Komatsu PC360LC-11,PC360NLC-11,PC390HRD-11 Excavator Shop Manual PDF

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Komatsu PC360LC-11,PC360NLC-11,PC390HRD-11 Hydraulic Excavator Shop Manual UENBM00391 – PDF DOWNLOAD

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Komatsu PC360LC-11,PC360NLC-11,PC390HRD-11 Hydraulic Excavator Shop Manual UENBM00391 – PDF DOWNLOAD

Language : English
Pages : 2870
Downloadable : Yes
File Type : PDF

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Komatsu PC360LC-11,PC360NLC-11,PC390HRD-11 Hydraulic Excavator Shop Manual UENBM00391 – PDF

SERIAL NUMBERS

• 90001 and up
• K70001 and up

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00 INDEX AND FOREWORD . 3
INDEX . 4
ABBREVIATION LIST . 22
FOREWORD, SAFETY, BASIC INFORMATION . 28
HOW TO READ THE SHOP MANUAL . 28
SAFETY NOTICE FOR OPERATION . 30
PRECAUTIONS TO PREVENT FIRE . 38
ACTIONS IF FIRE OCCURS 40
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS 41
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS . 42
PRECAUTIONS FOR DEF . 43
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING 43
PRECAUTIONS FOR ADDING 43
PRECAUTIONS FOR STORING . 43
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE . 43
THE OTHER PRECAUTIONS . 43
STORE AdBlue/DEF 44
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT 45
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS . 48
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT . 55
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT 57
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT 58
PRACTICAL USE OF KOMTRAX 59
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER . 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER . 60
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER . 61
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER . 62
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS 64
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR . 68
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR . 69
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL . 71
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH . 72
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE 74
HOW TO READ ELECTRICAL WIRE CODE 75
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD . 79
STANDARD TIGHTENING TORQUE TABLE 82
CONVERSION TABLE 89
01 SPECIFICATIONS . 95
CONTENTS 96
ABBREVIATION LIST . 97
SPECIFICATIONS 103
SPECIFICATION DRAWING . 103
SPECIFICATION DRAWING: PC360LC-11, PC360NLC-11 103
WORKING RANGE DRAWINGS 104
WORKING RANGE: PC360LC-11, PC360NLC-11 104
SPECIFICATIONS 105
SPECIFICATIONS: PC360LC-11, PC360NLC-11 . 105
WEIGHT TABLE 108
WEIGHT TABLE: PC360LC-11, PC360NLC-11 . 108
TABLE OF FUEL, COOLANT, AND LUBRICANTS 110
SPECIFICATIONS – PC390HRD-11 111
SPECIFICATION DRAWING . 111
SPECIFICATION DRAWING: PC390HRD-11 111
SPECIFICATIONS 114
SPECIFICATIONS: PC390HRD-11 . 114
WEIGHT TABLE 116
WEIGHT TABLE: PC390HRD-11 . 116
10 STRUCTURE AND FUNCTION . 119
CONTENTS 120
ABBREVIATION LIST . 124
UREA SCR SYSTEM . 130
LAYOUT DRAWING OF UREA SCR SYSTEM . 130
UREA SCR SYSTEM DIAGRAM . 134
FUNCTION OF UREA SCR SYSTEM . 135
FUNCTION OF AdBlue/DEF SYSTEM . 135
INDUCEMENT STRATEGY . 137
COMPONENT PARTS OF UREA SCR SYSTEM 152
AdBlue/DEF MIXING TUBE 152
SCR ASSEMBLY 152
AdBlue/DEF TANK . 155
AdBlue/DEF PUMP . 157
AdBlue/DEF INJECTOR . 158
AdBlue/DEF HOSE . 159
AdBlue/DEF TANK HEATING VALVE . 160
BOOT-UP SYSTEM 161
LAYOUT DRAWING OF BOOT-UP SYSTEM 161
SYSTEM OPERATING LAMP SYSTEM 163
SYSTEM OPERATING LAMP SYSTEM DIAGRAM 163
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM 163
BATTERY DISCONNECT SWITCH . 165
FUNCTION OF BATTERY DISCONNECT SWITCH . 165
ENGINE SYSTEM . 166
LAYOUT DRAWING OF ENGINE SYSTEM . 166
SPECIFICATIONS OF ENGINE SYSTEM . 167
FUNCTION OF ENGINE SYSTEM . 167
ENGINE CONTROL SYSTEM . 168
ENGINE CONTROL SYSTEM DIAGRAM . 168
FUNCTION OF ENGINE CONTROL SYSTEM . 169
AUTO-DECELERATION SYSTEM 171
AUTO-DECELERATION SYSTEM DIAGRAM 171
FUNCTION OF AUTO-DECELERATION SYSTEM 171
OPERATION OF AUTO-DECELERATION SYSTEM . 172
ENGINE AUTOMATIC WARM-UP SYSTEM . 173
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM . 173
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM . 174
OVERHEAT PREVENTION SYSTEM 175
OVERHEAT PREVENTION SYSTEM DIAGRAM 175
FUNCTION OF OVERHEAT PREVENTION SYSTEM 176
TURBOCHARGER PROTECTION SYSTEM 177
TURBOCHARGER PROTECTION SYSTEM DIAGRAM 177
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM 178
AUTOMATIC IDLE STOP SYSTEM 179
AUTOMATIC IDLE STOP SYSTEM DIAGRAM 179
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM 179
COMPONENT PARTS OF ENGINE SYSTEM 182
VGT . 182
EGR SYSTEM 185
EGR VALVE . 187
EGR COOLER 189
KCCV SYSTEM . 190
KCCV VENTILATOR . 192
KDPF 193
COOLING SYSTEM 198
LAYOUT DRAWING OF COOLING SYSTEM 198
SPECIFICATIONS OF COOLING SYSTEM 199
CONTROL SYSTEM 200
LAYOUT DRAWING OF CONTROL SYSTEM 200
MACHINE MONITOR SYSTEM 203
MACHINE MONITOR SYSTEM DIAGRAM 203
FUNCTION OF MACHINE MONITOR SYSTEM 203
KOMTRAX SYSTEM 205
KOMTRAX SYSTEM DIAGRAM 205
FUNCTION OF KOMTRAX SYSTEM 205
PPC LEVERS 206
LH PPC LEVER 206
RH PPC LEVER 207
AUTOMATIC GREASE SYSTEM . 208
OUTLINE OF AUTO GREASE SYSTEM . 208
COMPONENT PARTS OF CONTROL SYSTEM . 223
MACHINE MONITOR . 223
KOMTRAX TERMINAL 236
PUMP CONTROLLER . 238
RESISTOR FOR PC-EPC VALVE . 242
CAN TERMINATING RESISTOR 242
PPC OIL PRESSURE SWITCH . 243
ENGINE CONTROLLER . 244
FUEL CONTROL DIAL . 251
SENSOR 253
STRUCTURE OF AMBIENT PRESSURE SENSOR 253
FUNCTION OF AMBIENT PRESSURE SENSOR . 253
STRUCTURE OF ENGINE OIL PRESSURE SWITCH . 253
FUNCTION OF ENGINE OIL PRESSURE SWITCH 254
STRUCTURE OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR . 254
FUNCTION OF CHARGE (BOOST) PRESSURE AND TEMPERATURE SENSOR 254
STRUCTURE OF COOLANT TEMPERATURE SENSOR . 255
FUNCTION OF COOLANT TEMPERATURE SENSOR 255
STRUCTURE OF NE (CRANKSHAFT) SPEED SENSOR . 255
FUNCTION OF NE (CRANKSHAFT) SPEED SENSOR 256
STRUCTURE OF Bkup (CAMSHAFT) SPEED SENSOR . 256
FUNCTION OF Bkup (CAMSHAFT) SPEED SENSOR 256
STRUCTURE OF COMMON RAIL PRESSURE SENSOR 257
FUNCTION OF COMMON RAIL PRESSURE SENSOR . 257
STRUCTURE OF EGR VALVE LIFT SENSOR 257
FUNCTION OF EGR VALVE LIFT SENSOR . 257
STRUCTURE OF VGT SPEED SENSOR . 258
FUNCTION OF KVGT SPEED SENSOR . 258
STRUCTURE OF KVGT POSITION SENSOR . 258
FUNCTION OF KVGT POSITION SENSOR 259
STRUCTURE OF MASS AIR FLOW AND TEMPERATURE SENSOR . 259
STRUCTURE OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR 260
FUNCTION OF KDPF DIFFERENTIAL PRESSURE AND OUTLET PRESSURE SENSOR . 260
STRUCTURE OF CRANKCASE PRESSURE SENSOR 260
FUNCTION OF CRANKCASE PRESSURE SENSOR . 261
STRUCTURE OF ENGINE OIL LEVEL SENSOR 261
STRUCTURE OF AIR CLEANER CLOGGING SENSOR 261
FUNCTION OF AIR CLEANER CLOGGING SENSOR . 262
STRUCTURE OF WATER-IN-FUEL SENSOR . 262
FUNCTION OF WATER-IN-FUEL SENSOR 262
STRUCTURE OF QUICK COUPLER LOW PRESSURE WARNING SWITCH 262
SPECIFICATIONS – QUICK COUPLER LOW PRESSURE WARNING SWITCH 263
FUNCTION OF QUICK COUPLER LOW PRESSURE WARNING SWITCH . 263
STRUCTURE OF AUTO GREASE PRESSURE SWITCH 264
SPECIFICATIONS – AUTO GREASE PRESSURE SWITCH 264
FUNCTION OF AUTO GREASE PRESSURE SWITCH . 264
STRUCTURE OF OVERLOAD CAUTION SENSOR 264
SPECIFICATIONS – OVERLOAD CAUTION SENSOR 265
FUNCTION OF OVERLOAD CAUTION SENSOR . 265
HYDRAULIC SYSTEM 266
LAYOUT DRAWING OF HYDRAULIC SYSTEM 266
CLSS 269
STRUCTURE OF CLSS . 269
OPERATION OF UNLOAD VALVE AND LS PRESSURE . 271
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL . 272
PRESSURE COMPENSATION CONTROL . 285
ENGINE AND PUMP COMBINED CONTROL SYSTEM . 288
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM . 288
