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KOMATSU PC360LCi-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06601-16 – PDF DOWNLOAD
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KOMATSU PC360LCi-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06601-16 – PDF DOWNLOAD
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KOMATSU PC360LCi-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06601-16 – PDF DOWNLOAD
Language : English
Pages : 3768
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU PC360LCi-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06601-16 – PDF DOWNLOAD
Cover.................................................................................................................................................................... 1 00 Index and Foreword................................................................................................................................................... 3 Index............................................................................................................................................................... 4 Abbreviation List................................................................................................................................................... 23 Foreword, Safety, Basic Information................................................................................................................................. 26 How to Read the Shop Manual..................................................................................................................................... 26 Safety Notice for Operation..................................................................................................................................... 28 Precautions to Prevent Fire..................................................................................................................................... 36 Procedures If Fire Occurs....................................................................................................................................... 38 Precautions When You Discard Waste Materials.................................................................................................................... 39 Procedures for Exhaust Gas Regulations.......................................................................................................................... 40 Precautions for DEF............................................................................................................................................. 41 General Character and Precautions for Handling.............................................................................................................. 41 Precautions When You Add.................................................................................................................................... 41 Precautions for Storage..................................................................................................................................... 41 Precautions for Fire Hazard and Leakage..................................................................................................................... 41 Other Precautions........................................................................................................................................... 41 Store DEF....................................................................................................................................................... 42 Precautions When You Handle Hydraulic Equipment................................................................................................................. 43 Precautions When You Disconnect and Connect Pipings............................................................................................................. 46 Precautions When You Handle Electrical Equipment................................................................................................................ 53 Precautions When You Handle Fuel System Equipment............................................................................................................... 55 Precautions When You Handle Intake System Equipment............................................................................................................. 56 Practical Use of KOMTRAX........................................................................................................................................ 57 Disconnect and Connect Push-Pull Type Coupler................................................................................................................... 58 How to Disconnect and Connect Type 1 Push-Pull Type Coupler................................................................................................. 58 How to Disconnect and Connect Type 2 Push-Pull Type Coupler................................................................................................. 59 How to Disconnect and Connect Type 3 Push-Pull Type Coupler................................................................................................. 60 Precautions for Disconnection and Connection of Connectors...................................................................................................... 62 Disconnect and Connect Deutsch Connector........................................................................................................................ 66 How to Disconnect and Connect Slide Lock Type Connector......................................................................................................... 67 Disconnect and Connect Connector with Lock to Pull.............................................................................................................. 69 Disconnect and Connect Connector with Lock to Push.............................................................................................................. 70 Disconnect and Connect Connector with Housing to Rotate......................................................................................................... 72 How to Read the Codes for Electric Cable........................................................................................................................ 73 Explanation of Terms for Maintenance Standard................................................................................................................... 77 Standard Tightening Torque Table................................................................................................................................ 80 Conversion Table................................................................................................................................................ 87 01 Specification........................................................................................................................................................ 93 Table of Contents................................................................................................................................................... 94 Specifications...................................................................................................................................................... 95 Specification Drawing........................................................................................................................................... 95 Specification Drawing: PC360LCI-11.......................................................................................................................... 95 Working Range Drawings.......................................................................................................................................... 97 Working Range Drawings: PC360LCI-11......................................................................................................................... 97 Specifications.................................................................................................................................................. 98 Specification: PC360LCI-11.................................................................................................................................. 98 Weight Table.................................................................................................................................................... 101 Weight Table: PC360LCI-11................................................................................................................................... 101 Table of Fuel, Coolant, and Lubricants.......................................................................................................................... 103 10 Structure and Function............................................................................................................................................... 105 Table of Contents................................................................................................................................................... 106 Urea SCR System..................................................................................................................................................... 110 Layout Drawing of Urea SCR System............................................................................................................................... 110 Urea SCR System Diagram......................................................................................................................................... 114 Function of Urea SCR System..................................................................................................................................... 115 Function of DEF System...................................................................................................................................... 115 Inducement Strategy......................................................................................................................................... 117 Component Parts of Urea SCR System.............................................................................................................................. 131 DEF Mixing Tube............................................................................................................................................. 131 SCR Assembly................................................................................................................................................ 132 DEF Tank.................................................................................................................................................... 134 DEF Pump.................................................................................................................................................... 136 DEF Injector................................................................................................................................................ 