email protected]

TABLE OF CONTENTS:

Komatsu PC360LC-11E0 PC360NLC-11E0 PC390HRD-11E0 Excavator Shop Manual – PDF DOWNLOAD

00 INDEX AND FOREWORD 3
INDEX 4
ABBREVIATION LIST 23
FOREWORD, SAFETY, BASIC INFORMATION 29
HOW TO READ THE SHOP MANUAL 29
SAFETY NOTICE FOR OPERATION 31
PRECAUTIONS TO PREVENT FIRE 39
ACTIONS IF FIRE OCCURS 41
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 42
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS 43
METHOD FOR CHECKING ENGINE TYPE 44
PRECAUTIONS FOR DEF 46
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 46
PRECAUTIONS FOR ADDING 46
PRECAUTIONS FOR STORING 46
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE 46
THE OTHER PRECAUTIONS 46
STORE AdBlue/DEF 47
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 48
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS 51
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT 58
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 60
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 61
PRACTICAL USE OF KOMTRAX 62
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER 63
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER 63
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER 64
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER 65
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 67
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR 71
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL 74
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH 75
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 77
HOW TO READ ELECTRICAL WIRE CODE 78
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD 82
STANDARD TIGHTENING TORQUE TABLE 85
CONVERSION TABLE 92
01 SPECIFICATIONS 97
CONTENTS 98
ABBREVIATION LIST 99
SPECIFICATIONS 105
SPECIFICATION DRAWING 105
SPECIFICATION DRAWING: PC360LC-11E0, PC360NLC-11E0 105
WORKING RANGE DRAWINGS 107
WORKING RANGE: PC360LC-11E0, PC360NLC-11E0 107
SPECIFICATIONS 108
SPECIFICATIONS: PC360LC-11E0, PC360NLC-11E0 108
WEIGHT TABLE 111
WEIGHT TABLE: PC360LC-11E0, PC360NLC-11E0 111
TABLE OF FUEL, COOLANT, AND LUBRICANTS 113
SPECIFICATIONS – PC390HRD-11E0 114
SPECIFICATION DRAWING 114
SPECIFICATION DRAWING: PC390HRD-11E0 114
SPECIFICATIONS 117
SPECIFICATIONS: PC390HRD-11E0 117
WEIGHT TABLE 119
WEIGHT TABLE: PC390HRD-11E0 119
10 STRUCTURE AND FUNCTION 121
CONTENTS 122
ABBREVIATION LIST 126
UREA SCR SYSTEM 132
LAYOUT DRAWING OF UREA SCR SYSTEM 132
UREA SCR SYSTEM DIAGRAM 136
FUNCTION OF UREA SCR SYSTEM 137
FUNCTION OF AdBlue/DEF SYSTEM 137
INDUCEMENT STRATEGY 139
COMPONENT PARTS OF UREA SCR SYSTEM 158
AdBlue/DEF MIXING TUBE 158
SCR ASSEMBLY 158
AdBlue/DEF TANK 161
AdBlue/DEF PUMP 163
AdBlue/DEF INJECTOR 164
AdBlue/DEF HOSE 165
AdBlue/DEF TANK HEATING VALVE 166
BOOT-UP SYSTEM 167
LAYOUT DRAWING OF BOOT-UP SYSTEM 167
SYSTEM OPERATING LAMP SYSTEM 169
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 169
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 169
BATTERY DISCONNECT SWITCH 171
FUNCTION OF BATTERY DISCONNECT SWITCH 171
ENGINE SYSTEM 172
LAYOUT DRAWING OF ENGINE SYSTEM 172
SPECIFICATIONS OF ENGINE SYSTEM 173
FUNCTION OF ENGINE SYSTEM 173
ENGINE CONTROL SYSTEM 174
ENGINE CONTROL SYSTEM DIAGRAM 174
OPERATION OF ENGINE CONTROL SYSTEM 175
AUTO-DECELERATION SYSTEM 177
AUTO-DECELERATION SYSTEM DIAGRAM 177
FUNCTION OF AUTO-DECELERATION SYSTEM 177
OPERATION OF AUTO-DECELERATION SYSTEM 178
ENGINE AUTOMATIC WARM-UP SYSTEM 179
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM 179
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM 180
OVERHEAT PREVENTION SYSTEM 181
OVERHEAT PREVENTION SYSTEM DIAGRAM 181
FUNCTION OF OVERHEAT PREVENTION SYSTEM 182
TURBOCHARGER PROTECTION SYSTEM 183
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 183
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 184
AUTOMATIC IDLE STOP SYSTEM 185
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 185
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 185
OPERATION OF AUTOMATIC IDLE STOP SYSTEM 185
COMPONENT PARTS OF ENGINE SYSTEM 188
VGT 188
EGR SYSTEM 191
EGR VALVE 193
EGR COOLER 195
KCCV SYSTEM 196
KCCV VENTILATOR 198
KDPF 199
COOLING SYSTEM 204
LAYOUT DRAWING OF COOLING SYSTEM 204
SPECIFICATIONS OF COOLING SYSTEM 205
CONTROL SYSTEM 206
LAYOUT DRAWING OF CONTROL SYSTEM PARTS 206
MACHINE MONITOR SYSTEM 209
MACHINE MONITOR SYSTEM DIAGRAM 209
FUNCTION OF MACHINE MONITOR SYSTEM 209
KomVision SYSTEM 210
LAYOUT DRAWING OF KOMVISION SYSTEM 210
KomVision SYSTEM DIAGRAM 212
FUNCTION OF KomVision SYSTEM 212
KOMTRAX SYSTEM 214
KOMTRAX SYSTEM DIAGRAM 214
FUNCTION OF KOMTRAX SYSTEM 214
PPC LEVERS 215
LH PPC LEVER 215
RH PPC LEVER 216
AUTOMATIC GREASE SYSTEM 217
OUTLINE OF AUTO GREASE SYSTEM 217
COMPONENT PARTS OF CONTROL SYSTEM 231
MACHINE MONITOR 231
KomVision CONTROLLER 245
KomVision CAMERA 249
KOMTRAX TERMINAL 250
GATEWAY FUNCTION CONTROLLER 252
COMMUNICATION TERMINAL 255
PUMP CONTROLLER 257
RESISTOR FOR PC-EPC VALVE 261
CAN TERMINATING RESISTOR 261
PPC OIL PRESSURE SWITCH 262
ENGINE CONTROLLER 263
FUEL CONTROL DIAL 270
SENSOR 272
STRUCTURE OF AMBIENT PRESSURE SENSOR 272
FUNCTION OF AMBIENT PRESSURE SENSOR 272
STRUCTURE OF ENGINE OIL PRESSURE SWITCH 272
FUNCTION OF ENGINE OIL PRESSURE SWITCH 273
STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR 273
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR 273
STRUCTURE OF COOLANT TEMPERATURE SENSOR 274
FUNCTION OF COOLANT TEMPERATURE SENSOR 274
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR 274
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR 275
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR 275
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR 275
STRUCTURE OF COMMON RAIL PRESSURE SENSOR 276
FUNCTION OF COMMON RAIL PRESSURE SENSOR 276
STRUCTURE OF EGR VALVE LIFT SENSOR 276
FUNCTION OF EGR VALVE LIFT SENSOR 276
STRUCTURE OF VGT SPEED SENSOR 277
FUNCTION OF KVGT SPEED SENSOR 277
STRUCTURE OF KVGT POSITION SENSOR 277
FUNCTION OF KVGT POSITION SENSOR 278
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR 278
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR 279
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR 279
STRUCTURE OF CRANKCASE PRESSURE SENSOR 279
FUNCTION OF CRANKCASE PRESSURE SENSOR 280
STRUCTURE OF ENGINE OIL LEVEL SENSOR 280
STRUCTURE OF AIR CLEANER CLOGGING SENSOR 280
FUNCTION OF AIR CLEANER CLOGGING SENSOR 281
STRUCTURE OF WATER-IN-FUEL SENSOR 281
FUNCTION OF WATER-IN-FUEL SENSOR 281
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 281
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 282
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 282
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 282
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 283
FUNCTION OF AUTO GREASE PRESSURE SWITCH 283
STRUCTURE OF OVERLOAD CAUTION SENSOR 283
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 283
FUNCTION OF OVERLOAD CAUTION SENSOR 283
HYDRAULIC SYSTEM 284
LAYOUT DRAWING OF HYDRAULIC SYSTEM 284
CLSS 287
STRUCTURE OF CLSS 287
OPERATION OF UNLOAD VALVE AND LS PRESSURE 289
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL 290
PRESSURE COMPENSATION CONTROL 303
ENGINE AND PUMP COMBINED CONTROL SYSTEM 307
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM 307
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM 308
PUMP AND VALVE CONTROL SYSTEM 313
PUMP AND VALVE CONTROL SYSTEM DIAGRAM 313
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM 314
COMPONENT PARTS OF HYDRAULIC SYSTEM 316
HYDRAULIC TANK 316
MAIN PUMP 319
CONTROL VALVE 345
HYDRAULIC SYSTEM – PC390HRD-11E0 403
LAYOUT DRAWING OF HYDRAULIC SYSTEM 403
COMPONENT PARTS OF HYDRAULIC SYSTEM 406
