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KOMATSU PC360LC-11E0 PC360NLC-11E0 PC390HRD-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
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KOMATSU PC360LC-11E0 PC360NLC-11E0 PC390HRD-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
SERIAL NUMBERS:
PC360LC-11E0 – K75201~K75573
PC360NLC-11E0 – K75198~K75573
PC360HRD-11E0 – K75356 and up
PC360NLC-11E0 – K75198~K75573
PC360HRD-11E0 – K75356 and up
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KOMATSU PC360LC-11E0 PC360NLC-11E0 PC390HRD-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
FILE DETAILS:
KOMATSU PC360LC-11E0 PC360NLC-11E0 PC390HRD-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
Language : English
Pages : 3092
Downloadable : Yes
File Type : PDF
SERIAL NUMBERS:
PC360LC-11E0 – K75201~K75573
PC360NLC-11E0 – K75198~K75573
PC360HRD-11E0 – K75356 and up
PC360NLC-11E0 – K75198~K75573
PC360HRD-11E0 – K75356 and up
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU PC360LC-11E0 PC360NLC-11E0 PC390HRD-11E0 HYDRAULIC 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)................................................................................... 838 KomVision screen - Check 12 m visibility.................................................................................... 852 HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER..................................................................................... 855 HANDLE BATTERY DISCONNECT SWITCH................................................................................................ 856 TEST DIODES..................................................................................................................... 857 METHOD FOR TESTING DIODE USING DIGITAL TESTER............................................................................... 857 METHOD FOR TESTING DIODE USING ANALOG TESTER................................................................................ 857 ELECTRICAL SYSTEM - PC390HRD-11E0................................................................................................... 858 ELECTRICAL CIRCUIT DIAGRAMS OF WORK EQUIPMENT SYSTEM............................................................................ 858 HIGH REACH DEMOLITION ELECTRICAL DIAGRAM - BASE MACHINE..................................................................... 858 HIGH REACH DEMOLITION ELECTRICAL DIAGRAM - HIGH REACH DEMOLITION WORK EQUIPMENT............................................. 861 HIGH REACH DEMOLITION ELECTRICAL DIAGRAM - EXTENDED HIGH REACH DEMOLITION WORK EQUIPMENT.................................... 863 HIGH REACH DEMOLITION ELECTRICAL DIAGRAM - MEDIUM REACH DEMOLITION WORK EQUIPMENT........................................... 865 HIGH REACH DEMOLITION ELECTRICAL DIAGRAM - DEMOLITION DIGGING WORK EQUIPMENT................................................ 867 RH PPC LEVER................................................................................................................ 868 WORK EQUIPMENT CONFIGURATION SELECTION CIRCUIT.............................................................................. 869 CONSTANT LINK SPEED CIRCUIT................................................................................................. 870 PARALLEL LINK FRONT SCREEN WIPER............................................................................................ 871 Pm CLINIC........................................................................................................................... 872 Pm CLINIC SERVICE............................................................................................................... 872 Pm CLINIC CHECK SHEET....................................................................................................... 873 WORKING RANGE INDICATOR SYSTEM...................................................................................................... 887 WORKING RANGE INDICATOR SYSTEM LAYOUT........................................................................................... 887 METHOD FOR ACCESSING WORKING RANGE INDICATOR KOMATSU SERVICE MENU............................................................... 889 DIAGNOSTICS - WORKING RANGE INDICATOR SYSTEM.................................................................................... 891 MONITORING SYSTEM PARAMETERS AND SENSOR STATES.............................................................................. 891 USING THE PARAMETER CHANGE LOG.............................................................................................. 893 USING ERROR LISTS AND LOGS.................................................................................................. 894 EXPORT DATA FROM WORKING RANGE INDICATOR SYSTEM............................................................................. 895 IMPORT DATA TO WORKING RANGE INDICATOR SYSTEM............................................................................... 896 REPLACING COMPONENTS - WORKING RANGE INDICATOR SYSTEM........................................................................... 898 WORKING RANGE INDICATOR SYSTEM ANGLE SENSOR REPLACEMENT..................................................................... 898 WORKING RANGE INDICATOR SYSTEM MONITOR REPLACEMENT.......................................................................... 903 WORKING RANGE INDICATOR SYSTEM - UDATING SOFTWARE........................................................................... 908 CALIBRATION - WORKING RANGE INDICATOR SYSTEM.................................................................................... 912 WORKING RANGE INDICATOR SYSTEM CALIBRATION OVERVIEW......................................................................... 912 METHOD 1 - CALIBRATING AND CONFIRMING CALIBRATION ACCURACY - AUTO CALIBRATION............................................... 912 METHOD 2 - BASE MACHINE SET-UP AND 2-AXIS PITCH AND ROLL SENSOR CALIBRATION................................................. 920 METHOD 2 - CALIBRATING AND CONFIRMING CALIBRATION ACCURACY - MANUAL CALIBRATION............................................. 923 40 TROUBLESHOOTING...................................................................................................................... 939 CONTENTS............................................................................................................................ 940 ABBREVIATION LIST................................................................................................................... 951 RELATED INFORMATION ON TROUBLESHOOTING.............................................................................................. 957 GENERAL TROUBLESHOOTING POINTS.................................................................................................. 957 TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM...................................................................................... 958 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................................... 970 CHECKS BEFORE TROUBLESHOOTING................................................................................................... 972 INSPECTION PROCEDURE BEFORE TROUBLESHOOTING..................................................................................... 974 WALK-AROUND CHECK........................................................................................................... 974 TESTING IN ACCORDANCE WITH TESTING PROCEDURE.................................................................................... 976 CHECK FUEL LEVEL AND TYPE................................................................................................... 976 CHECK IMPURE INGREDIENT IN FUEL............................................................................................. 976 CHECK FUEL PREFILTER........................................................................................................ 977 WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT.......................................................................... 977 METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE............................................................................... 978 CHECK MAIN FILTER........................................................................................................... 979 CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN).............................................................................. 981 CHECK COOLANT LEVEL (RESERVOIR TANK)........................................................................................ 982 CHECK CLOGGING OF AIR CLEANER............................................................................................... 983 OUTER ELEMENT - CLEAN....................................................................................................... 983 ELEMENTS - REPLACE.......................................................................................................... 985 CHECK HYDRAULIC OIL LEVEL................................................................................................... 986 CHECK HYDRAULIC OIL STRAINER................................................................................................ 987 CHECK HYDRAULIC FILTER...................................................................................................... 988 CHECK OIL LEVEL IN SWING MACHINERY CASE..................................................................................... 989 CHECK OIL LEVEL IN DAMPER CASE.............................................................................................. 989 CHECK OIL LEVEL IN FINAL DRIVE CASE......................................................................................... 990 BLEED AIR FROM FUEL SYSTEM.................................................................................................. 990 BLEED AIR FROM HYDRAULIC SYSTEM............................................................................................. 990 ELECTRICAL EQUIPMENT - CHECK METHOD......................................................................................... 991 AUTOMATIC GREASE SYSTEM......................................................................................................... 996 FINDING MALFUNCTIONS........................................................................................................ 996 MALFUNCTION FINDING PROCEDURES..............................................................................................1000 ELECTRICAL SYSTEM TROUBLESHOOTING - PREPARATION.................................................................................1002 PROCEDURE FOR TESTING AND TROUBLESHOOTING.......................................................................................1015 SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS.................................................................................1018 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE..................................................................................1022 TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM.............................................1024 CONNECTOR LIST AND LAYOUT.......................................................................................................1027 CONNECTOR CONTACT IDENTIFICATION................................................................................................1042 T-BRANCH BOX AND T-BRANCH ADAPTER TABLE.........................................................................................1082 FUSE LOCATION TABLE.............................................................................................................1088 PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC).....................................................................1091 FAILURE CODE TABLE..............................................................................................................1095 PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]).........................................1113 TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)...................................................................................1115 FAILURE CODE [879AKA]...........................................................................................................1115 FAILURE CODE [879AKB]...........................................................................................................1116 FAILURE CODE [879BKA]...........................................................................................................1117 FAILURE CODE [879BKB]...........................................................................................................1119 FAILURE CODE [879CKA]...........................................................................................................1121 FAILURE CODE [879CKB]...........................................................................................................1122 FAILURE CODE [879DKZ]...........................................................................................................1123 FAILURE CODE [879EMC]...........................................................................................................1125 FAILURE CODE [879FMC]...........................................................................................................1126 FAILURE CODE [879GKX]...........................................................................................................1127 FAILURE CODE [989L00]...........................................................................................................1129 FAILURE CODE [989M00]...........................................................................................................1130 FAILURE CODE [989N00]...........................................................................................................1131 FAILURE CODE [A1U0N3]...........................................................................................................1132 FAILURE CODE [A1U0N4]...........................................................................................................1134 FAILURE CODE [A900FR]...........................................................................................................1136 FAILURE CODE [A900N6]...........................................................................................................1137 FAILURE CODE [A900NY]...........................................................................................................1138 FAILURE CODE [AA10NX]...........................................................................................................1139 FAILURE CODE [AB00KE]...........................................................................................................1141 FAILURE CODE [AQ10N3]...........................................................................................................1144 FAILURE CODE [AS00N3]...........................................................................................................1146 FAILURE CODE [AS00R2]...........................................................................................................1148 FAILURE CODE [AS00R3]...........................................................................................................1149 FAILURE CODE [AS00R4]...........................................................................................................1150 FAILURE CODE [AS00R5]...........................................................................................................1151 FAILURE CODE [AS00R6]...........................................................................................................1152 FAILURE CODE [AS00ZK]...........................................................................................................1153 FAILURE CODE [AS10KM]...........................................................................................................1154 FAILURE CODE [AS10NR]...........................................................................................................1155 FAILURE CODE [AS10NT]...........................................................................................................1156 FAILURE CODE [B@BAZG]...........................................................................................................1157 FAILURE CODE [B@BAZK]...........................................................................................................1158 FAILURE CODE [B@BCNS]...........................................................................................................1160 FAILURE CODE [B@BCQA]...........................................................................................................1161 FAILURE CODE [B@BCZK]...........................................................................................................1163 FAILURE CODE [B@HANS]...........................................................................................................1165 FAILURE CODE [CA115]............................................................................................................1166 FAILURE CODE [CA122]............................................................................................................1167 FAILURE CODE [CA123]............................................................................................................1169 