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM . 289
PUMP AND VALVE CONTROL SYSTEM . 294
PUMP AND VALVE CONTROL SYSTEM DIAGRAM . 294
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM . 295
COMPONENT PARTS OF HYDRAULIC SYSTEM . 297
HYDRAULIC TANK 297
MAIN PUMP . 300
CONTROL VALVE . 326
HYDRAULIC SYSTEM – PC390HRD-11 383
LAYOUT DRAWING OF HYDRAULIC SYSTEM 383
COMPONENT PARTS OF HYDRAULIC SYSTEM . 386
LAYOUT DRAWING OF VALVE CONTROL SYSTEM 386
WORK EQUIPMENT SYSTEM . 403
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 403
STRUCTURE OF VALVE CONTROL 409
ONE-TOUCH POWER MAXIMIZING SYSTEM . 411
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM . 411
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM . 412
MACHINE PUSH-UP SYSTEM 413
MACHINE PUSH-UP SYSTEM DIAGRAM 413
FUNCTION OF MACHINE PUSH-UP SYSTEM 414
PPC LOCK SYSTEM . 415
PPC LOCK SYSTEM DIAGRAM . 415
FUNCTION OF PPC LOCK SYSTEM . 415
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 416
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM . 416
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM . 416
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM 417
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 418
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT . 418
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT . 419
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM 420
WORK EQUIPMENT AND SWING PPC VALVE 420
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 425
2ND-LINE ATTACHMENT PPC VALVE . 430
SOLENOID VALVE 432
ATTACHMENT CIRCUIT SELECTOR VALVE . 435
ATT EPC VALVE ASSEMBLY 437
PILOT CIRCUIT ACCUMULATOR . 439
WORK EQUIPMENT SYSTEM – PC390HRD-11 . 440
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM . 440
SWING SYSTEM 444
LAYOUT DRAWING OF SWING SYSTEM 444
SWING CONTROL SYSTEM DIAGRAM 447
FUNCTION OF SWING CONTROL SYSTEM 447
COMPONENT PARTS OF SWING SYSTEM . 451
SWING MOTOR . 451
SWING MACHINERY . 462
SWING CIRCLE 463
TRAVEL SYSTEM . 465
LAYOUT DRAWING OF TRAVEL SYSTEM . 465
TRAVEL CONTROL SYSTEM DIAGRAM . 469
FUNCTION OF TRAVEL CONTROL SYSTEM . 469
COMPONENT PARTS OF TRAVEL SYSTEM 471
TRAVEL MOTOR 471
FINAL DRIVE . 484
TRAVEL PPC VALVE 485
CENTER SWIVEL JOINT . 490
UNDERCARRIAGE AND FRAME . 492
LAYOUT DRAWING OF UNDERCARRIAGE . 492
SPECIFICATIONS OF UNDERCARRIAGE . 492
WORK EQUIPMENT 493
STRUCTURE OF WORK EQUIPMENT . 493
FUNCTION OF WORK EQUIPMENT 494
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 495
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM 495
BUCKET CLEARANCE ADJUSTMENT SHIM 496
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM 496
CAB AND ITS ATTACHMENTS . 497
ROPS CAB 497
STRUCTURE OF ROPS CAB . 497
FUNCTION OF ROPS CAB 497
CAB MOUNT . 498
STRUCTURE OF CAB MOUNT 498
FUNCTION OF CAB MOUNT . 498
CAB TIPPING STOPPER . 499
STRUCTURE OF CAB TIPPING STOPPER 499
FUNCTION OF CAB TIPPING STOPPER . 499
TILTING CAB SYSTEM 500
STRUCTURE OF TILTING CAB SYSTEM . 500
OPERATION OF TILTING CAB SYSTEM . 500
20 STANDARD VALUE TABLE . 503
CONTENTS 504
ABBREVIATION LIST . 505
STANDARD VALUE TABLE FOR ENGINE . 511
STANDARD VALUE TABLE FOR ENGINE: PC360LC-11, PC360NLC-11 511
STANDARD VALUE TABLE FOR MACHINE 516
STANDARD VALUE TABLE FOR MACHINE: PC360LC-11, PC360NLC-11 . 516
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 530
STANDARD VALUE TABLE FOR MACHINE – PC390HRD-11 534
STANDARD VALUE FOR MACHINE: HIGH REACH DEMOLITION UNIQUE 534
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE . 541
STANDARD VALUE TABLE FOR ELECTRICAL . 545
STANDARD VALUE TABLE FOR ELECTRICAL . 545
30 TESTING AND ADJUSTING 555
CONTENTS 556
ABBREVIATION LIST . 560
RELATED INFORMATION ON TESTING AND ADJUSTING 566
TOOLS FOR TESTING AND ADJUSTING . 566
SKETCH OF TOOLS FOR TESTING AND ADJUSTING . 572
ENGINE AND COOLING SYSTEM . 574
TEST ENGINE SPEED . 574
METHOD FOR TESTING ENGINE SPEED . 574
TEST BOOST PRESSURE . 578
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR 578
METHOD FOR TESTING BOOST PRESSURE . 579
TEST EXHAUST GAS COLOR 580
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER . 580
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER . 581
TEST AND ADJUST VALVE CLEARANCE . 582
METHOD FOR TESTING VALVE CLEARANCE 582
METHOD FOR ADJUSTING VALVE CLEARANCE 584
TEST COMPRESSION PRESSURE . 585
METHOD FOR TESTING COMPRESSION PRESSURE . 585
TEST BLOWBY PRESSURE 588
METHOD FOR TESTING BLOWBY PRESSURE 588
TEST ENGINE OIL PRESSURE 590
METHOD FOR TESTING ENGINE OIL PRESSURE 590
TEST EGR VALVE AND VGT OIL PRESSURE . 592
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE . 592
TEST FUEL PRESSURE 594
METHOD FOR TESTING FUEL PRESSURE 595
TEST FUEL DISCHARGE, RETURN AND LEAKAGE . 601
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE . 602
BLEED AIR FROM FUEL SYSTEM 608
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM 608
TEST FUEL CIRCUIT FOR LEAKAGE . 609
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE . 609
HANDLE CYLINDER CUT-OUT MODE OPERATION 611
HANDLE NO-INJECTION CRANKING OPERATION 612
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION . 613
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION 613
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 613
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT 614
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER 615
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER . 615
TEST SCR RELATED FUNCTIONS 616
TEST AdBlue/DEF PUMP RAISED PRESSURE 619
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR 622
TEST AdBlue/DEF LINE HEATER RELAY 1 . 626
TEST AdBlue/DEF LINE HEATER RELAY 2 . 628
TEST AdBlue/DEF PUMP HEATER RELAY . 631
TEST AdBlue/DEF TANK HEATER VALVE . 634
TEST DENITRATION EFFICIENCY OF SCR 637
CLEAN AdBlue/DEF TANK . 641
METHOD FOR CLEANING AdBlue/DEF TANK . 641
POWER TRAIN . 645
TEST SWING CIRCLE BEARING CLEARANCE . 645
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE . 645
UNDERCARRIAGE AND FRAME . 646
TEST AND ADJUST TRACK TENSION . 646
METHOD FOR TESTING TRACK TENSION 646
METHOD FOR ADJUSTING TRACK TENSION 646
HYDRAULIC SYSTEM 648
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM 648
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK . 648
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT . 648
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT 651
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT . 651
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS 652
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 653
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS . 661
TEST OIL PRESSURE OF CONTROL CIRCUIT 665
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT 665
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT . 667
TEST PC VALVE OUTPUT PRESSURE (SERVO PISTON INLET PRESSURE) . 667
TEST PC-EPC VALVE OUTPUT PRESSURE . 668
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT 669
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT . 670
METHOD FOR TESTING OIL PRESSURE WITH SENSOR ADAPTER (SPECIAL TOOL) 670
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE . 672
METHOD FOR TESTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INLET PRESSURE) . 673
METHOD FOR TESTING LS-EPC VALVE OUTPUT PRESSURE . 674
METHOD FOR ADJUSTING LS VALVE . 674
TEST OUTLET PRESSURE OF SOLENOID VALVE 676
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE 676
OPERATING CONDITION OF SOLENOID VALVE . 677
TEST PPC VALVE OUTPUT PRESSURE 679
METHOD FOR TESTING PPC VALVE OUTPUT PRESSURE 679
ADJUST WORK EQUIPMENT AND SWING PPC VALVES 681
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES 681
MEASURING AND ADJUSTING QUICK COUPLER CONTROL VALVE OUTPUT PRESSURE . 682