LAYOUT DRAWING OF VALVE CONTROL SYSTEM 406
WORK EQUIPMENT SYSTEM 423
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 423
STRUCTURE OF VALVE CONTROL 429
ONE-TOUCH POWER MAXIMIZING SYSTEM 431
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM 431
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM 432
MACHINE PUSH-UP SYSTEM 433
MACHINE PUSH-UP SYSTEM DIAGRAM 433
FUNCTION OF MACHINE PUSH-UP SYSTEM 434
PPC LOCK SYSTEM 435
PPC LOCK SYSTEM DIAGRAM 435
FUNCTION OF PPC LOCK SYSTEM 435
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 436
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM 436
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 436
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 437
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 438
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT 438
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT 439
TOOL CONTROL SYSTEM 440
TOOL CONTROL SYSTEM DIAGRAM 440
FUNCTION OF TOOL CONTROL SYSTEM 441
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 442
WORK EQUIPMENT AND SWING PPC VALVE 442
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 447
2ND-LINE ATTACHMENT PPC VALVE 451
SOLENOID VALVE 453
ATTACHMENT CIRCUIT SELECTOR VALVE 456
ATT EPC VALVE ASSEMBLY 459
PILOT CIRCUIT ACCUMULATOR 460
1ST-LINE ATTACHMENT VARIABLE RELIEF VALVE 461
2ND-LINE ATTACHMENT VARIABLE RELIEF VALVE 464
ATTACHMENT BYPASS SOLENOID VALVE 466
WORK EQUIPMENT SYSTEM – PC390HRD-11E0 468
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM 468
SWING SYSTEM 472
LAYOUT DRAWING OF SWING SYSTEM 472
SWING CONTROL SYSTEM DIAGRAM 475
FUNCTION OF SWING CONTROL SYSTEM 475
COMPONENT PARTS OF SWING SYSTEM 479
SWING MOTOR 479
SWING MACHINERY 490
SWING CIRCLE 492
TRAVEL SYSTEM 493
LAYOUT DRAWING OF TRAVEL SYSTEM 493
TRAVEL CONTROL SYSTEM DIAGRAM 497
FUNCTION OF TRAVEL CONTROL SYSTEM 497
COMPONENT PARTS OF TRAVEL SYSTEM 499
TRAVEL MOTOR 499
FINAL DRIVE 512
TRAVEL PPC VALVE 513
CENTER SWIVEL JOINT 518
UNDERCARRIAGE AND FRAME 520
LAYOUT DRAWING OF UNDERCARRIAGE 520
SPECIFICATIONS OF UNDERCARRIAGE 520
WORK EQUIPMENT 522
STRUCTURE OF WORK EQUIPMENT 522
FUNCTION OF WORK EQUIPMENT 523
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 524
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 524
BUCKET CLEARANCE ADJUSTMENT SHIM 525
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 525
CAB AND ITS ATTACHMENTS 526
ROPS CAB 526
STRUCTURE OF ROPS CAB 526
FUNCTION OF ROPS CAB 526
CAB MOUNT 527
STRUCTURE OF CAB MOUNT 527
FUNCTION OF CAB MOUNT 527
CAB TIPPING STOPPER 528
STRUCTURE OF CAB TIPPING STOPPER 528
FUNCTION OF CAB TIPPING STOPPER 528
TILTING CAB SYSTEM 529
STRUCTURE OF TILTING CAB SYSTEM 529
OPERATION OF TILTING CAB SYSTEM 529
20 STANDARD VALUE TABLE 531
CONTENTS 532
ABBREVIATION LIST 533
STANDARD VALUE TABLE FOR ENGINE 539
STANDARD VALUE TABLE FOR ENGINE: PC360LC-11E0, PC360NLC-11E0 539
STANDARD VALUE TABLE FOR MACHINE 544
STANDARD VALUE TABLE FOR MACHINE: PC360LC-11E0, PC360NLC-11E0 544
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 558
STANDARD VALUE TABLE FOR MACHINE – PC390HRD-11E0 562
STANDARD VALUE FOR MACHINE: HIGH REACH DEMOLITION UNIQUE 562
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE 569
STANDARD VALUE TABLE FOR ELECTRICAL 573
STANDARD VALUE TABLE FOR ELECTRICAL 573
30 TESTING AND ADJUSTING 583
CONTENTS 584
ABBREVIATION LIST 588
RELATED INFORMATION ON TESTING AND ADJUSTING 594
TOOLS FOR TESTING AND ADJUSTING 594
SKETCH OF TOOLS FOR TESTING AND ADJUSTING 601
ENGINE AND COOLING SYSTEM 603
TEST ENGINE SPEED 603
METHOD FOR TESTING ENGINE SPEED 603
TEST BOOST PRESSURE 607
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 607
METHOD FOR TESTING BOOST PRESSURE 608
TEST EXHAUST GAS COLOR 609
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER 609
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER 610
TEST AND ADJUST VALVE CLEARANCE 611
METHOD FOR TESTING VALVE CLEARANCE 611
METHOD FOR ADJUSTING VALVE CLEARANCE 613
TEST COMPRESSION PRESSURE 614
METHOD FOR TESTING COMPRESSION PRESSURE 614
TEST BLOWBY PRESSURE 617
METHOD FOR TESTING BLOWBY PRESSURE 617
TEST ENGINE OIL PRESSURE 619
METHOD FOR TESTING ENGINE OIL PRESSURE 619
TEST EGR VALVE AND VGT OIL PRESSURE 621
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE 621
TEST FUEL PRESSURE 623
METHOD FOR TESTING FUEL PRESSURE 624
TEST FUEL DISCHARGE, RETURN AND LEAKAGE 630
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE 631
BLEED AIR FROM FUEL SYSTEM 637
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 637
TEST FUEL CIRCUIT FOR LEAKAGE 638
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE 638
HANDLE CYLINDER CUT-OUT MODE OPERATION 640
HANDLE NO-INJECTION CRANKING OPERATION 641
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION 642
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION 642
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 642
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 643
TEST FAN BELT AND ALTERNATOR BELT 644
TEST FAN BELT AND ALTERNATOR BELT 644
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 645
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 645
TEST SCR RELATED FUNCTIONS 646
TEST AdBlue/DEF PUMP RAISED PRESSURE 649
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 652
TEST AdBlue/DEF LINE HEATER RELAY 1 656
TEST AdBlue/DEF LINE HEATER RELAY 2 658
TEST AdBlue/DEF PUMP HEATER RELAY 661
TEST AdBlue/DEF TANK HEATER VALVE 664
TEST DENITRATION EFFICIENCY OF SCR 667
CLEAN AdBlue/DEF TANK 671
METHOD FOR CLEANING AdBlue/DEF TANK 671
TEST AUTO-TENSIONER 675
TEST AUTO-TENSIONER 675
POWER TRAIN 676
TEST SWING CIRCLE BEARING CLEARANCE 676
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE 676
UNDERCARRIAGE AND FRAME 677
TEST AND ADJUST TRACK TENSION 677
METHOD FOR TESTING TRACK TENSION 677
METHOD FOR ADJUSTING TRACK TENSION 677
HYDRAULIC SYSTEM 679
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 679
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK 679
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT 679
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 684
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT 684
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 685
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 686
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 694
TEST OIL PRESSURE OF CONTROL CIRCUIT 698
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 698
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 700
TEST PC VALVE OUTPUT PRESSURE (SERVO PISTON INLET PRESSURE) 700
TEST PC-EPC VALVE OUTPUT PRESSURE 701
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 702
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT 703
METHOD FOR TESTING OIL PRESSURE WITH SENSOR ADAPTER (SPECIAL TOOL) 703
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE 704
METHOD FOR TESTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INLET PRESSURE) 706
METHOD FOR TESTING LS-EPC VALVE OUTPUT PRESSURE 707
METHOD FOR ADJUSTING LS VALVE 707
TEST OUTLET PRESSURE OF SOLENOID VALVE 708
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 708
OPERATING CONDITION OF SOLENOID VALVE 709
TEST PPC VALVE OUTPUT PRESSURE 711
METHOD FOR TESTING PPC VALVE OUTPUT PRESSURE 711
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 713
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 713
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE 714
TEST PUMP SWASH PLATE SENSOR 716
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 716
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 717
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER 717