FAILURE CODE [CA131]............................................................................................................1171 FAILURE CODE [CA132]............................................................................................................1173 FAILURE CODE [CA144]............................................................................................................1175 FAILURE CODE [CA145]............................................................................................................1177 FAILURE CODE [CA153]............................................................................................................1179 FAILURE CODE [CA154]............................................................................................................1182 FAILURE CODE [CA187]............................................................................................................1185 FAILURE CODE [CA221]............................................................................................................1187 FAILURE CODE [CA222]............................................................................................................1189 FAILURE CODE [CA227]............................................................................................................1191 FAILURE CODE [CA234]............................................................................................................1192 FAILURE CODE [CA238]............................................................................................................1193 FAILURE CODE [CA239]............................................................................................................1195 FAILURE CODE [CA249]............................................................................................................1197 FAILURE CODE [CA256]............................................................................................................1199 FAILURE CODE [CA271]............................................................................................................1201 FAILURE CODE [CA272]............................................................................................................1203 FAILURE CODE [CA281]............................................................................................................1205 FAILURE CODE [CA322]............................................................................................................1206 FAILURE CODE [CA323]............................................................................................................1208 FAILURE CODE [CA324]............................................................................................................1210 FAILURE CODE [CA325]............................................................................................................1212 FAILURE CODE [CA331]............................................................................................................1214 FAILURE CODE [CA332]............................................................................................................1216 FAILURE CODE [CA343]............................................................................................................1218 FAILURE CODE [CA351]............................................................................................................1219 FAILURE CODE [CA352]............................................................................................................1220 FAILURE CODE [CA356]............................................................................................................1223 FAILURE CODE [CA357]............................................................................................................1225 FAILURE CODE [CA386]............................................................................................................1227 FAILURE CODE [CA428]............................................................................................................1228 FAILURE CODE [CA429]............................................................................................................1230 FAILURE CODE [CA435]............................................................................................................1232 FAILURE CODE [CA441]............................................................................................................1234 FAILURE CODE [CA442]............................................................................................................1236 FAILURE CODE [CA449]............................................................................................................1237 FAILURE CODE [CA451]............................................................................................................1241 FAILURE CODE [CA452]............................................................................................................1244 FAILURE CODE [CA488]............................................................................................................1246 FAILURE CODE [CA515]............................................................................................................1247 FAILURE CODE [CA516]............................................................................................................1249 FAILURE CODE [CA553]............................................................................................................1251 FAILURE CODE [CA555]............................................................................................................1252 FAILURE CODE [CA556]............................................................................................................1253 FAILURE CODE [CA559]............................................................................................................1254 FAILURE CODE [CA595]............................................................................................................1258 FAILURE CODE [CA687]............................................................................................................1259 FAILURE CODE [CA689]............................................................................................................1261 FAILURE CODE [CA691]............................................................................................................1266 FAILURE CODE [CA692]............................................................................................................1268 FAILURE CODE [CA697]............................................................................................................1270 FAILURE CODE [CA698]............................................................................................................1271 FAILURE CODE [CA731]............................................................................................................1272 FAILURE CODE [CA778]............................................................................................................1274 FAILURE CODE [CA1777]...........................................................................................................1279 FAILURE CODE [CA1664]...........................................................................................................1282 FAILURE CODE [CA1669]...........................................................................................................1284 FAILURE CODE [CA1673]...........................................................................................................1285 FAILURE CODE [CA1677]...........................................................................................................1286 FAILURE CODE [CA1678]...........................................................................................................1287 FAILURE CODE [CA1682]...........................................................................................................1288 FAILURE CODE [CA1683]...........................................................................................................1290 FAILURE CODE [CA1684]...........................................................................................................1292 FAILURE CODE [CA1686]...........................................................................................................1294 FAILURE CODE [CA1691]...........................................................................................................1295 FAILURE CODE [CA1694]...........................................................................................................1298 FAILURE CODE [CA1695]...........................................................................................................1301 FAILURE CODE [CA1696]...........................................................................................................1302 FAILURE CODE [CA1712]...........................................................................................................1304 FAILURE CODE [CA1713]...........................................................................................................1307 FAILURE CODE [CA1714]...........................................................................................................1309 FAILURE CODE [CA1715]...........................................................................................................1310 FAILURE CODE [CA1776]...........................................................................................................1311 FAILURE CODE [CA1777]...........................................................................................................1314 FAILURE CODE [CA1843]...........................................................................................................1317 FAILURE CODE [CA1844]...........................................................................................................1319 FAILURE CODE [CA1879]...........................................................................................................1322 FAILURE CODE [CA1881]...........................................................................................................1325 FAILURE CODE [CA1883]...........................................................................................................1327 FAILURE CODE [CA1885]...........................................................................................................1330 FAILURE CODE [CA1887]...........................................................................................................1332 FAILURE CODE [CA1921]...........................................................................................................1334 FAILURE CODE [CA1922]...........................................................................................................1337 FAILURE CODE [CA1942]...........................................................................................................1342 FAILURE CODE [CA1993]...........................................................................................................1343 FAILURE CODE [CA2185]...........................................................................................................1346 FAILURE CODE [CA2186]...........................................................................................................1348 FAILURE CODE [CA2249]...........................................................................................................1350 FAILURE CODE [CA2265]...........................................................................................................1351 FAILURE CODE [CA2266]...........................................................................................................1353 FAILURE CODE [CA2271]...........................................................................................................1355 FAILURE CODE [CA2272]...........................................................................................................1358 FAILURE CODE [CA2288]...........................................................................................................1361 FAILURE CODE [CA2311]...........................................................................................................1362 FAILURE CODE [CA2349]...........................................................................................................1363 FAILURE CODE [CA2353]...........................................................................................................1366 FAILURE CODE [CA2357]...........................................................................................................1368 FAILURE CODE [CA2381]...........................................................................................................1369 FAILURE CODE [CA2382]...........................................................................................................1372 FAILURE CODE [CA2383]...........................................................................................................1375 FAILURE CODE [CA2386]...........................................................................................................1378 FAILURE CODE [CA2387]...........................................................................................................1380 FAILURE CODE [CA2555]...........................................................................................................1381 FAILURE CODE [CA2556]...........................................................................................................1383 FAILURE CODE [CA2637]...........................................................................................................1385 FAILURE CODE [CA2639]...........................................................................................................1387 FAILURE CODE [CA2771]...........................................................................................................1390 FAILURE CODE [CA2777]...........................................................................................................1396 FAILURE CODE [CA2976]...........................................................................................................1399 FAILURE CODE [CA3133]...........................................................................................................1401 FAILURE CODE [CA3134]...........................................................................................................1403 FAILURE CODE [CA3135]...........................................................................................................1405 FAILURE CODE [CA3142]...........................................................................................................1408 FAILURE CODE [CA3143]...........................................................................................................1409 FAILURE CODE [CA3144]...........................................................................................................1410 FAILURE CODE [CA3146]...........................................................................................................1412 FAILURE CODE [CA3147]...........................................................................................................1413 FAILURE CODE [CA3148]...........................................................................................................1414 FAILURE CODE [CA3151]...........................................................................................................1416 FAILURE CODE [CA3165]...........................................................................................................1422 FAILURE CODE [CA3229]...........................................................................................................1424 FAILURE CODE [CA3231]...........................................................................................................1426 FAILURE CODE [CA3232]...........................................................................................................1428 FAILURE CODE [CA3235]...........................................................................................................1432 FAILURE CODE [CA3239]...........................................................................................................1434 FAILURE CODE [CA3241]...........................................................................................................1437 FAILURE CODE [CA3242]...........................................................................................................1440 FAILURE CODE [CA3251]...........................................................................................................1443 FAILURE CODE [CA3253]...........................................................................................................1445 FAILURE CODE [CA3254]...........................................................................................................1448 FAILURE CODE [CA3255]...........................................................................................................1451 FAILURE CODE [CA3256]...........................................................................................................1455 FAILURE CODE [CA3311]...........................................................................................................1457 