TEST PUMP SWASH PLATE SENSOR 684
METHOD FOR TESTING PUMP SWASH PLATE SENSOR 684
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT 685
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER . 685
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER 685
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE . 686
TEST OIL LEAKAGE 687
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER . 687
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER 687
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER . 688
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR . 688
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR 689
BLEED AIR FROM HYDRAULIC CIRCUIT 690
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT 692
HYDRAULIC SYSTEM – PC390HRD-11 695
MEASURING AND ADJUSTING SWING SPEED REDUCTION VALVE . 695
MEASURING AND ADJUSTING BOOM AND BUCKET PPC REDUCTION VALVE . 696
MEASURING AND ADJUSTING LINK CYLINDER FLOW CONTROL VALVE 697
MEASURING AND ADJUSTING ARM CYLINDER FLOW CONTROL VALVE . 698
CAB AND ITS ATTACHMENTS . 699
TEST CAB TIPPING STOPPER 699
METHOD FOR TESTING CAB TIPPING STOPPER 699
METHOD FOR ADJUSTING MIRRORS 700
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A) . 700
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A) . 701
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B) 702
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B) 703
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C) . 704
ELECTRICAL SYSTEM . 706
SET AND OPERATE MACHINE MONITOR . 706
OPERATOR MODE . 709
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN . 710
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN 710
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY) . 711
CHECKING FUNCTION OF SERVICE METER 711
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD . 711
SERVICE MODE 714
METHOD FOR OPERATING SERVICE MODE . 714
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION 716
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION 723
ABNORMALITY RECORD MENU . 733
METHOD FOR CONFIRMING MAINTENANCE RECORD 738
METHOD FOR OPERATING MAINTENANCE MODE SETTING . 739
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING . 743
DEFAULT MENU 744
DIAGNOSTIC TESTS MENU . 751
ADJUSTMENT MENU . 760
METHOD FOR PERFORMING NO-INJECTION CRANKING . 777
KOMTRAX SETTINGS MENU . 778
METHOD FOR DISPLAYING SERVICE MESSAGE . 781
METHOD FOR STARTING UP KOMTRAX TERMINAL . 783
ADJUST REARVIEW CAMERA ANGLE 788
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE . 788
ADJUST KomVision CAMERA ANGLE . 791
792
SETTING OF KomVision (CAMERA CALIBRATION) . 792
KomVision screen – Check 12 m visibility 805
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER . 808
HANDLE BATTERY DISCONNECT SWITCH 809
TEST DIODES . 810
METHOD FOR TESTING DIODE USING DIGITAL TESTER . 810
METHOD FOR TESTING DIODE USING ANALOG TESTER 810
ELECTRICAL SYSTEM – PC390HRD-11 . 811
ELECTRICAL CIRCUIT DIAGRAMS OF WORK EQUIPMENT SYSTEM 811
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – BASE MACHINE . 811
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – HIGH REACH DEMOLITION WORK EQUIPMENT . 814
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – EXTENDED HIGH REACH DEMOLITION WORK EQUIPMENT 816
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – MEDIUM REACH DEMOLITION WORK EQUIPMENT . 818
HIGH REACH DEMOLITION ELECTRICAL DIAGRAM – DEMOLITION DIGGING WORK EQUIPMENT 820
RH PPC LEVER 821
WORK EQUIPMENT CONFIGURATION SELECTION CIRCUIT 822
CONSTANT LINK SPEED CIRCUIT . 823
PARALLEL LINK FRONT SCREEN WIPER 824
Pm CLINIC . 825
Pm CLINIC SERVICE . 825
Pm CLINIC CHECK SHEET . 826
WORKING RANGE INDICATOR SYSTEM 842
WORKING RANGE INDICATOR SYSTEM LAYOUT . 842
METHOD FOR ACCESSING WORKING RANGE INDICATOR KOMATSU SERVICE MENU . 844
DIAGNOSTICS – WORKING RANGE INDICATOR SYSTEM 846
MONITORING SYSTEM PARAMETERS AND SENSOR STATES 846
USING THE PARAMETER CHANGE LOG 848
USING ERROR LISTS AND LOGS 849
EXPORT DATA FROM WORKING RANGE INDICATOR SYSTEM . 850
IMPORT DATA TO WORKING RANGE INDICATOR SYSTEM . 851
REPLACING COMPONENTS – WORKING RANGE INDICATOR SYSTEM . 853
WORKING RANGE INDICATOR SYSTEM ANGLE SENSOR REPLACEMENT . 853
WORKING RANGE INDICATOR SYSTEM MONITOR REPLACEMENT 858
WORKING RANGE INDICATOR SYSTEM – UDATING SOFTWARE . 863
CALIBRATION – WORKING RANGE INDICATOR SYSTEM 867
WORKING RANGE INDICATOR SYSTEM CALIBRATION OVERVIEW . 867
METHOD 1 – CALIBRATING AND CONFIRMING CALIBRATION ACCURACY – AUTO CALIBRATION . 867
METHOD 2 – BASE MACHINE SET-UP AND 2-AXIS PITCH AND ROLL SENSOR CALIBRATION . 875
METHOD 2 – CALIBRATING AND CONFIRMING CALIBRATION ACCURACY – MANUAL CALIBRATION . 878
40 TROUBLESHOOTING 895
CONTENTS 896
ABBREVIATION LIST . 907
RELATED INFORMATION ON TROUBLESHOOTING 913
GENERAL TROUBLESHOOTING POINTS 913
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM 915
SEQUENCE OF EVENTS IN TROUBLESHOOTING . 927
CHECKS BEFORE TROUBLESHOOTING . 929
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING . 931
WALK-AROUND CHECK . 931
TESTING IN ACCORDANCE WITH TESTING PROCEDURE 933
CHECK FUEL LEVEL AND TYPE . 933
CHECK IMPURE INGREDIENT IN FUEL . 933
CHECK FUEL PREFILTER 934
WATER SEPARATOR – CHECK / DRAIN WATER AND SEDIMENT 934
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE . 935
CHECK MAIN FILTER . 936
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN) 938
CHECK COOLANT LEVEL (RESERVOIR TANK) 939
CHECK CLOGGING OF AIR CLEANER . 940
OUTER ELEMENT – CLEAN . 940
ELEMENTS – REPLACE 942
CHECK HYDRAULIC OIL LEVEL . 943
CHECK HYDRAULIC OIL STRAINER 944
CHECK HYDRAULIC FILTER 945
CHECK OIL LEVEL IN SWING MACHINERY CASE . 946
CHECK OIL LEVEL IN DAMPER CASE 946
CHECK OIL LEVEL IN FINAL DRIVE CASE . 947
BLEED AIR FROM FUEL SYSTEM 947
BLEED AIR FROM HYDRAULIC SYSTEM . 947
ELECTRICAL EQUIPMENT – CHECK METHOD . 947
AUTOMATIC GREASE SYSTEM . 953
FINDING MALFUNCTIONS 953
MALFUNCTION FINDING PROCEDURES 955
ELECTRICAL SYSTEM TROUBLESHOOTING – PREPARATION . 957
PROCEDURE FOR TESTING AND TROUBLESHOOTING . 967
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS . 970
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 974
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM . 976
Connector list and layout . 979
CONNECTOR CONTACT IDENTIFICATION 992
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE .1032
FUSE LOCATION TABLE .1038
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC) .1040
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135]) .1044
FAILURE CODES TABLE .1046
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE) .1063
FAILURE CODE [879AKA] .1063
FAILURE CODE [879AKB] .1064
FAILURE CODE [879BKA] .1065
FAILURE CODE [879BKB] .1067
FAILURE CODE [879CKA] .1069
FAILURE CODE [879CKB] .1070
FAILURE CODE [879DKZ] .1071
FAILURE CODE [879EMC] .1073
FAILURE CODE [879FMC] .1074
FAILURE CODE [879GKX] .1075
FAILURE CODE [989L00] .1077
FAILURE CODE [989M00] .1078
FAILURE CODE [989N00] .1079
FAILURE CODE [A1U0N3] .1080
FAILURE CODE [A1U0N4] .1082
FAILURE CODE [A900FR] .1084
FAILURE CODE [A900N6] .1085
FAILURE CODE [A900NY] .1086
FAILURE CODE [AA10NX] .1087
FAILURE CODE [AB00KE] .1089
FAILURE CODE [AQ10N3] .1092
FAILURE CODE [AS00N3] .1094
FAILURE CODE [AS00R2] .1096
FAILURE CODE [AS00R3] .1097
FAILURE CODE [AS00R4] .1098
FAILURE CODE [AS00R5] .1099
FAILURE CODE [AS00R6] .1100
FAILURE CODE [AS00ZK] .1101
FAILURE CODE [AS10KM] .1102
FAILURE CODE [AS10NR] .1103
FAILURE CODE [AS10NT] .1104
FAILURE CODE [B@BAZG] .1105
FAILURE CODE [B@BAZK] .1106
FAILURE CODE [B@BCNS] .1108
FAILURE CODE [B@BCQA] .1109
FAILURE CODE [B@BCZK] .1111
FAILURE CODE [B@HANS] .1113
FAILURE CODE [CA115] 1114
FAILURE CODE [CA122] 1115
FAILURE CODE [CA123] 1117