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 717
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE 718
TEST OIL LEAKAGE 719
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER 719
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 719
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER 720
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR 720
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 721
BLEED AIR FROM HYDRAULIC CIRCUIT 722
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 724
HYDRAULIC SYSTEM – PC390HRD-11E0 727
MEASURING AND ADJUSTING SWING SPEED REDUCTION VALVE 727
MEASURING AND ADJUSTING BOOM AND BUCKET PPC REDUCTION VALVE 728
MEASURING AND ADJUSTING LINK CYLINDER FLOW CONTROL VALVE 729
MEASURING AND ADJUSTING ARM CYLINDER FLOW CONTROL VALVE 730
CAB AND ITS ATTACHMENTS 731
TEST CAB TIPPING STOPPER 731
METHOD FOR TESTING CAB TIPPING STOPPER 731
METHOD FOR ADJUSTING MIRRORS 732
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) 732
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) 733
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 734
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 735
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) 736
ELECTRICAL SYSTEM 738
SET AND OPERATE MACHINE MONITOR 738
OPERATOR MODE 741
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN 742
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 742
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) 743
CHECKING FUNCTION OF SERVICE METER 743
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD 743
SERVICE MODE 746
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 748
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 755
ABNORMALITY RECORD MENU 766
METHOD FOR CONFIRMING MAINTENANCE RECORD 771
METHOD FOR OPERATING MAINTENANCE MODE SETTING 772
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING 776
DEFAULT MENU 777
DIAGNOSTIC TESTS MENU 789
ADJUSTMENT MENU 798
METHOD FOR PERFORMING NO-INJECTION CRANKING 815
KOMTRAX SETTINGS MENU 816
METHOD FOR DISPLAYING SERVICE MESSAGE 819
METHOD FOR STARTING UP KOMTRAX TERMINAL 821
ADJUST REARVIEW CAMERA ANGLE 826
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE 826
ADJUST KomVision CAMERA ANGLE 829
METHOD FOR ADJUSTING KomVision CAMERA ANGLE 830
ADJUST KomVision RELATED ITEMS 834
SETTING OF KomVision (MAIN SETTING) 834
SETTING OF KomVision (CAMERA SETTING) 836
SETTING OF KomVision (CAMERA CALIBRATION) 837
KomVision screen – Check 12 m visibility 850
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER 853
HANDLE BATTERY DISCONNECT SWITCH 854
TEST DIODES 855
METHOD FOR TESTING DIODE USING DIGITAL TESTER 855
METHOD FOR TESTING DIODE USING ANALOG TESTER 855
ELECTRICAL SYSTEM – PC390HRD-11E0 856
ELECTRICAL CIRCUIT DIAGRAMS OF WORK EQUIPMENT SYSTEM 856
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – BASE MACHINE 856
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – HIGH REACH DEMOLITION WORK EQUIPMENT 859
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – EXTENDED HIGH REACH DEMOLITION WORK EQUIPMENT 861
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – MEDIUM REACH DEMOLITION WORK EQUIPMENT 863
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – DEMOLITION DIGGING WORK EQUIPMENT 865
RH PPC LEVER 866
WORK EQUIPMENT CONFIGURATION SELECTION CIRCUIT 867
CONSTANT LINK SPEED CIRCUIT 868
PARALLEL LINK FRONT SCREEN WIPER 869
Pm CLINIC 870
Pm CLINIC SERVICE 870
Pm CLINIC CHECK SHEET 871
WORKING RANGE INDICATOR SYSTEM 885
WORKING RANGE INDICATOR SYSTEM LAYOUT 885
METHOD FOR ACCESSING WORKING RANGE INDICATOR KOMATSU SERVICE MENU 887
DIAGNOSTICS – WORKING RANGE INDICATOR SYSTEM 889
MONITORING SYSTEM PARAMETERS AND SENSOR STATES 889
USING THE PARAMETER CHANGE LOG 891
USING ERROR LISTS AND LOGS 892
EXPORT DATA FROM WORKING RANGE INDICATOR SYSTEM 893
IMPORT DATA TO WORKING RANGE INDICATOR SYSTEM 894
REPLACING COMPONENTS – WORKING RANGE INDICATOR SYSTEM 896
WORKING RANGE INDICATOR SYSTEM ANGLE SENSOR REPLACEMENT 896
WORKING RANGE INDICATOR SYSTEM MONITOR REPLACEMENT 901
WORKING RANGE INDICATOR SYSTEM – UDATING SOFTWARE 906
CALIBRATION – WORKING RANGE INDICATOR SYSTEM 910
WORKING RANGE INDICATOR SYSTEM CALIBRATION OVERVIEW 910
METHOD 1 – CALIBRATING AND CONFIRMING CALIBRATION ACCURACY – AUTO CALIBRATION 910
METHOD 2 – BASE MACHINE SET-UP AND 2-AXIS PITCH AND ROLL SENSOR CALIBRATION 918
METHOD 2 – CALIBRATING AND CONFIRMING CALIBRATION ACCURACY – MANUAL CALIBRATION 921
40 TROUBLESHOOTING 937
CONTENTS 938
ABBREVIATION LIST 949
RELATED INFORMATION ON TROUBLESHOOTING 955
GENERAL TROUBLESHOOTING POINTS 955
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 956
SEQUENCE OF EVENTS IN TROUBLESHOOTING 968
CHECKS BEFORE TROUBLESHOOTING 970
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING 972
WALK-AROUND CHECK 972
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 974
CHECK FUEL LEVEL AND TYPE 974
CHECK IMPURE INGREDIENT IN FUEL 974
CHECK FUEL PREFILTER 975
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 975
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE 976
CHECK MAIN FILTER 977
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 979
CHECK COOLANT LEVEL (RESERVOIR TANK) 980
CHECK CLOGGING OF AIR CLEANER 981
OUTER ELEMENT – CLEAN 981
ELEMENTS – REPLACE 983
CHECK HYDRAULIC OIL LEVEL 984
CHECK HYDRAULIC OIL STRAINER 985
CHECK HYDRAULIC FILTER 986
CHECK OIL LEVEL IN SWING MACHINERY CASE 987
CHECK OIL LEVEL IN DAMPER CASE 987
CHECK OIL LEVEL IN FINAL DRIVE CASE 988
BLEED AIR FROM FUEL SYSTEM 988
BLEED AIR FROM HYDRAULIC SYSTEM 988
ELECTRICAL EQUIPMENT – CHECK METHOD 989
AUTOMATIC GREASE SYSTEM 994
FINDING MALFUNCTIONS 994
MALFUNCTION FINDING PROCEDURES 998
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION 1000
PROCEDURE FOR TESTING AND TROUBLESHOOTING 1013
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS 1016
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 1020
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM 1022
CONNECTOR LIST AND LAYOUT 1025
CONNECTOR CONTACT IDENTIFICATION 1040
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE 1080
FUSE LOCATION TABLE 1086
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) 1089
FAILURE CODE TABLE 1093
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) 1111
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) 1113
FAILURE CODE [879AKA] 1113
FAILURE CODE [879AKB] 1114
FAILURE CODE [879BKA] 1115
FAILURE CODE [879BKB] 1117
FAILURE CODE [879CKA] 1119
FAILURE CODE [879CKB] 1120
FAILURE CODE [879DKZ] 1121
FAILURE CODE [879EMC] 1123
FAILURE CODE [879FMC] 1124
FAILURE CODE [879GKX] 1125
FAILURE CODE [989L00] 1127
FAILURE CODE [989M00] 1128
FAILURE CODE [989N00] 1129
FAILURE CODE [A1U0N3] 1130
FAILURE CODE [A1U0N4] 1132
FAILURE CODE [A900FR] 1134
FAILURE CODE [A900N6] 1135
FAILURE CODE [A900NY] 1136
FAILURE CODE [AA10NX] 1137
FAILURE CODE [AB00KE] 1139
FAILURE CODE [AQ10N3] 1142
FAILURE CODE [AS00N3] 1144
FAILURE CODE [AS00R2] 1146
FAILURE CODE [AS00R3] 1147
FAILURE CODE [AS00R4] 1148
FAILURE CODE [AS00R5] 1149
FAILURE CODE [AS00R6] 1150
FAILURE CODE [AS00ZK] 1151
FAILURE CODE [AS10KM] 1152
FAILURE CODE [AS10NR] 1153
FAILURE CODE [AS10NT] 1154
FAILURE CODE [B@BAZG] 1155
FAILURE CODE [B@BAZK] 1156
FAILURE CODE [B@BCNS] 1158
FAILURE CODE [B@BCQA] 1159
FAILURE CODE [B@BCZK] 1161
FAILURE CODE [B@HANS] 1163
FAILURE CODE [CA115] 1164
FAILURE CODE [CA122] 1165
FAILURE CODE [CA123] 1167
FAILURE CODE [CA131] 1169
FAILURE CODE [CA132] 1171
FAILURE CODE [CA144] 1173
FAILURE CODE [CA145] 1175
FAILURE CODE [CA153] 1177
FAILURE CODE [CA154] 1180
FAILURE CODE [CA187] 1183
FAILURE CODE [CA221] 1185
FAILURE CODE [CA222] 1187
FAILURE CODE [CA227] 1189