137 DEF Hose.................................................................................................................................................... 138 DEF Tank Heating Valve...................................................................................................................................... 139 Boot-up System...................................................................................................................................................... 140 Layout Drawing of Boot-up System................................................................................................................................ 140 System Operating Lamp System.................................................................................................................................... 142 System Diagram of System Operating Lamp System.............................................................................................................. 142 Function of Operation Lamp System........................................................................................................................... 142 Battery Disconnect Switch....................................................................................................................................... 144 Function of Battery Disconnect Switch....................................................................................................................... 144 Engine System....................................................................................................................................................... 145 Layout Drawing of Engine System................................................................................................................................. 145 Specifications of Engine System............................................................................................................................. 146 Function of Engine System................................................................................................................................... 146 Engine Control System........................................................................................................................................... 147 System Diagram of Engine Control............................................................................................................................ 147 Function of Engine Control System........................................................................................................................... 148 Auto-Deceleration System........................................................................................................................................ 150 System Diagram of Auto-Deceleration System.................................................................................................................. 150 Function of Auto-Deceleration System........................................................................................................................ 150 Operation of Auto-Deceleration System....................................................................................................................... 151 Engine Automatic Warm-up System................................................................................................................................. 152 System Diagram of Engine Automatic Warm-up System........................................................................................................... 152 Function of Engine Automatic Warm-up System................................................................................................................. 153 Overheat Prevention System...................................................................................................................................... 154 Overheat Prevention System Diagram.......................................................................................................................... 154 Function of Overheat Prevention System...................................................................................................................... 155 Turbocharger Protection System.................................................................................................................................. 156 System Diagram of Turbocharger Protection System............................................................................................................ 156 Function of Turbocharger Protection System.................................................................................................................. 157 Automatic Idle Stop System...................................................................................................................................... 158 System Diagram of Automatic Idle Stop System................................................................................................................ 158 Function of Automatic Idle Stop System...................................................................................................................... 158 Component Parts of Engine System................................................................................................................................ 161 VGT......................................................................................................................................................... 161 EGR System.................................................................................................................................................. 165 EGR Valve................................................................................................................................................... 167 EGR Cooler.................................................................................................................................................. 169 KCCV System................................................................................................................................................. 171 KCCV Ventilator............................................................................................................................................. 173 KDPF........................................................................................................................................................ 175 Cooling System...................................................................................................................................................... 179 Layout Drawing of Cooling System................................................................................................................................ 179 Specifications of Cooling System............................................................................................................................ 180 Control System...................................................................................................................................................... 181 Layout Drawing of Control System................................................................................................................................ 181 Machine Monitor System.......................................................................................................................................... 184 System Diagram of Machine Monitor System.................................................................................................................... 184 Function of Machine Monitor System.......................................................................................................................... 184 KomVision System................................................................................................................................................ 186 Layout Drawing of KomVision System.......................................................................................................................... 186 System Diagram of KomVision System.......................................................................................................................... 188 Function of KomVision System................................................................................................................................ 188 KOMTRAX System.................................................................................................................................................. 190 System Diagram of KOMTRAX System............................................................................................................................ 190 Function of KOMTRAX System.................................................................................................................................. 190 Component Parts of Control System............................................................................................................................... 191 Machine Monitor............................................................................................................................................. 191 KomVision Controller........................................................................................................................................ 207 KomVision Camera............................................................................................................................................ 211 KOMTRAX Terminal............................................................................................................................................ 212 Pump Controller............................................................................................................................................. 214 Resistor for PC-EPC Valve................................................................................................................................... 219 CAN Terminating Resistor.................................................................................................................................... 220 Engine Controller........................................................................................................................................... 221 Fuel Control Dial........................................................................................................................................... 228 Hydraulic System.................................................................................................................................................... 230 Layout Drawing of Hydraulic System.............................................................................................................................. 230 CLSS............................................................................................................................................................ 233 Structure of CLSS........................................................................................................................................... 233 Operation of Unload Valve and LS Pressure................................................................................................................... 