FAILURE CODE [CA131] 1119
FAILURE CODE [CA132] 1121
FAILURE CODE [CA144] 1123
FAILURE CODE [CA145] 1125
FAILURE CODE [CA153] 1127
FAILURE CODE [CA154] 1130
FAILURE CODE [CA187] 1133
FAILURE CODE [CA221] 1135
FAILURE CODE [CA222] 1137
FAILURE CODE [CA227] 1139
FAILURE CODE [CA234] 1140
FAILURE CODE [CA238] 1141
FAILURE CODE [CA239] 1143
FAILURE CODE [CA249] 1145
FAILURE CODE [CA256] 1147
FAILURE CODE [CA271] 1149
FAILURE CODE [CA272] 1151
FAILURE CODE [CA281] 1153
FAILURE CODE [CA322] 1154
FAILURE CODE [CA323] 1156
FAILURE CODE [CA324] 1158
FAILURE CODE [CA325] 1160
FAILURE CODE [CA331] 1162
FAILURE CODE [CA332] 1164
FAILURE CODE [CA343] 1166
FAILURE CODE [CA351] 1167
FAILURE CODE [CA352] 1168
FAILURE CODE [CA356] 1171
FAILURE CODE [CA357] 1173
FAILURE CODE [CA386] 1175
FAILURE CODE [CA428] 1176
FAILURE CODE [CA429] 1178
FAILURE CODE [CA435] 1180
FAILURE CODE [CA441] 1182
FAILURE CODE [CA442] 1184
FAILURE CODE [CA449] 1185
FAILURE CODE [CA451] 1189
FAILURE CODE [CA452] 1192
FAILURE CODE [CA488] 1194
FAILURE CODE [CA515] 1195
FAILURE CODE [CA516] 1197
FAILURE CODE [CA553] 1199
FAILURE CODE [CA555] 1200
FAILURE CODE [CA556] 1201
FAILURE CODE [CA559] 1202
FAILURE CODE [CA595] 1206
FAILURE CODE [CA687] 1207
FAILURE CODE [CA689] 1209
FAILURE CODE [CA691] 1214
FAILURE CODE [CA692] 1216
FAILURE CODE [CA697] 1218
FAILURE CODE [CA698] 1219
FAILURE CODE [CA731] 1220
FAILURE CODE [CA778] 1222
FAILURE CODE [CA1117] .1227
FAILURE CODE [CA1664] .1228
FAILURE CODE [CA1669] .1230
FAILURE CODE [CA1673] .1231
FAILURE CODE [CA1677] .1232
FAILURE CODE [CA1678] .1233
FAILURE CODE [CA1682] .1234
FAILURE CODE [CA1683] .1236
FAILURE CODE [CA1684] .1238
FAILURE CODE [CA1686] .1240
FAILURE CODE [CA1691] .1241
FAILURE CODE [CA1694] .1244
FAILURE CODE [CA1695] .1247
FAILURE CODE [CA1696] .1248
FAILURE CODE [CA1712] .1250
FAILURE CODE [CA1713] .1253
FAILURE CODE [CA1714] .1255
FAILURE CODE [CA1715] .1256
FAILURE CODE [CA1776] .1257
FAILURE CODE [CA1777] .1260
FAILURE CODE [CA1843] .1263
FAILURE CODE [CA1844] .1265
FAILURE CODE [CA1879] .1268
FAILURE CODE [CA1881] .1271
FAILURE CODE [CA1883] .1273
FAILURE CODE [CA1885] .1276
FAILURE CODE [CA1887] .1278
FAILURE CODE [CA1921] .1280
FAILURE CODE [CA1922] .1283
FAILURE CODE [CA1942] .1288
FAILURE CODE [CA1993] .1289
FAILURE CODE [CA2185] .1292
FAILURE CODE [CA2186] .1294
FAILURE CODE [CA2249] .1296
FAILURE CODE [CA2265] .1297
FAILURE CODE [CA2266] .1299
FAILURE CODE [CA2271] .1301
FAILURE CODE [CA2272] .1304
FAILURE CODE [CA2288] .1307
FAILURE CODE [CA2311] .1308
FAILURE CODE [CA2349] .1309
FAILURE CODE [CA2353] .1312
FAILURE CODE [CA2357] .1314
FAILURE CODE [CA2381] .1315
FAILURE CODE [CA2382] .1318
FAILURE CODE [CA2383] .1321
FAILURE CODE [CA2386] .1324
FAILURE CODE [CA2387] .1326
FAILURE CODE [CA2555] .1327
FAILURE CODE [CA2556] .1329
FAILURE CODE [CA2637] .1331
FAILURE CODE [CA2639] .1333
FAILURE CODE [CA2771] .1336
FAILURE CODE [CA2777] .1342
FAILURE CODE [CA2976] .1345
FAILURE CODE [CA3133] .1347
FAILURE CODE [CA3134] .1349
FAILURE CODE [CA3135] .1351
FAILURE CODE [CA3142] .1354
FAILURE CODE [CA3143] .1355
FAILURE CODE [CA3144] .1356
FAILURE CODE [CA3146] .1358
FAILURE CODE [CA3147] .1359
FAILURE CODE [CA3148] .1360
FAILURE CODE [CA3151] .1362
FAILURE CODE [CA3165] .1368
FAILURE CODE [CA3229] .1370
FAILURE CODE [CA3231] .1372
FAILURE CODE [CA3232] .1374
FAILURE CODE [CA3235] .1378
FAILURE CODE [CA3239] .1380
FAILURE CODE [CA3241] .1383
FAILURE CODE [CA3242] .1386
FAILURE CODE [CA3251] .1389
FAILURE CODE [CA3253] .1391
FAILURE CODE [CA3254] .1394
FAILURE CODE [CA3255] .1397
FAILURE CODE [CA3256] .1401
FAILURE CODE [CA3311] .1403
FAILURE CODE [CA3312] .1405
FAILURE CODE [CA3313] .1408
FAILURE CODE [CA3314] .1409
FAILURE CODE [CA3315] .1410
FAILURE CODE [CA3316] .1412
FAILURE CODE [CA3317] .1413
FAILURE CODE [CA3318] .1414
FAILURE CODE [CA3319] .1416
FAILURE CODE [CA3321] .1417
FAILURE CODE [CA3322] .1419
FAILURE CODE [CA3419] .1421
FAILURE CODE [CA3421] .1423
FAILURE CODE [CA3497] .1425
FAILURE CODE [CA3498] .1426
FAILURE CODE [CA3543] .1427
FAILURE CODE [CA3545] .1434
FAILURE CODE [CA3547] .1436
FAILURE CODE [CA3558] .1437
FAILURE CODE [CA3559] .1439
FAILURE CODE [CA3562] .1441
FAILURE CODE [CA3563] .1443
FAILURE CODE [CA3567] .1446
FAILURE CODE [CA3568] .1449
FAILURE CODE [CA3571] .1453
FAILURE CODE [CA3572] .1455
FAILURE CODE [CA3574] .1457
FAILURE CODE [CA3575] .1459
FAILURE CODE [CA3577] .1461
FAILURE CODE [CA3578] .1463
FAILURE CODE [CA3582] .1465
FAILURE CODE [CA3583] .1471
FAILURE CODE [CA3596] .1473
FAILURE CODE [CA3649] .1475
FAILURE CODE [CA3681] .1477
FAILURE CODE [CA3682] .1482
FAILURE CODE [CA3713] .1488
FAILURE CODE [CA3717] .1491
FAILURE CODE [CA3718] .1492
FAILURE CODE [CA3725] .1493
FAILURE CODE [CA3741] .1496
FAILURE CODE [CA3748] .1497
FAILURE CODE [CA3751] .1499
FAILURE CODE [CA3755] .1501
FAILURE CODE [CA3866] .1503
FAILURE CODE [CA3867] .1506
FAILURE CODE [CA3868] .1509
FAILURE CODE [CA3899] .1513
FAILURE CODE [CA3911] .1515
FAILURE CODE [CA3912] .1519
FAILURE CODE [CA3932] .1521
FAILURE CODE [CA3933] .1523
FAILURE CODE [CA3934] .1525
FAILURE CODE [CA3935] .1528
FAILURE CODE [CA3936] .1530
FAILURE CODE [CA4151] .1532
FAILURE CODE [CA4152] .1536
FAILURE CODE [CA4155] .1540
FAILURE CODE [CA4156] .1542
FAILURE CODE [CA4157] .1545
FAILURE CODE [CA4158] .1547
FAILURE CODE [CA4159] .1548
FAILURE CODE [CA4161] .1549
FAILURE CODE [CA4162] .1552
FAILURE CODE [CA4163] .1555
FAILURE CODE [CA4164] .1557
FAILURE CODE [CA4165] .1559
FAILURE CODE [CA4166] .1561
FAILURE CODE [CA4168] .1563
FAILURE CODE [CA4169] .1566
FAILURE CODE [CA4171] .1568
FAILURE CODE [CA4249] .1571
FAILURE CODE [CA4251] .1573
FAILURE CODE [CA4259] .1575
FAILURE CODE [CA4261] .1578
FAILURE CODE [CA4277] .1581
FAILURE CODE [CA4281] .1584
FAILURE CODE [CA4459] .1587
FAILURE CODE [CA4461] .1590
FAILURE CODE [CA4658] .1593
FAILURE CODE [CA4731] .1597
FAILURE CODE [CA4732] .1598
FAILURE CODE [CA4739] .1599
FAILURE CODE [CA4768] .1600
FAILURE CODE [CA4769] .1602
FAILURE CODE [CA4842] .1605
FAILURE CODE [CA4952] .1608
FAILURE CODE [CA5115] .1610
FAILURE CODE [CA5179] .1613
FAILURE CODE [CA5181] .1615
FAILURE CODE [CA5383] .1617
FAILURE CODE [D110KB] .1619
FAILURE CODE [D19JKZ] .1621
FAILURE CODE [D811MC] .1624
FAILURE CODE [D862KA] .1625
FAILURE CODE [D8ALKA] .1626
FAILURE CODE [D8ALKB] .1628
FAILURE CODE [D8AQKR] .1630
FAILURE CODE [DA20MC] .1632
FAILURE CODE [DA22KK] .1633
FAILURE CODE [DA25KP] .1636
FAILURE CODE [DA29KQ] .1639
FAILURE CODE [DA2LKA] .1641
FAILURE CODE [DA2LKB] .1643
FAILURE CODE [DA2QKR] .1645
FAILURE CODE [DA2RKR] .1648
FAILURE CODE [DAF0MB] .1649
FAILURE CODE [DAF0MC] .1650
FAILURE CODE [DAF8KB] .1651
FAILURE CODE [DAF9KQ] .1653
FAILURE CODE [DAFGMC] .1654
FAILURE CODE [DAFLKA] .1655
FAILURE CODE [DAFLKB] .1657
FAILURE CODE [DAFQKR] .1659
FAILURE CODE [DAZ9KQ] .1660
FAILURE CODE [DAZQKR] .1661
FAILURE CODE [DB2QKR] .1666
FAILURE CODE [DB2RKR] .1671
FAILURE CODE [DDNRKA] .1676
FAILURE CODE [DDNRKY] .1678
FAILURE CODE [DDNS00] .1680
FAILURE CODE [DGH2KB] .1682
FAILURE CODE [DHA4KA] .1684
FAILURE CODE [DHAAMA] .1686
FAILURE CODE [DHACMA] .1688
FAILURE CODE [DHPAMA] .1690
FAILURE CODE [DHPBMA] .1693
FAILURE CODE [DHS3MA] .1696
FAILURE CODE [DHS4MA] .1699
FAILURE CODE [DHS8MA] .1702
FAILURE CODE [DHS9MA] .1705
FAILURE CODE [DHSAMA] .1708
FAILURE CODE [DHSBMA] .1711
FAILURE CODE [DHSCMA] .1714
FAILURE CODE [DHSDMA] .1717
FAILURE CODE [DHSFMA] .1720
FAILURE CODE [DHSGMA] .1723
FAILURE CODE [DHSHMA] .1726
FAILURE CODE [DHSJMA] .1729
FAILURE CODE [DKR0MA] .1732
FAILURE CODE [DKR1MA] .1735
FAILURE CODE [DKULKA] .1738
FAILURE CODE [DKULKB] .1740
FAILURE CODE [DKULKY] .1742
FAILURE CODE [DR21KX] .1743