FAILURE CODE [CA234] 1190
FAILURE CODE [CA238] 1191
FAILURE CODE [CA239] 1193
FAILURE CODE [CA249] 1195
FAILURE CODE [CA256] 1197
FAILURE CODE [CA271] 1199
FAILURE CODE [CA272] 1201
FAILURE CODE [CA281] 1203
FAILURE CODE [CA322] 1204
FAILURE CODE [CA323] 1206
FAILURE CODE [CA324] 1208
FAILURE CODE [CA325] 1210
FAILURE CODE [CA331] 1212
FAILURE CODE [CA332] 1214
FAILURE CODE [CA343] 1216
FAILURE CODE [CA351] 1217
FAILURE CODE [CA352] 1218
FAILURE CODE [CA356] 1221
FAILURE CODE [CA357] 1223
FAILURE CODE [CA386] 1225
FAILURE CODE [CA428] 1226
FAILURE CODE [CA429] 1228
FAILURE CODE [CA435] 1230
FAILURE CODE [CA441] 1232
FAILURE CODE [CA442] 1234
FAILURE CODE [CA449] 1235
FAILURE CODE [CA451] 1239
FAILURE CODE [CA452] 1242
FAILURE CODE [CA488] 1244
FAILURE CODE [CA515] 1245
FAILURE CODE [CA516] 1247
FAILURE CODE [CA553] 1249
FAILURE CODE [CA555] 1250
FAILURE CODE [CA556] 1251
FAILURE CODE [CA559] 1252
FAILURE CODE [CA595] 1256
FAILURE CODE [CA687] 1257
FAILURE CODE [CA689] 1259
FAILURE CODE [CA691] 1264
FAILURE CODE [CA692] 1266
FAILURE CODE [CA697] 1268
FAILURE CODE [CA698] 1269
FAILURE CODE [CA731] 1270
FAILURE CODE [CA778] 1272
FAILURE CODE [CA1777] 1277
FAILURE CODE [CA1664] 1280
FAILURE CODE [CA1669] 1282
FAILURE CODE [CA1673] 1283
FAILURE CODE [CA1677] 1284
FAILURE CODE [CA1678] 1285
FAILURE CODE [CA1682] 1286
FAILURE CODE [CA1683] 1288
FAILURE CODE [CA1684] 1290
FAILURE CODE [CA1686] 1292
FAILURE CODE [CA1691] 1293
FAILURE CODE [CA1694] 1296
FAILURE CODE [CA1695] 1299
FAILURE CODE [CA1696] 1300
FAILURE CODE [CA1712] 1302
FAILURE CODE [CA1713] 1305
FAILURE CODE [CA1714] 1307
FAILURE CODE [CA1715] 1308
FAILURE CODE [CA1776] 1309
FAILURE CODE [CA1777] 1312
FAILURE CODE [CA1843] 1315
FAILURE CODE [CA1844] 1317
FAILURE CODE [CA1879] 1320
FAILURE CODE [CA1881] 1323
FAILURE CODE [CA1883] 1325
FAILURE CODE [CA1885] 1328
FAILURE CODE [CA1887] 1330
FAILURE CODE [CA1921] 1332
FAILURE CODE [CA1922] 1335
FAILURE CODE [CA1942] 1340
FAILURE CODE [CA1993] 1341
FAILURE CODE [CA2185] 1344
FAILURE CODE [CA2186] 1346
FAILURE CODE [CA2249] 1348
FAILURE CODE [CA2265] 1349
FAILURE CODE [CA2266] 1351
FAILURE CODE [CA2271] 1353
FAILURE CODE [CA2272] 1356
FAILURE CODE [CA2288] 1359
FAILURE CODE [CA2311] 1360
FAILURE CODE [CA2349] 1361
FAILURE CODE [CA2353] 1364
FAILURE CODE [CA2357] 1366
FAILURE CODE [CA2381] 1367
FAILURE CODE [CA2382] 1370
FAILURE CODE [CA2383] 1373
FAILURE CODE [CA2386] 1376
FAILURE CODE [CA2387] 1378
FAILURE CODE [CA2555] 1379
FAILURE CODE [CA2556] 1381
FAILURE CODE [CA2637] 1383
FAILURE CODE [CA2639] 1385
FAILURE CODE [CA2771] 1388
FAILURE CODE [CA2777] 1394
FAILURE CODE [CA2976] 1397
FAILURE CODE [CA3133] 1399
FAILURE CODE [CA3134] 1401
FAILURE CODE [CA3135] 1403
FAILURE CODE [CA3142] 1406
FAILURE CODE [CA3143] 1407
FAILURE CODE [CA3144] 1408
FAILURE CODE [CA3146] 1410
FAILURE CODE [CA3147] 1411
FAILURE CODE [CA3148] 1412
FAILURE CODE [CA3151] 1414
FAILURE CODE [CA3165] 1420
FAILURE CODE [CA3229] 1422
FAILURE CODE [CA3231] 1424
FAILURE CODE [CA3232] 1426
FAILURE CODE [CA3235] 1430
FAILURE CODE [CA3239] 1432
FAILURE CODE [CA3241] 1435
FAILURE CODE [CA3242] 1438
FAILURE CODE [CA3251] 1441
FAILURE CODE [CA3253] 1443
FAILURE CODE [CA3254] 1446
FAILURE CODE [CA3255] 1449
FAILURE CODE [CA3256] 1453
FAILURE CODE [CA3311] 1455
FAILURE CODE [CA3312] 1457
FAILURE CODE [CA3313] 1460
FAILURE CODE [CA3314] 1461
FAILURE CODE [CA3315] 1462
FAILURE CODE [CA3316] 1464
FAILURE CODE [CA3317] 1465
FAILURE CODE [CA3318] 1466
FAILURE CODE [CA3319] 1468
FAILURE CODE [CA3321] 1469
FAILURE CODE [CA3322] 1471
FAILURE CODE [CA3419] 1473
FAILURE CODE [CA3421] 1475
FAILURE CODE [CA3497] 1477
FAILURE CODE [CA3498] 1478
FAILURE CODE [CA3543] 1479
FAILURE CODE [CA3545] 1486
FAILURE CODE [CA3547] 1488
FAILURE CODE [CA3558] 1489
FAILURE CODE [CA3559] 1491
FAILURE CODE [CA3562] 1493
FAILURE CODE [CA3563] 1495
FAILURE CODE [CA3567] 1498
FAILURE CODE [CA3568] 1501
FAILURE CODE [CA3571] 1505
FAILURE CODE [CA3572] 1507
FAILURE CODE [CA3574] 1509
FAILURE CODE [CA3575] 1511
FAILURE CODE [CA3577] 1513
FAILURE CODE [CA3578] 1515
FAILURE CODE [CA3582] 1517
FAILURE CODE [CA3583] 1523
FAILURE CODE [CA3596] 1525
FAILURE CODE [CA3649] 1527
FAILURE CODE [CA3681] 1529
FAILURE CODE [CA3682] 1534
FAILURE CODE [CA3713] 1540
FAILURE CODE [CA3717] 1543
FAILURE CODE [CA3718] 1544
FAILURE CODE [CA3725] 1545
FAILURE CODE [CA3741] 1548
FAILURE CODE [CA3748] 1549
FAILURE CODE [CA3751] 1551
FAILURE CODE [CA3755] 1553
FAILURE CODE [CA3866] 1555
FAILURE CODE [CA3867] 1559
FAILURE CODE [CA3868] 1562
FAILURE CODE [CA3899] 1566
FAILURE CODE [CA3911] 1568
FAILURE CODE [CA3912] 1572
FAILURE CODE [CA3932] 1574
FAILURE CODE [CA3933] 1576
FAILURE CODE [CA3934] 1578
FAILURE CODE [CA3935] 1581
FAILURE CODE [CA3936] 1583
FAILURE CODE [CA4151] 1585
FAILURE CODE [CA4152] 1589
FAILURE CODE [CA4155] 1593
FAILURE CODE [CA4156] 1595
FAILURE CODE [CA4157] 1597
FAILURE CODE [CA4158] 1599
FAILURE CODE [CA4159] 1600
FAILURE CODE [CA4161] 1601
FAILURE CODE [CA4162] 1604
FAILURE CODE [CA4163] 1607
FAILURE CODE [CA4164] 1609
FAILURE CODE [CA4165] 1611
FAILURE CODE [CA4166] 1613
FAILURE CODE [CA4168] 1615
FAILURE CODE [CA4169] 1618
FAILURE CODE [CA4171] 1620
FAILURE CODE [CA4249] 1623
FAILURE CODE [CA4251] 1625
FAILURE CODE [CA4259] 1627
FAILURE CODE [CA4261] 1630
FAILURE CODE [CA4277] 1633
FAILURE CODE [CA4281] 1637
FAILURE CODE [CA4459] 1640
FAILURE CODE [CA4461] 1643
FAILURE CODE [CA4658] 1646
FAILURE CODE [CA4731] 1650
FAILURE CODE [CA4732] 1651
FAILURE CODE [CA4739] 1652
FAILURE CODE [CA4768] 1653
FAILURE CODE [CA4769] 1655
FAILURE CODE [CA4842] 1658
FAILURE CODE [CA4952] 1662
FAILURE CODE [CA5115] 1664
FAILURE CODE [CA5179] 1667
FAILURE CODE [CA5181] 1669
FAILURE CODE [CA5383] 1671
FAILURE CODE [D110KB] 1673
FAILURE CODE [D19JKZ] 1675
FAILURE CODE [D811MC] 1678
FAILURE CODE [D862KA] 1679
FAILURE CODE [D8ALKA] 1681
FAILURE CODE [D8ALKB] 1684
FAILURE CODE [D8AQKR] 1686
FAILURE CODE [D8G1KT] 1693
FAILURE CODE [D8G6KT] 1694
FAILURE CODE [DA20MC] 1695
FAILURE CODE [DA22KK] 1696
FAILURE CODE [DA25KP] 1699
FAILURE CODE [DA29KQ] 1702
FAILURE CODE [DA2LKA] 1704
FAILURE CODE [DA2LKB] 1707
FAILURE CODE [DA2QKR] 1709
FAILURE CODE [DA2RKR] 1718
FAILURE CODE [DAF0KM] 1719
FAILURE CODE [DAF0MB] 1720
FAILURE CODE [DAF0MC] 1721
FAILURE CODE [DAF8KB] 1722
FAILURE CODE [DAF9KQ] 1724
FAILURE CODE [DAFGMC] 1725
FAILURE CODE [DAFLKA] 1726
FAILURE CODE [DAFLKB] 1729
FAILURE CODE [DAFQKR] 1731
FAILURE CODE [DAZ9KQ] 1739
FAILURE CODE [DAZQKR] 1740
FAILURE CODE [DBPQKR] 1747
FAILURE CODE [DBP0KM] 1755
FAILURE CODE [DBP0KT] 1756
FAILURE CODE [DBP5KB] 1757
FAILURE CODE [DBP5KY] 1760
FAILURE CODE [DB2QKR] 1763
FAILURE CODE [DB2RKR] 1771
FAILURE CODE [DDNRKA] 1776
FAILURE CODE [DDNRKY] 1778
FAILURE CODE [DDNS00] 1780
FAILURE CODE [DFB1KZ] 1782
FAILURE CODE [DFB2KZ] 1784
FAILURE CODE [DFB3L8] 1786
FAILURE CODE [DFB4L8] 1788
FAILURE CODE [DFB5KZ] 1790
FAILURE CODE [DFB6KZ] 1792
FAILURE CODE [DGH2KB] 1794
FAILURE CODE [DHA4KA] 1796
FAILURE CODE [DHAAMA] 1798
FAILURE CODE [DHACMA] 1800
FAILURE CODE [DHPAMA] 1802
FAILURE CODE [DHPBMA] 1805
FAILURE CODE [DHS3MA] 1808
FAILURE CODE [DHS4MA] 1811
FAILURE CODE [DHS8MA] 1814
FAILURE CODE [DHS9MA] 1817
FAILURE CODE [DHSAMA] 1820
FAILURE CODE [DHSBMA] 1823
FAILURE CODE [DHSCMA] 1826
FAILURE CODE [DHSDMA] 1829
FAILURE CODE [DHSFMA] 1832
FAILURE CODE [DHSGMA] 1835
FAILURE CODE [DHSHMA] 1838
FAILURE CODE [DHSJMA] 1841
FAILURE CODE [DHZAMA] 1844
FAILURE CODE [DHZCL8] 1848
FAILURE CODE [DKR0MA] 1849
FAILURE CODE [DKR1MA] 1852
FAILURE CODE [DKULKA] 1855
FAILURE CODE [DKULKB] 1857
FAILURE CODE [DKULKY] 1859
FAILURE CODE [DR10KA] 1861
FAILURE CODE [DR12KA] 1864