FAILURE CODE [CA3312]...........................................................................................................1459 FAILURE CODE [CA3313]...........................................................................................................1462 FAILURE CODE [CA3314]...........................................................................................................1463 FAILURE CODE [CA3315]...........................................................................................................1464 FAILURE CODE [CA3316]...........................................................................................................1466 FAILURE CODE [CA3317]...........................................................................................................1467 FAILURE CODE [CA3318]...........................................................................................................1468 FAILURE CODE [CA3319]...........................................................................................................1470 FAILURE CODE [CA3321]...........................................................................................................1471 FAILURE CODE [CA3322]...........................................................................................................1473 FAILURE CODE [CA3419]...........................................................................................................1475 FAILURE CODE [CA3421]...........................................................................................................1477 FAILURE CODE [CA3497]...........................................................................................................1479 FAILURE CODE [CA3498]...........................................................................................................1480 FAILURE CODE [CA3543]...........................................................................................................1481 FAILURE CODE [CA3545]...........................................................................................................1488 FAILURE CODE [CA3547]...........................................................................................................1490 FAILURE CODE [CA3558]...........................................................................................................1491 FAILURE CODE [CA3559]...........................................................................................................1493 FAILURE CODE [CA3562]...........................................................................................................1495 FAILURE CODE [CA3563]...........................................................................................................1497 FAILURE CODE [CA3567]...........................................................................................................1500 FAILURE CODE [CA3568]...........................................................................................................1503 FAILURE CODE [CA3571]...........................................................................................................1507 FAILURE CODE [CA3572]...........................................................................................................1509 FAILURE CODE [CA3574]...........................................................................................................1511 FAILURE CODE [CA3575]...........................................................................................................1513 FAILURE CODE [CA3577]...........................................................................................................1515 FAILURE CODE [CA3578]...........................................................................................................1517 FAILURE CODE [CA3582]...........................................................................................................1519 FAILURE CODE [CA3583]...........................................................................................................1525 FAILURE CODE [CA3596]...........................................................................................................1527 FAILURE CODE [CA3649]...........................................................................................................1529 FAILURE CODE [CA3681]...........................................................................................................1531 FAILURE CODE [CA3682]...........................................................................................................1536 FAILURE CODE [CA3713]...........................................................................................................1542 FAILURE CODE [CA3717]...........................................................................................................1545 FAILURE CODE [CA3718]...........................................................................................................1546 FAILURE CODE [CA3725]...........................................................................................................1547 FAILURE CODE [CA3741]...........................................................................................................1550 FAILURE CODE [CA3748]...........................................................................................................1551 FAILURE CODE [CA3751]...........................................................................................................1553 FAILURE CODE [CA3755]...........................................................................................................1555 FAILURE CODE [CA3866]...........................................................................................................1557 FAILURE CODE [CA3867]...........................................................................................................1561 FAILURE CODE [CA3868]...........................................................................................................1564 FAILURE CODE [CA3899]...........................................................................................................1568 FAILURE CODE [CA3911]...........................................................................................................1570 FAILURE CODE [CA3912]...........................................................................................................1574 FAILURE CODE [CA3932]...........................................................................................................1576 FAILURE CODE [CA3933]...........................................................................................................1578 FAILURE CODE [CA3934]...........................................................................................................1580 FAILURE CODE [CA3935]...........................................................................................................1583 FAILURE CODE [CA3936]...........................................................................................................1585 FAILURE CODE [CA4151]...........................................................................................................1587 FAILURE CODE [CA4152]...........................................................................................................1591 FAILURE CODE [CA4155]...........................................................................................................1595 FAILURE CODE [CA4156]...........................................................................................................1597 FAILURE CODE [CA4157]...........................................................................................................1599 FAILURE CODE [CA4158]...........................................................................................................1601 FAILURE CODE [CA4159]...........................................................................................................1602 FAILURE CODE [CA4161]...........................................................................................................1603 FAILURE CODE [CA4162]...........................................................................................................1606 FAILURE CODE [CA4163]...........................................................................................................1609 FAILURE CODE [CA4164]...........................................................................................................1611 FAILURE CODE [CA4165]...........................................................................................................1613 FAILURE CODE [CA4166]...........................................................................................................1615 FAILURE CODE [CA4168]...........................................................................................................1617 FAILURE CODE [CA4169]...........................................................................................................1620 FAILURE CODE [CA4171]...........................................................................................................1622 FAILURE CODE [CA4249]...........................................................................................................1625 FAILURE CODE [CA4251]...........................................................................................................1627 FAILURE CODE [CA4259]...........................................................................................................1629 FAILURE CODE [CA4261]...........................................................................................................1632 FAILURE CODE [CA4277]...........................................................................................................1635 FAILURE CODE [CA4281]...........................................................................................................1639 FAILURE CODE [CA4459]...........................................................................................................1642 FAILURE CODE [CA4461]...........................................................................................................1645 FAILURE CODE [CA4658]...........................................................................................................1648 FAILURE CODE [CA4731]...........................................................................................................1652 FAILURE CODE [CA4732]...........................................................................................................1653 FAILURE CODE [CA4739]...........................................................................................................1654 FAILURE CODE [CA4768]...........................................................................................................1655 FAILURE CODE [CA4769]...........................................................................................................1657 FAILURE CODE [CA4842]...........................................................................................................1660 FAILURE CODE [CA4952]...........................................................................................................1664 FAILURE CODE [CA5115]...........................................................................................................1666 FAILURE CODE [CA5179]...........................................................................................................1669 FAILURE CODE [CA5181]...........................................................................................................1671 FAILURE CODE [CA5383]...........................................................................................................1673 FAILURE CODE [D110KB]...........................................................................................................1675 FAILURE CODE [D19JKZ]...........................................................................................................1677 FAILURE CODE [D811MC]...........................................................................................................1680 FAILURE CODE [D862KA]...........................................................................................................1681 FAILURE CODE [D8ALKA]...........................................................................................................1683 FAILURE CODE [D8ALKB]...........................................................................................................1686 FAILURE CODE [D8AQKR]...........................................................................................................1688 FAILURE CODE [D8G1KT]...........................................................................................................1695 FAILURE CODE [D8G6KT]...........................................................................................................1696 FAILURE CODE [DA20MC]...........................................................................................................1697 FAILURE CODE [DA22KK]...........................................................................................................1698 FAILURE CODE [DA25KP]...........................................................................................................1701 FAILURE CODE [DA29KQ]...........................................................................................................1704 FAILURE CODE [DA2LKA]...........................................................................................................1706 FAILURE CODE [DA2LKB]...........................................................................................................1709 FAILURE CODE [DA2QKR]...........................................................................................................1711 FAILURE CODE [DA2RKR]...........................................................................................................1720 FAILURE CODE [DAF0KM]...........................................................................................................1721 FAILURE CODE [DAF0MB]...........................................................................................................1722 FAILURE CODE [DAF0MC]...........................................................................................................1723 FAILURE CODE [DAF8KB]...........................................................................................................1724 FAILURE CODE [DAF9KQ]...........................................................................................................1726 FAILURE CODE [DAFGMC]...........................................................................................................1727 FAILURE CODE [DAFLKA]...........................................................................................................1728 FAILURE CODE [DAFLKB]...........................................................................................................1731 FAILURE CODE [DAFQKR]...........................................................................................................1733 FAILURE CODE [DAZ9KQ]...........................................................................................................1741 FAILURE CODE [DAZQKR]...........................................................................................................1742 FAILURE CODE [DBPQKR]...........................................................................................................1749 FAILURE CODE [DBP0KM]...........................................................................................................1757 FAILURE CODE [DBP0KT]...........................................................................................................1758 FAILURE CODE [DBP5KB]...........................................................................................................1759 FAILURE CODE [DBP5KY]...........................................................................................................1762 FAILURE CODE [DB2QKR]...........................................................................................................1765 FAILURE CODE [DB2RKR]...........................................................................................................1773 FAILURE CODE [DDNRKA]...........................................................................................................1778 FAILURE CODE [DDNRKY]...........................................................................................................1780 FAILURE CODE [DDNS00]...........................................................................................................1782 FAILURE CODE [DFB1KZ]...........................................................................................................1784 FAILURE CODE [DFB2KZ]...........................................................................................................1786 FAILURE CODE [DFB3L8]...........................................................................................................1788 FAILURE CODE [DFB4L8]...........................................................................................................1790 FAILURE CODE [DFB5KZ]...........................................................................................................1792 FAILURE CODE [DFB6KZ]...........................................................................................................1794 FAILURE CODE [DGH2KB]...........................................................................................................1796 FAILURE CODE [DHA4KA]...........................................................................................................1798 FAILURE CODE [DHAAMA]...........................................................................................................1800 FAILURE CODE [DHACMA]...........................................................................................................1802 FAILURE CODE [DHPAMA]...........................................................................................................1804 FAILURE CODE [DHPBMA]...........................................................................................................1807 FAILURE CODE [DHS3MA]...........................................................................................................1810 FAILURE CODE [DHS4MA]...........................................................................................................1813 FAILURE CODE [DHS8MA]...........................................................................................................1816 FAILURE CODE [DHS9MA]...........................................................................................................1819 FAILURE CODE [DHSAMA]...........................................................................................................1822 FAILURE CODE [DHSBMA]...........................................................................................................1825 FAILURE CODE [DHSCMA]...........................................................................................................1828 FAILURE CODE [DHSDMA]...........................................................................................................1831 FAILURE CODE [DHSFMA]...........................................................................................................1834 FAILURE CODE [DHSGMA]...........................................................................................................1837 FAILURE CODE [DHSHMA]...........................................................................................................1840 FAILURE CODE [DHSJMA]...........................................................................................................1843 FAILURE CODE [DHZAMA]...........................................................................................................1846 FAILURE CODE [DHZCL8]...........................................................................................................1850 FAILURE CODE [DKR0MA]...........................................................................................................1851 FAILURE CODE [DKR1MA]...........................................................................................................1854 FAILURE CODE [DKULKA]...........................................................................................................1857 FAILURE CODE [DKULKB]...........................................................................................................1859 FAILURE CODE [DKULKY]...........................................................................................................1861 FAILURE CODE [DR10KA]...........................................................................................................1863 FAILURE CODE [DR12KA]...........................................................................................................1866 FAILURE CODE [DR20KA]...........................................................................................................1868 FAILURE CODE [DR21KX]...........................................................................................................1870 FAILURE CODE [DR30KA]...........................................................................................................1872 FAILURE CODE [DR31KX]...........................................................................................................1874 FAILURE CODE [DR40KA]...........................................................................................................1876 FAILURE CODE [DUMBKA]...........................................................................................................1878 FAILURE CODE [DUMBKB]...........................................................................................................1881 FAILURE CODE [DV00KA]...........................................................................................................1883 FAILURE CODE [DV00KB]...........................................................................................................1884 FAILURE CODE [DV20KB]...........................................................................................................1885 FAILURE CODE [DW43KA]...........................................................................................................1887 FAILURE CODE [DW43KB]...........................................................................................................1889 FAILURE CODE [DW43KY]...........................................................................................................1891 FAILURE CODE [DW45KA]...........................................................................................................1893 FAILURE CODE [DW45KB]...........................................................................................................1896 FAILURE CODE [DW45KY]...........................................................................................................1899 FAILURE CODE [DW4CKY]...........................................................................................................1901 FAILURE CODE [DW91KA]...........................................................................................................1902 FAILURE CODE [DW91KB]...........................................................................................................1904 FAILURE CODE [DW91KY]...........................................................................................................1906 FAILURE CODE [DWA2KA]...........................................................................................................1908 FAILURE CODE [DWA2KB]...........................................................................................................1910 FAILURE CODE [DWA2KY]...........................................................................................................1912 FAILURE CODE [DWK0KA]...........................................................................................................1914 FAILURE CODE [DWK0KB]...........................................................................................................1916 FAILURE CODE [DWK0KY]...........................................................................................................1918 FAILURE CODE [DWK2KA]...........................................................................................................1920 FAILURE CODE [DWK2KB]...........................................................................................................1922 FAILURE CODE [DWK2KY]...........................................................................................................1924 FAILURE CODE [DWK8KA]...........................................................................................................1926 FAILURE CODE [DWK8KB]...........................................................................................................1928 FAILURE CODE [DWK8KY]...........................................................................................................1930 FAILURE CODE [DWPUKA]...........................................................................................................1932 FAILURE CODE [DWPUKB]...........................................................................................................1934 FAILURE CODE [DWPUKY]...........................................................................................................1936 FAILURE CODE [DXA8KA]...........................................................................................................1938 FAILURE CODE [DXA8KB]...........................................................................................................1941 FAILURE CODE [DXA9KA]...........................................................................................................1943 FAILURE CODE [DXA9KB]...........................................................................................................1946 FAILURE CODE [DXE0KA]...........................................................................................................1948 FAILURE CODE [DXE0KB]...........................................................................................................1950 FAILURE CODE [DXE4KA]...........................................................................................................1952 FAILURE CODE [DXE4KB]...........................................................................................................1954 FAILURE CODE [DXE4KY]...........................................................................................................1956 FAILURE CODE [DXE5KA]...........................................................................................................1957 FAILURE CODE [DXE5KB]...........................................................................................................1959 FAILURE CODE [DXE6KA]...........................................................................................................1961 FAILURE CODE [DXE6KB]...........................................................................................................1963 FAILURE CODE [DXE7KA]...........................................................................................................1965 FAILURE CODE [DXE7KB]...........................................................................................................1967 FAILURE CODE [DXE7KY]...........................................................................................................1969 FAILURE CODE [DXE8KA]...........................................................................................................1971 FAILURE CODE [DXE8KB]...........................................................................................................1973 FAILURE CODE [DXE8KY]...........................................................................................................1975 FAILURE CODE [DXE9KA]...........................................................................................................1977 FAILURE CODE [DXE9KB]...........................................................................................................1979 FAILURE CODE [DXE9KY]...........................................................................................................1981 FAILURE CODE [DXEAKA]...........................................................................................................1983 FAILURE CODE [DXEAKB]...........................................................................................................1985 FAILURE CODE [DXEAKY]...........................................................................................................1987 FAILURE CODE [DXEKKA]...........................................................................................................1989 FAILURE CODE [DXEKKB]...........................................................................................................1991 FAILURE CODE [DXEKKY]...........................................................................................................1993 FAILURE CODE [DXELKA]...........................................................................................................1995 FAILURE CODE [DXELKB]...........................................................................................................1997 FAILURE CODE [DXELKY]...........................................................................................................1999 FAILURE CODE [DY20KA]...........................................................................................................2001 FAILURE CODE [DY20MA]...........................................................................................................2004 FAILURE CODE [DY2CKB]...........................................................................................................2006 FAILURE CODE [DY2DKB]...........................................................................................................2009 FAILURE CODE [DY2EKB]...........................................................................................................2011 FAILURE CODE [F313KA]...........................................................................................................2013 FAILURE CODE [F313KB]...........................................................................................................2015 FAILURE CODE [F318KB]...........................................................................................................2018 FAILURE CODE [F318KY]...........................................................................................................2021 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).......................................................................................2023 E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)...............................................................................2023 E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK......................................................................................2029 E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK...................................................................................2032 E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP...........................................................2034 E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING.............................................2036 E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW..........2039 E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW....2040 E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING...............................................2041 E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING................................................2042 E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING...................................................2043 E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING..............................................................2044 E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING................................................................2045 E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...........................................................2046 E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING................................................2047 E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.......................................................2048 E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING.................................................2049 E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM...................................................................2050 E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL.......................................................................2052 E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM.............................................2053 E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE........................................2054 E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM..............................................2055 E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE.............................................2057 E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED.....................................................................2058 E-24 FUNCTION SWITCH DOES NOT OPERATE...........................................................................................2059 E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)...................................................................2060 E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF....................2061 E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER....................................................................2062 E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED.......................................2063 E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED..........................................2064 E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE.................................................2065 E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE................................................2066 E-32 ALARM BUZZER CANNOT BE CANCELED............................................................................................2068 