FAILURE CODE [DR31KX] .1745
FAILURE CODE [DV20KB] .1747
FAILURE CODE [DW43KA] .1749
FAILURE CODE [DW43KB] .1751
FAILURE CODE [DW43KY] .1753
FAILURE CODE [DW45KA] .1755
FAILURE CODE [DW45KB] .1758
FAILURE CODE [DW45KY] .1761
FAILURE CODE [DW4CKY] .1763
FAILURE CODE [DW91KA] .1764
FAILURE CODE [DW91KB] .1766
FAILURE CODE [DW91KY] .1768
FAILURE CODE [DWA2KA] .1770
FAILURE CODE [DWA2KB] .1772
FAILURE CODE [DWA2KY] .1774
FAILURE CODE [DWK0KA] .1776
FAILURE CODE [DWK0KB] .1778
FAILURE CODE [DWK0KY] .1780
FAILURE CODE [DWK2KA] .1782
FAILURE CODE [DWK2KB] .1784
FAILURE CODE [DWK2KY] .1786
FAILURE CODE [DWK8KA] .1788
FAILURE CODE [DWK8KB] .1790
FAILURE CODE [DWK8KY] .1792
FAILURE CODE [DXA8KA] .1794
FAILURE CODE [DXA8KB] .1797
FAILURE CODE [DXA9KA] .1799
FAILURE CODE [DXA9KB] .1802
FAILURE CODE [DXE0KA] .1804
FAILURE CODE [DXE0KB] .1806
FAILURE CODE [DXE4KA] .1808
FAILURE CODE [DXE4KB] .1810
FAILURE CODE [DXE4KY] .1812
FAILURE CODE [DXE5KA] .1813
FAILURE CODE [DXE5KB] .1815
FAILURE CODE [DXE6KA] .1817
FAILURE CODE [DXE6KB] .1819
FAILURE CODE [DXE7KA] .1821
FAILURE CODE [DXE7KB] .1823
FAILURE CODE [DXE7KY] .1825
FAILURE CODE [DXE8KA] .1827
FAILURE CODE [DXE8KB] .1829
FAILURE CODE [DXE8KY] .1831
FAILURE CODE [DXE9KA] .1833
FAILURE CODE [DXE9KB] .1835
FAILURE CODE [DXE9KY] .1837
FAILURE CODE [DXEAKA] .1839
FAILURE CODE [DXEAKB] .1841
FAILURE CODE [DXEAKY] .1843
FAILURE CODE [DY20KA] .1845
FAILURE CODE [DY20MA] .1848
FAILURE CODE [DY2CKB] .1850
FAILURE CODE [DY2DKB] .1853
FAILURE CODE [DY2EKB] .1855
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) .1857
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK) .1857
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK 1863
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK .1866
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP .1868
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING .1870
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW 1873
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW 1874
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING .1875
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING 1876
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING .1877
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1878
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1879
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1880
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING 1881
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1882
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING .1883
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1884
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL .1886
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM .1887
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE 1888
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM 1889
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE .1891
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED .1892
E-24 FUNCTION SWITCH DOES NOT OPERATE .1893
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER) .1894
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF 1895
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER 1896
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED .1897
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED 1898
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE .1899
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE 1900
E-32 ALARM BUZZER CANNOT BE CANCELED 1902
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION .1903
E-34 SERVICE MODE CANNOT BE SELECTED 1904
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE 1905
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK .1907
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING .1908
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE .1911
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR .1913
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED .1915
E-41 ALARM DOES NOT SOUND DURING TRAVEL .1916
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED 1918
E-43 HORN DOES NOT SOUND 1919
E-44 HORN DOES NOT STOP SOUNDING 1923
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF .1925
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE .1926
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE 1928
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1929
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1930
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1931
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1932
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1933
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1934
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1935
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION 1936
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION .1937
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED .1939
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY .1940
E-59 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED 1941
E-60 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1943
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .1944
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE) .1944
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS 1945
FAILURE MODE AND CAUSE TABLE 1947
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK 1956
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER .1957
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR 1960
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP .1961
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS 1962
H-6 SPEED OR POWER OF BOOM IS LOW .1964
H-7 ARM SPEED OR POWER IS LOW .1970
H-8 BUCKET SPEED OR POWER IS LOW 1975
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION 1978
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE .1979
H-11 HYDRAULIC DRIFT OF ARM IS LARGE 1981
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE .1983
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES .1984
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE 1985
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE .1986
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE 1987
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED .1988
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED .1989
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER 1990
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY 1991
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW 1992
H-22 MACHINE DOES NOT TRAVEL STRAIGHT .1993
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW .1995
H-24 TRAVEL SPEED IS LOW 1998
H-25 ONE OF TRACKS DOES NOT RUN .2000
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST 2002
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT 2003
H-28 SWINGS ONLY IN ONE DIRECTION .2004
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT) .2005
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION 2006
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT) 2007
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT) 2008
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING .2009
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING .2010
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED) .2011
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED) 2012
H-37 Quick coupler cylinder will not extend .2013
H-38 Quick coupler cylinder will not retract (but buzzer doesnot sound) .2015
H-39 Buzzer does not sound (but quick coupler cylinder doesretract) .2017
H-40 Quick coupler cylinder extends and retracts slowly .2019
TROUBLESHOOTING OF ENGINE (S-MODE) 2020