FAILURE CODE [DR20KA] 1866
FAILURE CODE [DR21KX] 1868
FAILURE CODE [DR30KA] 1870
FAILURE CODE [DR31KX] 1872
FAILURE CODE [DR40KA] 1874
FAILURE CODE [DUMBKA] 1876
FAILURE CODE [DUMBKB] 1879
FAILURE CODE [DV00KA] 1881
FAILURE CODE [DV00KB] 1882
FAILURE CODE [DV20KB] 1883
FAILURE CODE [DW43KA] 1885
FAILURE CODE [DW43KB] 1887
FAILURE CODE [DW43KY] 1889
FAILURE CODE [DW45KA] 1891
FAILURE CODE [DW45KB] 1894
FAILURE CODE [DW45KY] 1897
FAILURE CODE [DW4CKY] 1899
FAILURE CODE [DW91KA] 1900
FAILURE CODE [DW91KB] 1902
FAILURE CODE [DW91KY] 1904
FAILURE CODE [DWA2KA] 1906
FAILURE CODE [DWA2KB] 1908
FAILURE CODE [DWA2KY] 1910
FAILURE CODE [DWK0KA] 1912
FAILURE CODE [DWK0KB] 1914
FAILURE CODE [DWK0KY] 1916
FAILURE CODE [DWK2KA] 1918
FAILURE CODE [DWK2KB] 1920
FAILURE CODE [DWK2KY] 1922
FAILURE CODE [DWK8KA] 1924
FAILURE CODE [DWK8KB] 1926
FAILURE CODE [DWK8KY] 1928
FAILURE CODE [DWPUKA] 1930
FAILURE CODE [DWPUKB] 1932
FAILURE CODE [DWPUKY] 1934
FAILURE CODE [DXA8KA] 1936
FAILURE CODE [DXA8KB] 1939
FAILURE CODE [DXA9KA] 1941
FAILURE CODE [DXA9KB] 1944
FAILURE CODE [DXE0KA] 1946
FAILURE CODE [DXE0KB] 1948
FAILURE CODE [DXE4KA] 1950
FAILURE CODE [DXE4KB] 1952
FAILURE CODE [DXE4KY] 1954
FAILURE CODE [DXE5KA] 1955
FAILURE CODE [DXE5KB] 1957
FAILURE CODE [DXE6KA] 1959
FAILURE CODE [DXE6KB] 1961
FAILURE CODE [DXE7KA] 1963
FAILURE CODE [DXE7KB] 1965
FAILURE CODE [DXE7KY] 1967
FAILURE CODE [DXE8KA] 1969
FAILURE CODE [DXE8KB] 1971
FAILURE CODE [DXE8KY] 1973
FAILURE CODE [DXE9KA] 1975
FAILURE CODE [DXE9KB] 1977
FAILURE CODE [DXE9KY] 1979
FAILURE CODE [DXEAKA] 1981
FAILURE CODE [DXEAKB] 1983
FAILURE CODE [DXEAKY] 1985
FAILURE CODE [DXEKKA] 1987
FAILURE CODE [DXEKKB] 1989
FAILURE CODE [DXEKKY] 1991
FAILURE CODE [DXELKA] 1993
FAILURE CODE [DXELKB] 1995
FAILURE CODE [DXELKY] 1997
FAILURE CODE [DY20KA] 1999
FAILURE CODE [DY20MA] 2002
FAILURE CODE [DY2CKB] 2004
FAILURE CODE [DY2DKB] 2007
FAILURE CODE [DY2EKB] 2009
FAILURE CODE [F313KA] 2011
FAILURE CODE [F313KB] 2013
FAILURE CODE [F318KB] 2016
FAILURE CODE [F318KY] 2019
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 2021
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) 2021
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 2027
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK 2030
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP 2032
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING 2034
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 2037
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 2038
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 2039
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 2040
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING 2041
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2042
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2043
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2044
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2045
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2046
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 2047
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2048
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL 2050
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2051
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 2052
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 2053
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE 2055
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED 2056
E-24 FUNCTION SWITCH DOES NOT OPERATE 2057
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) 2058
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 2059
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 2060
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED 2061
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 2062
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE 2063
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 2064
E-32 ALARM BUZZER CANNOT BE CANCELED 2066
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION 2067
E-34 SERVICE MODE CANNOT BE SELECTED 2068
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 2069
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK 2071
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING 2072
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE 2075
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR 2077
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED 2079
E-41 ALARM DOES NOT SOUND DURING TRAVEL 2080
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 2082
E-43 HORN DOES NOT SOUND 2083
E-44 HORN DOES NOT STOP SOUNDING 2087
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF 2089
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE 2090
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 2092
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2093
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2094
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2095
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2096
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2097
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2098
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2099
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2100
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 2101
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED 2103
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY 2104
E-59 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED 2105
E-60 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 2107
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 2108
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) 2108
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 2109
FAILURE MODE AND CAUSE TABLE 2111
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 2122
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER 2123
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 2126
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP 2127
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 2128
H-6 SPEED OR POWER OF BOOM IS LOW 2130
H-7 ARM SPEED OR POWER IS LOW 2136
H-8 BUCKET SPEED OR POWER IS LOW 2141
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 2145
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE 2146
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 2148
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE 2150
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES 2151
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 2152
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE 2153
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 2154
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED 2155
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED 2156
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 2157
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 2158
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 2159
H-22 MACHINE DOES NOT TRAVEL STRAIGHT 2160
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW 2162
H-24 TRAVEL SPEED IS LOW 2165
H-25 ONE OF TRACKS DOES NOT RUN 2167
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2169
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 2170
H-28 SWINGS ONLY IN ONE DIRECTION 2171
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) 2172
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 2173
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 2174
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 2175
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING 2176
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING 2177
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) 2178