E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION...................................................2069 E-34 SERVICE MODE CANNOT BE SELECTED............................................................................................2070 E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE............................................................2071 E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK.............................................................2073 E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING.............................................2074 E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE.............................2077 E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR.......................2079 E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED.......................................................................2081 E-41 ALARM DOES NOT SOUND DURING TRAVEL.........................................................................................2082 E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED......................................................................2084 E-43 HORN DOES NOT SOUND........................................................................................................2085 E-44 HORN DOES NOT STOP SOUNDING................................................................................................2089 E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF...................................................2091 E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE...........................................................2092 E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE......................................................2094 E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION....................................................2095 E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION....................................................2096 E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.......................................................2097 E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................................2098 E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...................................................2099 E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...................................................2100 E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.........................................................2101 E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION........................................................2102 E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION.......................................................2103 E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED.............................................................................2105 E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY...................................................................................2106 E-59 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED................................................................................2107 E-60 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE..................................................................................2109 TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE).......................................................................2110 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE).........................................................................2110 SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS................................................................................2111 FAILURE MODE AND CAUSE TABLE....................................................................................................2113 H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK............................................................................2124 H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER...................................................................2125 H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR................................................................................2128 H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP...........................................................................2129 H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS..................................................................................2130 H-6 SPEED OR POWER OF BOOM IS LOW...............................................................................................2132 H-7 ARM SPEED OR POWER IS LOW...................................................................................................2138 H-8 BUCKET SPEED OR POWER IS LOW................................................................................................2143 H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION............................................................................2147 H-10 HYDRAULIC DRIFT OF BOOM IS LARGE...........................................................................................2148 H-11 HYDRAULIC DRIFT OF ARM IS LARGE............................................................................................2150 H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE.........................................................................................2152 H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES...........................................2153 H-14 TIME LAG OF WORK EQUIPMENT IS LARGE........................................................................................2154 H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE.......................................................................2155 H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE..................................................................................2156 H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED.......................................................................................2157 H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED...........................................................................2158 H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER........................................2159 H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY......................................................2160 H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW....................................................2161 H-22 MACHINE DOES NOT TRAVEL STRAIGHT...........................................................................................2162 H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW.......................................................................2164 H-24 TRAVEL SPEED IS LOW........................................................................................................2167 H-25 ONE OF TRACKS DOES NOT RUN.................................................................................................2169 H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST..........................................................2171 H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT..................................................................2172 H-28 SWINGS ONLY IN ONE DIRECTION...............................................................................................2173 H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)...............................................2174 H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION........................................2175 H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)..........................................2176 H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)......................2177 H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING.........................................................................2178 H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING...........................................................2179 H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED).....................................................2180 H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)....................................................2181 H-37 Quick coupler cylinder will not extend.....................................................................................2182 H-38 Quick coupler cylinder will not retract (but buzzer doesnot sound).........................................................2184 H-39 Buzzer does not sound (but quick coupler cylinder doesretract).............................................................2186 H-40 Quick coupler cylinder extends and retracts slowly.........................................................................2188 TROUBLESHOOTING OF ENGINE (S-MODE)..................................................................................................2189 INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE).........................................................................2189 S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION......................................................2190 S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT..................................................................................2191 S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)..............................2192 S-4 ENGINE STARTABILITY IS POOR.................................................................................................2194 S-5 ENGINE DOES NOT PICK UP SMOOTHLY............................................................................................2196 S-6 ENGINE STOPS DURING OPERATION...............................................................................................2198 S-7 ENGINE RUNS ROUGH OR IS UNSTABLE............................................................................................2200 S-8 ENGINE LACKS POWER..........................................................................................................2201 S-9 KDPF GETS CLOGGED IN A SHORT TIME...........................................................................................2203 S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE........................................................................................2205 S-11 OIL BECOMES CONTAMINATED QUICKLY...........................................................................................2206 S-12 FUEL CONSUMPTION IS EXCESSIVE..............................................................................................2207 S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)......................................................2208 S-14 OIL PRESSURE DROPS.........................................................................................................2209 S-15 FUEL MIXES INTO ENGINE OIL.................................................................................................2211 S-16 WATER MIXES INTO ENGINE OIL (MILKY)........................................................................................2212 S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)...........................................................................2213 S-18 UNUSUAL NOISE IS HEARD.....................................................................................................2214 S-19 VIBRATION IS EXCESSIVE.....................................................................................................2215 S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT.......................................................................................2216 S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY.................................................................................2217 S-22 ACTIVE REGENERATION TAKES TIME.............................................................................................2219 S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION........................................................................2220 S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE........................................................................................2221 S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)...................................................................................2223 S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)..................................................................2224 TROUBLESHOOTING OF WORKING RANGE INDICATOR BY FAILURE CODE (IF EQUIPPED)............................................................2225 20 SUPPLY VOLTAGE > 32VDC.......................................................................................................2225 21 SUPPLY VOLTAGE < 12VDC.......................................................................................................2226 25 FILE ERROR FACTORY SETTINGS..................................................................................................2227 26 FILE ERROR USER SETTINGS.....................................................................................................2228 27 FILE ERROR INPUT DATA........................................................................................................2229 30 PROXIMITY SWITCHES DIFFERENCE................................................................................................2230 86 ANGLE SENSOR A2 TIMEOUT......................................................................................................2231 96 ANGLE SENSOR A3/A5 TIMEOUT...................................................................................................2232 106 ANGLE SENSOR A4/A6 TIMEOUT..................................................................................................2233 116 ANGLE SENSOR PITCH TIMEOUT..................................................................................................2234 126 ANGLE SENSOR ROLL TIMEOUT...................................................................................................2235 50 DISASSEMBLY AND ASSEMBLY.............................................................................................................2237 CONTENTS............................................................................................................................2238 ABBREVIATION LIST...................................................................................................................2243 RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY.....................................................................................2249 HOW TO READ THIS MANUAL.........................................................................................................2249 COATING MATERIALS LIST..........................................................................................................2251 SPECIAL TOOLS LIST..............................................................................................................2256 SKETCHES OF SPECIAL TOOLS.......................................................................................................2271 ENGINE AND COOLING SYSTEM...........................................................................................................2279 REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY.........................................................................................2279 METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY....................................................................................2279 METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY..................................................................................2284 REMOVE AND INSTALL INJECTOR ASSEMBLY............................................................................................2292 METHOD FOR REMOVING INJECTOR ASSEMBLY.......................................................................................2292 METHOD FOR INSTALLING INJECTOR ASSEMBLY.....................................................................................2299 REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY.......................................................................................2311 METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY..................................................................................2312 METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY................................................................................2321 REMOVE AND INSTALL EGR VALVE ASSEMBLY...........................................................................................2339 METHOD FOR REMOVING EGR VALVE ASSEMBLY......................................................................................2339 METHOD FOR INSTALLING EGR VALVE ASSEMBLY....................................................................................2340 REMOVE AND INSTALL EGR COOLER ASSEMBLY..........................................................................................2342 METHOD FOR REMOVING EGR COOLER ASSEMBLY.....................................................................................2342 METHOD FOR INSTALLING EGR COOLER ASSEMBLY...................................................................................2343 REMOVE AND INSTALL STARTER ASSEMBLY.............................................................................................2346 METHOD