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE) .2020
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION 2021
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT 2022
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START) 2023
S-4 ENGINE STARTABILITY IS POOR .2025
S-5 ENGINE DOES NOT PICK UP SMOOTHLY 2027
S-6 ENGINE STOPS DURING OPERATION .2029
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE 2031
S-8 ENGINE LACKS POWER 2032
S-9 KDPF GETS CLOGGED IN A SHORT TIME .2034
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE 2036
S-11 OIL BECOMES CONTAMINATED QUICKLY .2037
S-12 FUEL CONSUMPTION IS EXCESSIVE 2038
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN) 2039
S-14 OIL PRESSURE DROPS .2040
S-15 FUEL MIXES INTO ENGINE OIL .2042
S-16 WATER MIXES INTO ENGINE OIL (MILKY) 2043
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING) .2044
S-18 UNUSUAL NOISE IS HEARD .2046
S-19 VIBRATION IS EXCESSIVE .2047
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT .2048
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY .2049
S-22 ACTIVE REGENERATION TAKES TIME .2051
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION 2052
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE 2053
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR) .2055
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES) 2056
TROUBLESHOOTING OF WORKING RANGE INDICATOR BY FAILURE CODE (IF EQUIPPED) 2057
20 SUPPLY VOLTAGE > 32VDC .2057
21 SUPPLY VOLTAGE < 12VDC .2058
25 FILE ERROR FACTORY SETTINGS 2059
26 FILE ERROR USER SETTINGS .2060
27 FILE ERROR INPUT DATA 2061
30 PROXIMITY SWITCHES DIFFERENCE 2062
86 ANGLE SENSOR A2 TIMEOUT 2063
96 ANGLE SENSOR A3/A5 TIMEOUT .2064
106 ANGLE SENSOR A4/A6 TIMEOUT 2065
116 ANGLE SENSOR PITCH TIMEOUT 2066
126 ANGLE SENSOR ROLL TIMEOUT .2067
50 DISASSEMBLY AND ASSEMBLY .2069
CONTENTS 2070
ABBREVIATION LIST .2075
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY .2081
HOW TO READ THIS MANUAL .2081
COATING MATERIALS LIST 2083
SPECIAL TOOLS LIST 2087
SKETCHES OF SPECIAL TOOLS .2102
ENGINE AND COOLING SYSTEM .2110
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY .2110
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY 2110
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY 2115
REMOVE AND INSTALL INJECTOR ASSEMBLY 2123
METHOD FOR REMOVING INJECTOR ASSEMBLY .2123
METHOD FOR INSTALLING INJECTOR ASSEMBLY .2130
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY .2142
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY 2143
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY 2152
REMOVE AND INSTALL EGR VALVE ASSEMBLY .2170
METHOD FOR REMOVING EGR VALVE ASSEMBLY 2170
METHOD FOR INSTALLING EGR VALVE ASSEMBLY 2171
REMOVE AND INSTALL EGR COOLER ASSEMBLY 2173
METHOD FOR REMOVING EGR COOLER ASSEMBLY .2173
METHOD FOR INSTALLING EGR COOLER ASSEMBLY .2174
REMOVE AND INSTALL STARTER ASSEMBLY .2177
METHOD FOR REMOVING STARTER ASSEMBLY 2177
METHOD FOR INSTALLING STARTER ASSEMBLY 2178
REMOVE AND INSTALL ALTERNATOR BELT 2179
METHOD FOR REMOVING ALTERNATOR BELT .2179
METHOD FOR INSTALLING ALTERNATOR BELT .2182
REMOVE AND INSTALL RADIATOR ASSEMBLY 2185
METHOD FOR REMOVING RADIATOR ASSEMBLY .2185
METHOD FOR INSTALLING RADIATOR ASSEMBLY .2187
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY 2189
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY .2189
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY .2191
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY .2194
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY 2194
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY 2195
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY 2197
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY .2198
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY .2209
REMOVE AND INSTALL ENGINE FRONT OIL SEAL 2224
METHOD FOR REMOVING ENGINE FRONT OIL SEAL .2224
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL .2228
REMOVE AND INSTALL ENGINE REAR OIL SEAL .2232
METHOD FOR REMOVING ENGINE REAR OIL SEAL 2233
METHOD FOR INSTALLING ENGINE REAR OIL SEAL 2234
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY .2241
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY 2241
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY 2242
REMOVE AND INSTALL FUEL TANK ASSEMBLY .2245
METHOD FOR REMOVING FUEL TANK ASSEMBLY 2245
METHOD FOR INSTALLING FUEL TANK ASSEMBLY 2249
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY .2252
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY 2252
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY 2258
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY .2264
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2264
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY 2270
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR .2275
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR 2275
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR 2275
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER .2277
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER 2277
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER 2277
REMOVE AND INSTALL AdBlue/DEF TANK FILLER PORT FILTER .2278
METHOD FOR REMOVING AdBlue/DEF TANK FILLER PORT FILTER 2278
METHOD FOR INSTALLING AdBlue/DEF TANK FILLER PORT FILTER 2280
REMOVE AND INSTALL KDPF ASSEMBLY 2283
METHOD FOR REMOVING KDPF ASSEMBLY .2283
METHOD FOR INSTALLING KDPF ASSEMBLY .2286
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY .2290
METHOD FOR DISASSEMBLING KDPF ASSEMBLY 2291
METHOD FOR ASSEMBLING KDPF ASSEMBLY .2294
REMOVE AND INSTALL SCR ASSEMBLY .2299
METHOD FOR REMOVING SCR ASSEMBLY 2299
METHOD FOR INSTALLING SCR ASSEMBLY 2302
REMOVE AND INSTALL KDPF, SCR ASSEMBLY .2305
METHOD FOR REMOVING KDPF, SCR ASSEMBLY 2306
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY 2312
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET .2319
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET 2319
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET 2322
REMOVE AND INSTALL KCCV ASSEMBLY 2327
METHOD FOR REMOVING KCCV ASSEMBLY .2327
METHOD FOR INSTALLING KCCV ASSEMBLY .2328
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE .2330
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE 2331
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE 2334
REMOVE AND INSTALL AdBlue/DEF INJECTOR 2338
METHOD FOR REMOVING AdBlue/DEF INJECTOR .2338
METHOD FOR INSTALLING AdBlue/DEF INJECTOR .2341
REMOVE AND INSTALL AdBlue/DEF PUMP 2345
METHOD FOR REMOVING AdBlue/DEF PUMP .2345
METHOD FOR INSTALLING AdBlue/DEF PUMP .2348
REMOVE AND INSTALL AdBlue/DEF HOSE 2350
METHOD FOR REMOVING AdBlue/DEF HOSE .2351
METHOD FOR INSTALLING AdBlue/DEF HOSE .2357
REMOVE AND INSTALL AIR CLEANER ASSEMBLY .2365
METHOD FOR REMOVING AIR CLEANER ASSEMBLY 2365
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY 2367
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY 2369
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY .2369
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY .2370
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY .2372
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY 2372
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY 2373
POWER TRAIN .2374
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY 2374
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2374
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY .2375
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY .2377
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY .2378
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY 2382
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY .2390