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2179
H-37 Quick coupler cylinder will not extend 2180
H-38 Quick coupler cylinder will not retract (but buzzer doesnot sound) 2182
H-39 Buzzer does not sound (but quick coupler cylinder doesretract) 2184
H-40 Quick coupler cylinder extends and retracts slowly 2186
TROUBLESHOOTING OF ENGINE (S-MODE) 2187
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) 2187
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2188
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2189
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2190
S-4 ENGINE STARTABILITY IS POOR 2192
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2194
S-6 ENGINE STOPS DURING OPERATION 2196
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2198
S-8 ENGINE LACKS POWER 2199
S-9 KDPF GETS CLOGGED IN A SHORT TIME 2201
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2203
S-11 OIL BECOMES CONTAMINATED QUICKLY 2204
S-12 FUEL CONSUMPTION IS EXCESSIVE 2205
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2206
S-14 OIL PRESSURE DROPS 2207
S-15 FUEL MIXES INTO ENGINE OIL 2209
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2210
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) 2211
S-18 UNUSUAL NOISE IS HEARD 2212
S-19 VIBRATION IS EXCESSIVE 2213
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT 2214
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY 2215
S-22 ACTIVE REGENERATION TAKES TIME 2217
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2218
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2219
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) 2221
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2222
TROUBLESHOOTING OF WORKING RANGE INDICATOR BY FAILURE CODE (IF EQUIPPED) 2223
20 SUPPLY VOLTAGE > 32VDC 2223
21 SUPPLY VOLTAGE < 12VDC 2224
25 FILE ERROR FACTORY SETTINGS 2225
26 FILE ERROR USER SETTINGS 2226
27 FILE ERROR INPUT DATA 2227
30 PROXIMITY SWITCHES DIFFERENCE 2228
86 ANGLE SENSOR A2 TIMEOUT 2229
96 ANGLE SENSOR A3/A5 TIMEOUT 2230
106 ANGLE SENSOR A4/A6 TIMEOUT 2231
116 ANGLE SENSOR PITCH TIMEOUT 2232
126 ANGLE SENSOR ROLL TIMEOUT 2233
50 DISASSEMBLY AND ASSEMBLY 2235
CONTENTS 2236
ABBREVIATION LIST 2241
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY 2247
HOW TO READ THIS MANUAL 2247
COATING MATERIALS LIST 2249
SPECIAL TOOLS LIST 2253
SKETCHES OF SPECIAL TOOLS 2268
ENGINE AND COOLING SYSTEM 2276
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY 2276
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2276
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2281
REMOVE AND INSTALL INJECTOR ASSEMBLY 2289
METHOD FOR REMOVING INJECTOR ASSEMBLY 2289
METHOD FOR INSTALLING INJECTOR ASSEMBLY 2296
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY 2308
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2309
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2318
REMOVE AND INSTALL EGR VALVE ASSEMBLY 2336
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2336
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2337
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2339
METHOD FOR REMOVING EGR COOLER ASSEMBLY 2339
METHOD FOR INSTALLING EGR COOLER ASSEMBLY 2340
REMOVE AND INSTALL STARTER ASSEMBLY 2343
METHOD FOR REMOVING STARTER ASSEMBLY 2343
METHOD FOR INSTALLING STARTER ASSEMBLY 2344
REMOVE AND INSTALL ALTERNATOR BELT 2345
METHOD FOR REMOVING ALTERNATOR BELT 2345
METHOD FOR INSTALLING ALTERNATOR BELT 2348
REMOVE AND INSTALL RADIATOR ASSEMBLY 2351
METHOD FOR REMOVING RADIATOR ASSEMBLY 2351
METHOD FOR INSTALLING RADIATOR ASSEMBLY 2353
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2355
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY 2355
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY 2357
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY 2360
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2360
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2361
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2363
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY 2364
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY 2376
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2391
METHOD FOR REMOVING ENGINE FRONT OIL SEAL 2391
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL 2395
REMOVE AND INSTALL ENGINE REAR OIL SEAL 2399
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2400
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2401
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY 2408
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2408
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2409
REMOVE AND INSTALL FUEL TANK ASSEMBLY 2412
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2412
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2416
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY 2419
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2419
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2425
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2430
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2430
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2437
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR 2442
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2442
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2442
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER 2449
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2449
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2449
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER 2450
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2450
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2452
REMOVE AND INSTALL KDPF ASSEMBLY 2455
METHOD FOR REMOVING KDPF ASSEMBLY 2455
METHOD FOR INSTALLING KDPF ASSEMBLY 2458
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY 2462
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2463
METHOD FOR ASSEMBLING KDPF ASSEMBLY 2466
REMOVE AND INSTALL SCR ASSEMBLY 2471
METHOD FOR REMOVING SCR ASSEMBLY 2471
METHOD FOR INSTALLING SCR ASSEMBLY 2474
REMOVE AND INSTALL KDPF, SCR ASSEMBLY 2477
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2478
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2484
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET 2491
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2491
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2494
REMOVE AND INSTALL KCCV ASSEMBLY 2499
METHOD FOR REMOVING KCCV ASSEMBLY 2499
METHOD FOR INSTALLING KCCV ASSEMBLY 2500
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE 2502
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2503
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2506
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2510
METHOD FOR REMOVING AdBlue/DEF INJECTOR 2510
METHOD FOR INSTALLING AdBlue/DEF INJECTOR 2513
REMOVE AND INSTALL AdBlue/DEF PUMP 2517
METHOD FOR REMOVING AdBlue/DEF PUMP 2517
METHOD FOR INSTALLING AdBlue/DEF PUMP 2520
REMOVE AND INSTALL AdBlue/DEF HOSE 2522
METHOD FOR REMOVING AdBlue/DEF HOSE 2523
METHOD FOR INSTALLING AdBlue/DEF HOSE 2529
REMOVE AND INSTALL AIR CLEANER ASSEMBLY 2537
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2537
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2539
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2541
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY 2541
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY 2542
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY 2544
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2544
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2545
POWER TRAIN 2546