FOR REMOVING STARTER ASSEMBLY........................................................................................2346 METHOD FOR INSTALLING STARTER ASSEMBLY......................................................................................2347 REMOVE AND INSTALL ALTERNATOR BELT..............................................................................................2348 METHOD FOR REMOVING ALTERNATOR BELT.........................................................................................2348 METHOD FOR INSTALLING ALTERNATOR BELT.......................................................................................2351 REMOVE AND INSTALL RADIATOR ASSEMBLY............................................................................................2354 METHOD FOR REMOVING RADIATOR ASSEMBLY.......................................................................................2354 METHOD FOR INSTALLING RADIATOR ASSEMBLY.....................................................................................2356 REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY................................................................................2358 METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY...........................................................................2358 METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY.........................................................................2360 REMOVE AND INSTALL AFTERCOOLER ASSEMBLY.........................................................................................2363 METHOD FOR REMOVING AFTERCOOLER ASSEMBLY....................................................................................2363 METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY..................................................................................2364 REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY................................................................................2366 METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY...........................................................................2367 METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY.........................................................................2379 REMOVE AND INSTALL ENGINE FRONT OIL SEAL........................................................................................2394 METHOD FOR REMOVING ENGINE FRONT OIL SEAL...................................................................................2394 METHOD FOR INSTALLING ENGINE FRONT OIL SEAL.................................................................................2398 REMOVE AND INSTALL ENGINE REAR OIL SEAL.........................................................................................2402 METHOD FOR REMOVING ENGINE REAR OIL SEAL....................................................................................2403 METHOD FOR INSTALLING ENGINE REAR OIL SEAL..................................................................................2404 REMOVE AND INSTALL ENGINE HOOD ASSEMBLY.........................................................................................2411 METHOD FOR REMOVING ENGINE HOOD ASSEMBLY....................................................................................2411 METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY..................................................................................2412 REMOVE AND INSTALL FUEL TANK ASSEMBLY...........................................................................................2415 METHOD FOR REMOVING FUEL TANK ASSEMBLY......................................................................................2415 METHOD FOR INSTALLING FUEL TANK ASSEMBLY....................................................................................2419 REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY.....................................................................................2422 METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY................................................................................2422 METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY..............................................................................2428 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY.......................................................................2433 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY..................................................................2433 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY................................................................2440 REMOVE AND INSTALL AdBlue/DEF TANK SENSOR.......................................................................................2445 METHOD FOR REMOVING AdBlue/DEF TANK SENSOR..................................................................................2445 METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR................................................................................2445 REMOVE AND INSTALL AdBlue/DEF TANK STRAINER.....................................................................................2452 METHOD FOR REMOVING AdBlue/DEF TANK STRAINER................................................................................2452 METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER..............................................................................2452 REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER...........................................................................2453 METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER......................................................................2453 METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER....................................................................2455 REMOVE AND INSTALL KDPF ASSEMBLY................................................................................................2458 METHOD FOR REMOVING KDPF ASSEMBLY...........................................................................................2458 METHOD FOR INSTALLING KDPF ASSEMBLY.........................................................................................2461 DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY.......................................................................................2465 METHOD FOR DISASSEMBLING KDPF ASSEMBLY......................................................................................2466 METHOD FOR ASSEMBLING KDPF ASSEMBLY.........................................................................................2469 REMOVE AND INSTALL SCR ASSEMBLY.................................................................................................2474 METHOD FOR REMOVING SCR ASSEMBLY............................................................................................2474 METHOD FOR INSTALLING SCR ASSEMBLY..........................................................................................2477 REMOVE AND INSTALL KDPF, SCR ASSEMBLY...........................................................................................2480 METHOD FOR REMOVING KDPF, SCR ASSEMBLY......................................................................................2481 METHOD FOR INSTALLING KDPF, SCR ASSEMBLY....................................................................................2487 REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET...................................................................................2494 METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET..............................................................................2494 METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET............................................................................2497 REMOVE AND INSTALL KCCV ASSEMBLY................................................................................................2502 METHOD FOR REMOVING KCCV ASSEMBLY...........................................................................................2502 METHOD FOR INSTALLING KCCV ASSEMBLY.........................................................................................2503 REMOVE AND INSTALL AdBlue/DEF MIXING TUBE.......................................................................................2505 METHOD FOR REMOVING AdBlue/DEF MIXING TUBE..................................................................................2506 METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE................................................................................2509 REMOVE AND INSTALL AdBlue/DEF INJECTOR..........................................................................................2513 METHOD FOR REMOVING AdBlue/DEF INJECTOR.....................................................................................2513 METHOD FOR INSTALLING AdBlue/DEF INJECTOR...................................................................................2516 REMOVE AND INSTALL AdBlue/DEF PUMP..............................................................................................2520 METHOD FOR REMOVING AdBlue/DEF PUMP.........................................................................................2520 METHOD FOR INSTALLING AdBlue/DEF PUMP.......................................................................................2523 REMOVE AND INSTALL AdBlue/DEF HOSE..............................................................................................2525 METHOD FOR REMOVING AdBlue/DEF HOSE.........................................................................................2526 METHOD FOR INSTALLING AdBlue/DEF HOSE.......................................................................................2532 REMOVE AND INSTALL AIR CLEANER ASSEMBLY.........................................................................................2540 METHOD FOR REMOVING AIR CLEANER ASSEMBLY....................................................................................2540 METHOD FOR INSTALLING AIR CLEANER ASSEMBLY..................................................................................2542 REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY..........................................................................2544 METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY.....................................................................2544 METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY...................................................................2545 REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...........................................................................2547 METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY......................................................................2547 METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY....................................................................2548 POWER TRAIN.........................................................................................................................2549 REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY........................................................................2549 METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...................................................................2549 METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY.................................................................2550 DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY...................................................................................2552 METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY...............................................................................2553 METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY..................................................................................2557 REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY.....................................................................2565 METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY................................................................2565 METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY..............................................................2566 DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY...............................................................................2568 METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY...........................................................................2568 METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY..............................................................................2571 REMOVE AND INSTALL SWING CIRCLE ASSEMBLY........................................................................................2579 METHOD FOR REMOVING SWING CIRCLE ASSEMBLY...................................................................................2579 METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY.................................................................................2579 UNDERCARRIAGE AND FRAME.............................................................................................................2581 SEPARATION AND CONNECTION OF TRACK ASSEMBLY.....................................................................................2581 METHOD FOR SEPARATING TRACK ASSEMBLY........................................................................................2581 METHOD FOR INSTALLING TRACK ASSEMBLY........................................................................................2583 REMOVE AND INSTALL SPROCKET.....................................................................................................2586 METHOD FOR REMOVING SPROCKET................................................................................................2586 METHOD FOR INSTALLING SPROCKET..............................................................................................2586 REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY.............................................................................2588 METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY........................................................................2588 METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY......................................................................2589 DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY.........................................................................................2590 METHOD FOR DISASSEMBLING IDLER ASSEMBLY.....................................................................................2590 METHOD FOR ASSEMBLING IDLER ASSEMBLY........................................................................................2591 DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY..............................................................................2595 METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY.............................................................................2596 METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY................................................................................2596 DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY..................................................................................2598 METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY..............................................................................2599 METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY.................................................................................2600 DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY.................................................................................2602 METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY............................................................................2602 METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY...............................................................................2603 REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY.....................................................................................2606 METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY................................................................................2606 METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY..............................................................................2608 METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY - PC390HRD-11E0..............................................................2610 REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY.......................................................................................2611 METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY..................................................................................2611 METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY................................................................................2612 HYDRAULIC SYSTEM....................................................................................................................2615 REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY.................................................................................2615 METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY............................................................................2615 METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY..........................................................................2616 DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY...........................................................................2619 METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY.......................................................................2620 METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY..........................................................................2621 REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY......................................................................................2622 METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY.................................................................................2622 METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY...............................................................................2626 REMOVE AND INSTALL MAIN PUMP ASSEMBLY...........................................................................................2630 METHOD FOR REMOVING MAIN PUMP ASSEMBLY......................................................................................2630 METHOD FOR INSTALLING MAIN PUMP ASSEMBLY....................................................................................2633 REMOVE AND INSTALL CONTROL VALVE ASSEMBLY.......................................................................................2636 METHOD FOR REMOVING CONTROL VALVE ASSEMBLY..................................................................................2636 METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY................................................................................2643 DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY.................................................................................2650 METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING..................................................................2651 METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY................................................................................2652 REMOVE AND INSTALL ATT BYPASS SOLENOID..........................................................................................2657 REMOVE ATT BYPASS SOLENOID..................................................................................................2657 INSTALL ATT BYPASS SOLENOID.................................................................................................2660 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY......................................................................2662 METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY..................................................................2662 METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY.....................................................................2663 DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY..............................................................................2665 METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY..........................................................................2665 METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY.............................................................................2666 REMOVE AND INSTALL QUICK COUPLER VALVE..........................................................................................2668 WORK EQUIPMENT......................................................................................................................2670 REMOVE AND INSTALL BUCKET ASSEMBLY..............................................................................................2670 METHOD FOR REMOVING BUCKET ASSEMBLY.........................................................................................2670 METHOD FOR INSTALLING BUCKET ASSEMBLY.......................................................................................2670 REMOVE AND INSTALL ARM ASSEMBLY.................................................................................................2672 METHOD FOR REMOVING ARM ASSEMBLY............................................................................................2672 METHOD FOR INSTALLING ARM ASSEMBLY..........................................................................................2673 REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY......................................................................................2675 METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY.................................................................................2675 METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY...............................................................................2678 DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY.......................................................................2681 METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY...................................................................2681 METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY......................................................................2684 CAB AND ITS ATTACHMENTS.............................................................................................................2691 REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY......................................................................................2691 METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY.................................................................................2691 METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY...............................................................................2699 REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)...........................................................................2706 METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)......................................................................2708 METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)....................................................................2708 REMOVE AND INSTALL FRONT WINDOW ASSEMBLY........................................................................................2718 METHOD FOR REMOVING FRONT WINDOW ASSEMBLY...................................................................................2718 METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY.................................................................................2721 REMOVE AND INSTALL FLOOR FRAME ASSEMBLY.........................................................................................2727 METHOD FOR REMOVING FLOOR FRAME ASSEMBLY....................................................................................2728 METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY..................................................................................2734 REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY................................................................................2742 METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY...........................................................................2742 METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY.........................................................................2748 REMOVE AND INSTALL OPERATOR'S SEAT..............................................................................................2754 METHOD FOR REMOVING OPERATOR'S SEAT.........................................................................................2754 METHOD FOR INSTALLING OPERATOR'S SEAT.......................................................................................2756 REMOVE AND INSTALL SEAT BELT....................................................................................................2759 METHOD FOR REMOVING SEAT BELT...............................................................................................2759 METHOD FOR INSTALLING SEAT BELT.............................................................................................2760 REMOVE AND INSTALL FRONT WIPER ASSEMBLY.........................................................................................2761 METHOD FOR REMOVING FRONT WIPER ASSEMBLY....................................................................................2761 METHOD FOR INSTALLING FRONT WIPER ASSEMBLY..................................................................................2766 ELECTRICAL SYSTEM...................................................................................................................2775 REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...................................................................................2775 METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY..............................................................................2775 METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY............................................................................2777 REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY.....................................................................................2781 METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY................................................................................2781 METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY..............................................................................2784 REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY................................................................................2788 METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY...........................................................................2788 METHOD FOR INSTALLING KomVision CONTROLLER..................................................................................2789 REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY.....................................................................................2790 METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY................................................................................2790 METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY..............................................................................2793 REMOVE AND INSTALL PUMP SWASH PLATE SENSOR......................................................................................2797 METHOD FOR REMOVING PUMP SWASH PLATE SENSOR.................................................................................2797 METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR...............................................................................2797 REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR.........................................................................2799 METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR....................................................................2799 METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR..................................................................2800 REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR...............................................................................2801 METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR..........................................................................2801 METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR........................................................................2802 REMOVE AND INSTALL SCR TEMPERATURE SENSOR.......................................................................................2803 METHOD FOR REMOVING SCR TEMPERATURE SENSOR..................................................................................2803 METHOD FOR INSTALLING SCR TEMPERATURE SENSOR................................................................................2804 REMOVE AND INSTALL REARVIEW CAMERA..............................................................................................2806 METHOD FOR REMOVING REARVIEW CAMERA.........................................................................................2806 METHOD FOR INSTALLING REARVIEW CAMERA.......................................................................................2807 REMOVE AND INSTALL KomVision CAMERA.............................................................................................2809 METHOD FOR REMOVING KomVision CAMERA........................................................................................2809 METHOD FOR INSTALLING KomVision CAMERA......................................................................................2810 REMOVE AND INSTALL GATEWAY FUNCTION CONTROLLER ASSEMBLY.........................................................................2812 METHOD FOR REMOVING GATEWAY FUNCTION CONTROLLER ASSEMBLY....................................................................2812 METHOD FOR INSTALLING GATEWAY FUNCTION CONTROLLER ASSEMBLY..................................................................2817 REMOVE AND INSTALL COMMUNICATION TERMINAL WIRING HARNESS........................................................................2822 METHOD FOR REMOVING COMMUNICATION TERMINAL WIRING HARNESS...................................................................2822 METHOD FOR INSTALLING COMMUNICATION TERMINAL WIRING HARNESS.................................................................2830 REMOVE AND INSTALL COMMUNICATION TERMINAL.......................................................................................2839 METHOD FOR REMOVING COMMUNICATION TERMINAL..................................................................................2839 METHOD FOR INSTALLING COMMUNICATION TERMINAL................................................................................2841 60 MAINTENANCE STANDARD.................................................................................................................2845 CONTENTS............................................................................................................................2846 ABBREVIATION LIST...................................................................................................................2847 ENGINE AND COOLING SYSTEM...........................................................................................................2853 MAINTENANCE STANDARD OF ENGINE MOUNT............................................................................................2853 MAINTENANCE STANDARD OF COOLING SYSTEM..........................................................................................2855 POWER TRAIN.........................................................................................................................2857 MAINTENANCE STANDARD OF SWING CIRCLE............................................................................................2857 MAINTENANCE STANDARD OF SWING MACHINERY.........................................................................................2858 MAINTENANCE STANDARD OF FINAL DRIVE.............................................................................................2860 MAINTENANCE STANDARD OF SPROCKET................................................................................................2862 MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING...............................................................2863 UNDERCARRIAGE AND FRAME.............................................................................................................2865 MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION...........................................................................2865 MAINTENANCE STANDARD OF IDLER...................................................................................................2867 MAINTENANCE STANDARD OF TRACK ROLLER............................................................................................2869 MAINTENANCE STANDARD OF CARRIER ROLLER..........................................................................................2871 MAINTENANCE STANDARD OF TRACK SHOE..............................................................................................2872 MAINTENANCE STANDARD OF TRIPLE SHOE.............................................................................................2875 HYDRAULIC SYSTEM....................................................................................................................2876 MAINTENANCE STANDARD OF HYDRAULIC TANK..........................................................................................2876 MAINTENANCE STANDARD OF MAIN PUMP...............................................................................................2877 MAINTENANCE STANDARD OF SWING MOTOR.............................................................................................2879 MAINTENANCE STANDARD OF TRAVEL MOTOR............................................................................................2882 MAINTENANCE STANDARD OF CONTROL VALVE...........................................................................................2885 MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE......................................................................2895 MAINTENANCE STANDARD OF TRAVEL PPC VALVE........................................................................................2898 MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)..........................................................2901 MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE..........................................................2903 MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE...........................................................................2904 MAINTENANCE STANDARD OF SOLENOID VALVE..........................................................................................2906 MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE........................................................................2907 MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE.......................................................................2909 MAINTENANCE STANDARD OF CENTER SWIVEL JOINT.....................................................................................2910 WORK EQUIPMENT......................................................................................................................2911 MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE..................................................................................2911 DIMENSION OF ARM............................................................................................................2916 DIMENSIONS OF BUCKET........................................................................................................2918 MAINTENANCE STANDARD OF BOOM CYLINDER...........................................................................................2920 MAINTENANCE STANDARD OF ARM CYLINDER............................................................................................2921 MAINTENANCE STANDARD OF BUCKET CYLINDER.........................................................................................2922 WORK EQUIPMENT - PC390HRD-11E0......................................................................................................2923 WORK EQUIPMENT - HIGH REACH DEMOLITION..........................................................................................2923 DIMENSION OF ARM............................................................................................................2923 MAINTENANCE STANDARD OF BOOM CYLINDER.......................................................................................2924 MAINTENANCE STANDARD OF LINK CYLINDER.......................................................................................2925 MAINTENANCE STANDARD OF ARM CYLINDER........................................................................................2926 MAINTENANCE STANDARD OF BUCKET CYLINDER.....................................................................................2927 WORK EQUIPMENT - DEMOLITION DIGGING.............................................................................................2928 MAINTENANCE STANDARD OF ARM CYLINDER........................................................................................2928 MAINTENANCE STANDARD OF BUCKET CYLINDER.....................................................................................2929 80 APPENDIX.............................................................................................................................2931 CONTENTS............................................................................................................................2932 ABBREVIATION LIST...................................................................................................................2934 AIR CONDITIONER SYSTEM..............................................................................................................2940 PRECAUTIONS FOR REFRIGERANT.....................................................................................................2940 AIR CONDITIONER COMPONENT.......................................................................................................2941 SPECIFICATIONS OF AIR CONDITIONER...............................................................................................2943 CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE...............................................................................2944 OUTLINE OF REFRIGERATION CYCLE..................................................................................................2945 COMPONENT PARTS OF AIR CONDITIONER SYSTEM...........................................................................................2947 AIR CONDITIONER UNIT............................................................................................................2947 CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT...............................................................................2947 FUNCTION OF AIR CONDITIONER UNIT............................................................................................2949 COMPONENT PARTS OF AIR CONDITIONER UNIT.........................................................................................2951 FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT....................................................................2952 FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT...................................................................2952 FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT.................................................2952 FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT...................................................................2952 STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT..............................................................2953 FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...............................................................2953 OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...................................................................2953 FUNCTION OF DUAL PRESSURE SWITCH............................................................................................2954 AIR CONDITIONER CONTROLLER......................................................................................................2955 STRUCTURE OF AIR CONDITIONER CONTROLLER.....................................................................................2955 COMPRESSOR......................................................................................................................2956 STRUCTURE OF COMPRESSOR.....................................................................................................2956 SPECIFICATIONS OF COMPRESSOR................................................................................................2956 FUNCTION OF COMPRESSOR......................................................................................................2956 CONDENSER.......................................................................................................................2957 STRUCTURE OF CONDENSER......................................................................................................2957 SPECIFICATIONS OF CONDENSER.................................................................................................2957 FUNCTION OF CONDENSER.......................................................................................................2957 RECEIVER DRIER..................................................................................................................2958 STRUCTURE OF RECEIVER DRIER.................................................................................................2958 SPECIFICATIONS OF RECEIVER DRIER............................................................................................2958 FUNCTION OF RECEIVER DRIER..................................................................................................2958 SENSORS FOR AIR CONDITIONER SYSTEM..............................................................................................2959 STRUCTURE OF SUNLIGHT SENSOR................................................................................................2959 FUNCTION OF SUNLIGHT SENSOR.................................................................................................2959 STRUCTURE OF AMBIENT TEMPERATURE SENSOR.....................................................................................2959 FUNCTION OF AMBIENT TEMPERATURE SENSOR......................................................................................2959 EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER.........................................................2961 CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER...............................................................2963 AIR CONDITIONER SYSTEM DIAGRAM......................................................................................................2965 INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER..........................................................................2966 FUNCTION OF AIR CONDITIONER CONTROLLER......................................................................................2967 INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS.......................................................2968 TESTING AIR LEAKAGE (DUCT)..........................................................................................................2972 METHOD FOR TESTING AIR LEAKAGE (DUCT)...........................................................................................2972 TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION...............................................................................2974 HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR..................................2975 TEST VENT (MODE) CHANGEOVER.........................................................................................................2976 METHOD FOR TESTING VENT (MODE) CHANGEOVER.......................................................................................2976 TESTING FRESH/RECIRC AIR CHANGEOVER.................................................................................................2978 METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER..................................................................................2978 TEST SUNLIGHT SENSOR................................................................................................................2979 METHOD FOR TESTING SUNLIGHT SENSOR..............................................................................................2979 TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT.........................................................................................2980 METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT.......................................................................2980 TEST RELAYS.........................................................................................................................2981 METHOD FOR TESTING RELAYS.......................................................................................................2981 AIR CONDITIONER TROUBLESHOOTING CHART 1.............................................................................................2982 AIR CONDITIONER TROUBLESHOOTING CHART 2.............................................................................................2983 INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE......................................................................................2986 FAILURE CODE [879AKA]...............................................................................................................2988 FAILURE CODE [879AKB]...............................................................................................................2989 FAILURE CODE [879BKA]...............................................................................................................2990 FAILURE CODE [879BKB]...............................................................................................................2992 FAILURE CODE [879CKA]...............................................................................................................2994 FAILURE CODE [879CKB]...............................................................................................................2995 FAILURE CODE [879DKZ]...............................................................................................................2996 FAILURE CODE [879EMC]...............................................................................................................2998 FAILURE CODE [879FMC]...............................................................................................................2999 FAILURE CODE [879GKX]...............................................................................................................3000 A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)......................................................3002 A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED).......................................................3004 A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)..............................................3007 A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER.................................................................................3009 TROUBLESHOOTING USING GAUGE PRESSURE................................................................................................3011 CONNECTION OF SERVICE TOOL..........................................................................................................3014 METHOD FOR CONNECTING SERVICE TOOL..............................................................................................3014 PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS.............................................3016 HANDLE COMPRESSOR OIL...............................................................................................................3018 90 CIRCUIT DIAGRAMS.....................................................................................................................3021 CONTENTS............................................................................................................................3022 ABBREVIATION LIST...................................................................................................................3023 HYDRAULIC CIRCUIT DIAGRAM...........................................................................................................3029 SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM.......................................................................................3029 HYDRAULIC CIRCUIT DIAGRAM (1/3).................................................................................................3033 HYDRAULIC CIRCUIT DIAGRAM (2/3).................................................................................................3035 HYDRAULIC CIRCUIT DIAGRAM (3/3).................................................................................................3037 HYDRAULIC CIRCUIT DIAGRAM (1/3) - PC390HRD-11E0.................................................................................3039 HYDRAULIC CIRCUIT DIAGRAM (2/3) - PC390HRD-11E0.................................................................................3041 HYDRAULIC CIRCUIT DIAGRAM (3/3) - PC390HRD-11E0.................................................................................3043 ELECTRICAL CIRCUIT DIAGRAM..........................................................................................................3045 SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM......................................................................................3045 ELECTRICAL DIAGRAM (1/12).......................................................................................................3049 ELECTRICAL DIAGRAM (2/12).......................................................................................................3051 ELECTRICAL DIAGRAM (3/12).......................................................................................................3053 ELECTRICAL DIAGRAM (4/12).......................................................................................................3055 ELECTRICAL DIAGRAM (5/12).......................................................................................................3057 ELECTRICAL DIAGRAM (6/12).......................................................................................................3059 ELECTRICAL DIAGRAM (7/12).......................................................................................................3061 ELECTRICAL DIAGRAM (8/12).......................................................................................................3063 ELECTRICAL DIAGRAM (9/12).......................................................................................................3065 ELECTRICAL DIAGRAM (10/12)......................................................................................................3067 ELECTRICAL DIAGRAM (11/12)......................................................................................................3069 ELECTRICAL DIAGRAM (12/12)......................................................................................................3071 INDEX....................................................................................................................................3073
DESCRIPTION:
KOMATSU PC360LC-11E0 PC360NLC-11E0 PC390HRD-11E0 HYDRAULIC EXCAVATOR SHOP MANUAL – PDF DOWNLOAD
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.
S.S 17/12/24