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2390
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY 2391
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY .2393
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY .2393
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY 2396
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY 2403
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY .2403
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY .2403
UNDERCARRIAGE AND FRAME .2405
SEPARATION AND CONNECTION OF TRACK ASSEMBLY .2405
METHOD FOR SEPARATING TRACK ASSEMBLY 2405
METHOD FOR INSTALLING TRACK ASSEMBLY 2407
REMOVE AND INSTALL SPROCKET .2410
METHOD FOR REMOVING SPROCKET 2410
METHOD FOR INSTALLING SPROCKET 2410
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY .2412
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY 2412
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY 2413
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY .2415
METHOD FOR DISASSEMBLING IDLER ASSEMBLY .2415
METHOD FOR ASSEMBLING IDLER ASSEMBLY 2416
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY 2420
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY .2420
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY 2421
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY 2423
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY 2424
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY .2425
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY .2427
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY 2427
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY .2428
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY .2431
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY 2431
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY 2433
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY – PC390HRD-11 2435
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY .2436
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY 2436
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY 2437
HYDRAULIC SYSTEM 2440
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY .2440
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY 2440
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY 2441
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY .2444
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY .2445
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY 2446
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY 2447
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY .2447
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY .2450
REMOVE AND INSTALL MAIN PUMP ASSEMBLY .2454
METHOD FOR REMOVING MAIN PUMP ASSEMBLY 2454
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY 2457
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY .2460
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY 2460
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY 2467
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY .2474
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING 2475
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY 2476
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY 2481
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY 2481
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY .2482
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY 2484
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY 2484
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY .2485
REMOVE AND INSTALL QUICK COUPLER VALVE 2487
WORK EQUIPMENT 2489
REMOVE AND INSTALL BUCKET ASSEMBLY 2489
METHOD FOR REMOVING BUCKET ASSEMBLY .2489
METHOD FOR INSTALLING BUCKET ASSEMBLY .2489
REMOVE AND INSTALL ARM ASSEMBLY .2491
METHOD FOR REMOVING ARM ASSEMBLY 2491
METHOD FOR INSTALLING ARM ASSEMBLY 2492
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY 2494
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY .2494
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY .2497
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT CYLINDER ASSEMBLY .2500
METHOD FOR DISASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY .2500
METHOD FOR ASSEMBLING WORK EQUIPMENT CYLINDER ASSEMBLY 2503
CAB AND ITS ATTACHMENTS .2510
REMOVE AND INSTALL OPERATOR’S CAB ASSEMBLY 2510
METHOD FOR REMOVING OPERATOR CAB ASSEMBLY .2510
METHOD FOR INSTALLING OPERATOR CAB ASSEMBLY .2516
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS) .2523
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS) 2525
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS) 2525
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY 2536
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY .2536
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY .2539
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY .2545
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY 2546
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY 2552
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY 2560
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY .2560
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY .2565
REMOVE AND INSTALL OPERATOR’S SEAT 2571
METHOD FOR REMOVING OPERATOR’S SEAT .2571
METHOD FOR INSTALLING OPERATOR’S SEAT .2573
REMOVE AND INSTALL SEAT BELT 2576
METHOD FOR REMOVING SEAT BELT .2576
METHOD FOR INSTALLING SEAT BELT .2577
REMOVE AND INSTALL FRONT WIPER ASSEMBLY .2578
METHOD FOR REMOVING FRONT WIPER ASSEMBLY 2578
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY 2583
ELECTRICAL SYSTEM .2592
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY .2592
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY 2592
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY 2594
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY .2598
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY 2598
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY 2601
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY .2605
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY 2605
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY 2608
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR 2612
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR .2612
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR .2612
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR .2614
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR 2614
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR 2615
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR .2616
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR 2616
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR 2617
REMOVE AND INSTALL SCR TEMPERATURE SENSOR .2618
METHOD FOR REMOVING SCR TEMPERATURE SENSOR 2618
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR 2619
REMOVE AND INSTALL REARVIEW CAMERA 2621
METHOD FOR REMOVING REARVIEW CAMERA .2621
METHOD FOR INSTALLING REARVIEW CAMERA .2622
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY 2624
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY .2624
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY .2627
60 MAINTENANCE STANDARD .2631
CONTENTS 2632
ABBREVIATION LIST .2633
ENGINE AND COOLING SYSTEM .2639
MAINTENANCE STANDARD OF ENGINE MOUNT 2639
MAINTENANCE STANDARD OF COOLING SYSTEM 2641
POWER TRAIN .2643
MAINTENANCE STANDARD OF SWING CIRCLE 2643
MAINTENANCE STANDARD OF SWING MACHINERY .2644
MAINTENANCE STANDARD OF FINAL DRIVE .2646
MAINTENANCE STANDARD OF SPROCKET 2648
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING .2649
UNDERCARRIAGE AND FRAME .2651
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION .2651
MAINTENANCE STANDARD OF IDLER .2653
MAINTENANCE STANDARD OF TRACK ROLLER 2655