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2546
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2546
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2547
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY 2549
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY 2550
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2554
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY 2562
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2562
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2563
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY 2565
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY 2565
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2568
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2576
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY 2576
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY 2576
UNDERCARRIAGE AND FRAME 2578
SEPARATION AND CONNECTION OF TRACK ASSEMBLY 2578
METHOD FOR SEPARATING TRACK ASSEMBLY 2578
METHOD FOR INSTALLING TRACK ASSEMBLY 2580
REMOVE AND INSTALL SPROCKET 2583
METHOD FOR REMOVING SPROCKET 2583
METHOD FOR INSTALLING SPROCKET 2583
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY 2585
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2585
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2586
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY 2587
METHOD FOR DISASSEMBLING IDLER ASSEMBLY 2587
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2588
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2592
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY 2593
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2593
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2595
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2596
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY 2597
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY 2599
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2599
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY 2600
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY 2603
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2603
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2605
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY – PC390HRD-11E0 2607
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY 2608
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2608
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2609
HYDRAULIC SYSTEM 2612
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY 2612
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2612
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2613
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY 2616
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2617
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2618
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2619
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY 2619
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY 2623
REMOVE AND INSTALL MAIN PUMP ASSEMBLY 2627
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2627
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2630
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY 2633
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2633
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2640
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY 2647
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2648
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2649
REMOVE AND INSTALL ATT BYPASS SOLENOID 2654
REMOVE ATT BYPASS SOLENOID 2654
INSTALL ATT BYPASS SOLENOID 2657
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2659
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2659
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2660
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2662
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2662
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2663
REMOVE AND INSTALL QUICK COUPLER VALVE 2665
WORK EQUIPMENT 2667
REMOVE AND INSTALL BUCKET ASSEMBLY 2667
METHOD FOR REMOVING BUCKET ASSEMBLY 2667
METHOD FOR INSTALLING BUCKET ASSEMBLY 2667
REMOVE AND INSTALL ARM ASSEMBLY 2669
METHOD FOR REMOVING ARM ASSEMBLY 2669
METHOD FOR INSTALLING ARM ASSEMBLY 2670
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2672
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY 2672
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY 2675
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY 2678
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2678
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2681
CAB AND ITS ATTACHMENTS 2688
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2688
METHOD FOR REMOVING OPERATOR’S CAB ASSEMBLY 2688
METHOD FOR INSTALLING OPERATOR’S CAB ASSEMBLY 2696
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) 2703
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2705
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2705
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2715
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY 2715
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY 2718
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY 2724
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2725
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2731
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2739
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY 2739
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY 2745
REMOVE AND INSTALL OPERATOR’S SEAT 2751
METHOD FOR REMOVING OPERATOR’S SEAT 2751
METHOD FOR INSTALLING OPERATOR’S SEAT 2753
REMOVE AND INSTALL SEAT BELT 2756
METHOD FOR REMOVING SEAT BELT 2756
METHOD FOR INSTALLING SEAT BELT 2757
REMOVE AND INSTALL FRONT WIPER ASSEMBLY 2758
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2758
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2763
ELECTRICAL SYSTEM 2772
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY 2772
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2772
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2774
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY 2778
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2778
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2781
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY 2785
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY 2785
METHOD FOR INSTALLING KomVision CONTROLLER 2786
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY 2787
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2787
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2790
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2794
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR 2794
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR 2794
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR 2796
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2796
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2797
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR 2798
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2798
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2799
REMOVE AND INSTALL SCR TEMPERATURE SENSOR 2800
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2800
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2801
REMOVE AND INSTALL REARVIEW CAMERA 2803
METHOD FOR REMOVING REARVIEW CAMERA 2803
METHOD FOR INSTALLING REARVIEW CAMERA 2804
REMOVE AND INSTALL KomVision CAMERA 2806
METHOD FOR REMOVING KomVision CAMERA 2806
METHOD FOR INSTALLING KomVision CAMERA 2807
REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY 2809
METHOD FOR REMOVING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2809
METHOD FOR INSTALLING GATEWAY FUNCTION CONTROLLER ASSEMBLY 2814
REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS 2819
METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS 2819
METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS 2827
REMOVE AND INSTALL COMMUNICATION TERMINAL 2836
METHOD FOR REMOVING COMMUNICATION TERMINAL 2836
METHOD FOR INSTALLING COMMUNICATION TERMINAL 2838
60 MAINTENANCE STANDARD 2841
CONTENTS 2842
ABBREVIATION LIST 2843
ENGINE AND COOLING SYSTEM 2849
MAINTENANCE STANDARD OF ENGINE MOUNT 2849
MAINTENANCE STANDARD OF COOLING SYSTEM 2851
POWER TRAIN 2853
MAINTENANCE STANDARD OF SWING CIRCLE 2853
MAINTENANCE STANDARD OF SWING MACHINERY 2854
MAINTENANCE STANDARD OF FINAL DRIVE 2856
MAINTENANCE STANDARD OF SPROCKET 2858
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING 2859
UNDERCARRIAGE AND FRAME 2861
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION 2861
MAINTENANCE STANDARD OF IDLER 2863
MAINTENANCE STANDARD OF TRACK ROLLER 2865
MAINTENANCE STANDARD OF CARRIER ROLLER 2867
MAINTENANCE STANDARD OF TRACK SHOE 2868
MAINTENANCE STANDARD OF TRIPLE SHOE 2871
HYDRAULIC SYSTEM 2872
MAINTENANCE STANDARD OF HYDRAULIC TANK 2872
MAINTENANCE STANDARD OF MAIN PUMP 2873
MAINTENANCE STANDARD OF SWING MOTOR 2875
MAINTENANCE STANDARD OF TRAVEL MOTOR 2878
MAINTENANCE STANDARD OF CONTROL VALVE 2881
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2891
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2894
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2897
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2899
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE 2900
MAINTENANCE STANDARD OF SOLENOID VALVE 2902
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 2903
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE 2905
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT 2906
WORK EQUIPMENT 2907
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2907
DIMENSION OF ARM 2912
DIMENSIONS OF BUCKET 2914
MAINTENANCE STANDARD OF BOOM CYLINDER 2916
MAINTENANCE STANDARD OF ARM CYLINDER 2917
MAINTENANCE STANDARD OF BUCKET CYLINDER 2918
WORK EQUIPMENT – PC390HRD-11E0 2919
WORK EQUIPMENT – HIGH REACH DEMOLITION 2919
DIMENSION OF ARM 2919
MAINTENANCE STANDARD OF BOOM CYLINDER 2920
MAINTENANCE STANDARD OF LINK CYLINDER 2921
MAINTENANCE STANDARD OF ARM CYLINDER 2922
MAINTENANCE STANDARD OF BUCKET CYLINDER 2923
WORK EQUIPMENT – DEMOLITION DIGGING 2924
MAINTENANCE STANDARD OF ARM CYLINDER 2924
MAINTENANCE STANDARD OF BUCKET CYLINDER 2925
80 APPENDIX 2927
CONTENTS 2928
ABBREVIATION LIST 2930
AIR CONDITIONER SYSTEM 2936
PRECAUTIONS FOR REFRIGERANT 2936
AIR CONDITIONER COMPONENT 2937
SPECIFICATIONS OF AIR CONDITIONER 2939
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE 2940
OUTLINE OF REFRIGERATION CYCLE 2941
COMPONENT PARTS OF AIR CONDITIONER SYSTEM 2943
AIR CONDITIONER UNIT 2943
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT 2943
FUNCTION OF AIR CONDITIONER UNIT 2945
COMPONENT PARTS OF AIR CONDITIONER UNIT 2947
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2948
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT 2948
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT 2948
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT 2948
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2949
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2949
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2949
FUNCTION OF DUAL PRESSURE SWITCH 2950
AIR CONDITIONER CONTROLLER 2951
STRUCTURE OF AIR CONDITIONER CONTROLLER 2951
COMPRESSOR 2952
STRUCTURE OF COMPRESSOR 2952
SPECIFICATIONS OF COMPRESSOR 2952
FUNCTION OF COMPRESSOR 2952
CONDENSER 2953
STRUCTURE OF CONDENSER 2953
SPECIFICATIONS OF CONDENSER 2953
FUNCTION OF CONDENSER 2953
RECEIVER DRIER 2954
STRUCTURE OF RECEIVER DRIER 2954
SPECIFICATIONS OF RECEIVER DRIER 2954
FUNCTION OF RECEIVER DRIER 2954
SENSORS FOR AIR CONDITIONER SYSTEM 2955
STRUCTURE OF SUNLIGHT SENSOR 2955
FUNCTION OF SUNLIGHT SENSOR 2955
STRUCTURE OF AMBIENT TEMPERATURE SENSOR 2955
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2955
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER 2957
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER 2959
AIR CONDITIONER SYSTEM DIAGRAM 2961
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2962
FUNCTION OF AIR CONDITIONER CONTROLLER 2963
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS 2964
TESTING AIR LEAKAGE (DUCT) 2968
METHOD FOR TESTING AIR LEAKAGE (DUCT) 2968
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION 2970
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2971
TEST VENT (MODE) CHANGEOVER 2972
METHOD FOR TESTING VENT (MODE) CHANGEOVER 2972
TESTING FRESH/RECIRC AIR CHANGEOVER 2974
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2974
TEST SUNLIGHT SENSOR 2975
METHOD FOR TESTING SUNLIGHT SENSOR 2975
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2976
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT 2976
TEST RELAYS 2977
METHOD FOR TESTING RELAYS 2977
AIR CONDITIONER TROUBLESHOOTING CHART 1 2978
AIR CONDITIONER TROUBLESHOOTING CHART 2 2979
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2982
FAILURE CODE [879AKA] 2984
FAILURE CODE [879AKB] 2985
FAILURE CODE [879BKA] 2986
FAILURE CODE [879BKB] 2988
FAILURE CODE [879CKA] 2990
FAILURE CODE [879CKB] 2991
FAILURE CODE [879DKZ] 2992
FAILURE CODE [879EMC] 2994
FAILURE CODE [879FMC] 2995
FAILURE CODE [879GKX] 2996
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2998
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) 3000
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 3003
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER 3005
TROUBLESHOOTING USING GAUGE PRESSURE 3007
CONNECTION OF SERVICE TOOL 3010
METHOD FOR CONNECTING SERVICE TOOL 3010
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS 3012
HANDLE COMPRESSOR OIL 3014
90 CIRCUIT DIAGRAMS 3017
CONTENTS 3018
ABBREVIATION LIST 3019
HYDRAULIC CIRCUIT DIAGRAM 3025
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM 3025
HYDRAULIC CIRCUIT DIAGRAM (1/2) 3029
HYDRAULIC CIRCUIT DIAGRAM (2/2) 3031
HYDRAULIC CIRCUIT DIAGRAM (1/3) – PC390HRD-11E0 3033
HYDRAULIC CIRCUIT DIAGRAM (2/3) – PC390HRD-11E0 3035
HYDRAULIC CIRCUIT DIAGRAM (3/3) – PC390HRD-11E0 3037
ELECTRICAL CIRCUIT DIAGRAM 3039
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 3039
ELECTRICAL CIRCUIT DIAGRAM (1/8) 3043
ELECTRICAL CIRCUIT DIAGRAM (2/8) 3045
ELECTRICAL CIRCUIT DIAGRAM (3/8) 3047
ELECTRICAL CIRCUIT DIAGRAM (4/8) 3049
ELECTRICAL CIRCUIT DIAGRAM (5/8) 3051
ELECTRICAL CIRCUIT DIAGRAM (6/8) 3053
ELECTRICAL CIRCUIT DIAGRAM (7/8) 3055
ELECTRICAL CIRCUIT DIAGRAM (8/8) 3057
HYDRAULIC CIRCUIT DIAGRAM GATEWAY 3059
HYDRAULIC CIRCUIT DIAGRAM (1/3) 3061
HYDRAULIC CIRCUIT DIAGRAM (2/3) 3063
HYDRAULIC CIRCUIT DIAGRAM (3/3) 3065
WIRING DIAGRAM (BEFORE GATEWAY) 3067
WIRING DIAGRAM (1/11) 3069
WIRING DIAGRAM (2/11) 3071
WIRING DIAGRAM (3/11) 3073
WIRING DIAGRAM (4/11) 3075
WIRING DIAGRAM (5/11) 3077
WIRING DIAGRAM (6/11) 3079
WIRING DIAGRAM (7/11) 3081
WIRING DIAGRAM (8/11) 3083
WIRING DIAGRAM (9/11) 3085
WIRING DIAGRAM (10/11) 3087
WIRING DIAGRAM (11/11) 3089
WIRING DIAGRAM (AFTER GATEWAY) 3091
WIRING DIAGRAM (1/12) 3093
WIRING DIAGRAM (2/12) 3095
WIRING DIAGRAM (3/12) 3097
WIRING DIAGRAM (4/12) 3099
WIRING DIAGRAM (5/12) 3101
WIRING DIAGRAM (6/12) 3103
WIRING DIAGRAM (7/12) 3105
WIRING DIAGRAM (8/12) 3107
WIRING DIAGRAM (9/12) 3109
WIRING DIAGRAM (10/12) 3111
WIRING DIAGRAM (11/12) 3113
WIRING DIAGRAM (12/12) 3115
INDEX 3117

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

S.V