MAINTENANCE STANDARD OF CARRIER ROLLER 2657
MAINTENANCE STANDARD OF TRACK SHOE 2658
MAINTENANCE STANDARD OF TRIPLE SHOE .2661
HYDRAULIC SYSTEM 2662
MAINTENANCE STANDARD OF HYDRAULIC TANK 2662
MAINTENANCE STANDARD OF MAIN PUMP .2663
MAINTENANCE STANDARD OF SWING MOTOR .2665
MAINTENANCE STANDARD OF TRAVEL MOTOR 2668
MAINTENANCE STANDARD OF CONTROL VALVE .2671
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE 2681
MAINTENANCE STANDARD OF TRAVEL PPC VALVE 2684
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE) 2687
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE 2688
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE .2690
MAINTENANCE STANDARD OF SOLENOID VALVE 2692
MAINTENANCE STANDARD OF HYDRAULIC DRIFT PREVENTION VALVE 2693
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE .2695
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT .2696
WORK EQUIPMENT 2697
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE 2697
DIMENSION OF ARM 2702
DIMENSIONS OF BUCKET 2704
MAINTENANCE STANDARD OF BOOM CYLINDER .2706
MAINTENANCE STANDARD OF ARM CYLINDER 2707
MAINTENANCE STANDARD OF BUCKET CYLINDER .2708
WORK EQUIPMENT – PC390HRD-11 2709
WORK EQUIPMENT – HIGH REACH DEMOLITION 2709
DIMENSION OF ARM 2709
MAINTENANCE STANDARD OF BOOM CYLINDER .2710
MAINTENANCE STANDARD OF LINK CYLINDER .2711
MAINTENANCE STANDARD OF ARM CYLINDER 2712
MAINTENANCE STANDARD OF BUCKET CYLINDER .2713
WORK EQUIPMENT – DEMOLITION DIGGING .2714
MAINTENANCE STANDARD OF ARM CYLINDER 2714
MAINTENANCE STANDARD OF BUCKET CYLINDER .2715
80 APPENDIX .2717
CONTENTS 2718
ABBREVIATION LIST .2720
AIR CONDITIONER SYSTEM 2726
PRECAUTIONS FOR REFRIGERANT .2726
AIR CONDITIONER COMPONENT .2727
SPECIFICATIONS OF AIR CONDITIONER .2729
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE .2730
OUTLINE OF REFRIGERATION CYCLE 2731
COMPONENT PARTS OF AIR CONDITIONER SYSTEM .2733
AIR CONDITIONER UNIT 2733
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT .2733
FUNCTION OF AIR CONDITIONER UNIT 2735
COMPONENT PARTS OF AIR CONDITIONER UNIT .2737
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT 2738
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT .2738
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT .2738
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT .2738
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT 2739
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2739
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT .2739
FUNCTION OF DUAL PRESSURE SWITCH 2740
AIR CONDITIONER CONTROLLER 2741
STRUCTURE OF AIR CONDITIONER CONTROLLER .2741
COMPRESSOR 2742
STRUCTURE OF COMPRESSOR .2742
SPECIFICATIONS OF COMPRESSOR 2742
FUNCTION OF COMPRESSOR 2742
CONDENSER .2743
STRUCTURE OF CONDENSER 2743
SPECIFICATIONS OF CONDENSER .2743
FUNCTION OF CONDENSER .2743
RECEIVER DRIER 2744
STRUCTURE OF RECEIVER DRIER .2744
SPECIFICATIONS OF RECEIVER DRIER 2744
FUNCTION OF RECEIVER DRIER 2744
SENSORS FOR AIR CONDITIONER SYSTEM 2745
STRUCTURE OF SUNLIGHT SENSOR 2745
FUNCTION OF SUNLIGHT SENSOR .2745
STRUCTURE OF AMBIENT TEMPERATURE SENSOR .2745
FUNCTION OF AMBIENT TEMPERATURE SENSOR 2745
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER .2747
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER .2749
AIR CONDITIONER SYSTEM DIAGRAM 2751
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER 2752
FUNCTION OF AIR CONDITIONER CONTROLLER 2753
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS .2754
TESTING AIR LEAKAGE (DUCT) 2758
METHOD FOR TESTING AIR LEAKAGE (DUCT) .2758
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION .2760
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR 2761
TEST VENT (MODE) CHANGEOVER .2762
METHOD FOR TESTING VENT (MODE) CHANGEOVER .2762
TESTING FRESH/RECIRC AIR CHANGEOVER .2764
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER 2764
TEST SUNLIGHT SENSOR 2765
METHOD FOR TESTING SUNLIGHT SENSOR 2765
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2766
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT .2766
TEST RELAYS .2768
METHOD FOR TESTING RELAYS .2768
AIR CONDITIONER TROUBLESHOOTING CHART 1 .2769
AIR CONDITIONER TROUBLESHOOTING CHART 2 .2771
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE 2774
FAILURE CODE [879AKA] .2776
FAILURE CODE [879AKB] .2777
FAILURE CODE [879BKA] .2778
FAILURE CODE [879BKB] .2780
FAILURE CODE [879CKA] .2782
FAILURE CODE [879CKB] .2783
FAILURE CODE [879DKZ] .2784
FAILURE CODE [879EMC] .2786
FAILURE CODE [879FMC] .2787
FAILURE CODE [879GKX] .2788
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE) 2790
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED) .2792
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL) 2795
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER .2797
TROUBLESHOOTING USING GAUGE PRESSURE 2799
CONNECTION OF SERVICE TOOL 2802
METHOD FOR CONNECTING SERVICE TOOL 2802
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS .2804
HANDLE COMPRESSOR OIL .2806
90 CIRCUIT DIAGRAMS .2809
CONTENTS 2810
ABBREVIATION LIST .2811
HYDRAULIC CIRCUIT DIAGRAM .2817
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM .2817
HYDRAULIC CIRCUIT DIAGRAM (1/2) .2821
HYDRAULIC CIRCUIT DIAGRAM (2/2) .2823
HYDRAULIC CIRCUIT DIAGRAM (1/3) – PC390HRD-11 .2825
HYDRAULIC CIRCUIT DIAGRAM (2/3) – PC390HRD-11 .2827
HYDRAULIC CIRCUIT DIAGRAM (3/3) – PC390HRD-11 .2829
ELECTRICAL CIRCUIT DIAGRAM 2831
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM 2831
ELECTRICAL CIRCUIT DIAGRAM (1/8) 2835
ELECTRICAL CIRCUIT DIAGRAM (2/8) 2837
ELECTRICAL CIRCUIT DIAGRAM (3/8) 2839
ELECTRICAL CIRCUIT DIAGRAM (4/8) 2841
ELECTRICAL CIRCUIT DIAGRAM (5/8) 2843
ELECTRICAL CIRCUIT DIAGRAM (6/8) 2845
ELECTRICAL CIRCUIT DIAGRAM (7/8) 2847
ELECTRICAL CIRCUIT DIAGRAM (8/8) 2849
INDEX 2851

DESCRIPTION:

Komatsu PC360LC-11,PC360NLC-11,PC390HRD-11 Hydraulic Excavator Shop Manual UENBM00391 – PDF DOWNLOAD

SERIAL NUMBERS

• 90001 and up
• K70001 and up

FOREWORD, SAFETY, BASIC INFORMATION 
HOW TO READ THE SHOP MANUAL 
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
Composition of the shop manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 INDEX AND FOREWORD
This section describes the index, foreword, safety, and basic information.
01 SPECIFICATIONS
This section describes the specifications of the machine.
10 STRUCTURE AND FUNCTION
This section describes the structure and operation of each component with respect to each system. “STRUCTURE
AND FUNCTION” is helpful in not only understanding the structure of each component but performing
troubleshooting.
20 STANDARD VALUE TABLE
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 TESTING AND ADJUSTING
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “STANDARD VALUE TABLE”.
40 TROUBLESHOOTING
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.
50 DISASSEMBLY AND ASSEMBLY
This section describes the special tools, work procedures, and safety precautions necessary for removal, installation,
disassembly, and assembly of the components and parts. In addition, tightening torques, quantity, and
weight of the coating materials, lubricants, and coolant necessary to these works are shown.
60 MAINTENANCE STANDARD
This section describes the maintenance standard value of each component. The maintenance standard shows
the criteria and remedies for disassembly and assembly.
80 THE OTHER INFORMATION
This section describes the structure and function, testing and adjusting, and troubleshooting for all of the other
components or equipment which cannot be separately classified in the appendix.
90 Circuit diagrams
This section describes hydraulic circuit diagrams and electrical circuit diagrams

G.B 31/12/24