235 Pump Swash Plate Angle (Oil Flow) Control................................................................................................................... 236 Pressure Compensation Control............................................................................................................................... 253 Engine and Pump Combined Control System......................................................................................................................... 257 Engine and Pump Combined Control System Diagram............................................................................................................. 257 Function of Engine and Pump Combined Control System......................................................................................................... 258 Pump and Valve Control System................................................................................................................................... 263 Pump and Valve Control System Diagram....................................................................................................................... 263 Function of Pump and Valve Control System................................................................................................................... 264 Component Parts of Hydraulic System............................................................................................................................. 266 Hydraulic Tank.............................................................................................................................................. 266 Main Pump................................................................................................................................................... 269 Control Valve............................................................................................................................................... 295 Work Equipment System............................................................................................................................................... 359 Layout Drawing of Work Equipment System......................................................................................................................... 359 Structure of Valve Control...................................................................................................................................... 364 One-Touch Power Maximizing System............................................................................................................................... 366 System Diagram of One-Touch Power Maximizing System......................................................................................................... 366 Function of One-Touch Power Maximizing System............................................................................................................... 367 Machine Push-up System.......................................................................................................................................... 368 Machine Push-up System Diagram.............................................................................................................................. 368 Function of Machine Push-up System.......................................................................................................................... 369 PPC Lock System................................................................................................................................................. 370 System Diagram of PPC Lock.................................................................................................................................. 370 Function of PPC Lock System................................................................................................................................. 370 Work Equipment and Travel Automatic Lock System................................................................................................................. 371 System Diagram of Lock Lever Automatic Lock System.......................................................................................................... 371 Function of Work Equipment and Travel Automatic Lock System................................................................................................. 371 Operation of Lock Lever Automatic Lock System............................................................................................................... 372 Attachment Oil Flow Adjuster System............................................................................................................................. 373 Attachment Oil Flow Adjuster System Diagram................................................................................................................. 373 Function of Attachment Oil Flow Adjuster System............................................................................................................. 374 Tool Control System............................................................................................................................................. 375 Tool Control System Diagram................................................................................................................................. 375 Component Parts of Work Equipment System........................................................................................................................ 377 Work Equipment and Swing PPC Valve.......................................................................................................................... 377 1st-Line Attachment PPC Valve (with EPC Valve).............................................................................................................. 384 2nd-Line Attachment PPC Valve............................................................................................................................... 389 Solenoid Valve.............................................................................................................................................. 391 Attachment Circuit Selector Valve........................................................................................................................... 394 1st-Line Attachment Variable Relief Valve................................................................................................................... 397 Attachment Bypass Solenoid Valve............................................................................................................................ 400 Pilot Circuit Accumulator................................................................................................................................... 402 ICT System.......................................................................................................................................................... 403 Layout Drawing of ICT System.................................................................................................................................... 403 System Diagram of ICT Control System............................................................................................................................ 405 Bucket Edge Position Detection System........................................................................................................................... 406 Bucket Edge Position Detection System Diagram............................................................................................................... 406 Function of Bucket Edge Position Detection System........................................................................................................... 406 Operation of Bucket Edge Position Detection System.......................................................................................................... 406 The Intelligent Machine Control System.......................................................................................................................... 408 Function of Intelligent Machine Control System.............................................................................................................. 408 Auto Grade Assist Control................................................................................................................................... 409 Auto Stop Control........................................................................................................................................... 416 Cushion System for Arm IN End................................................................................................................................... 424 Cushion System for Arm IN End Diagram....................................................................................................................... 424 Function of Cushion System for Arm IN End................................................................................................................... 424 Operation of Cushion System for Arm IN End.................................................................................................................. 424 Cushion System for Boom Raise End............................................................................................................................... 426 Cushion System for Boom Raise End Diagram................................................................................................................... 426 Function of Cushion System for Boom Raise End............................................................................................................... 426 Operation of Cushion System for Boom Raise End.............................................................................................................. 426 Boom Secondary Drive Switch..................................................................................................................................... 428 Control Function When Boom Secondary Drive Switch is Turned to ON Position.................................................................................. 428 Component Parts of ICT System................................................................................................................................... 429 ICT Sensor Controller....................................................................................................................................... 429 Work Equipment Controller................................................................................................................................... 433 Control Box................................................................................................................................................. 437 GNSS Receiver............................................................................................................................................... 441 GNSS Antenna................................................................................................................................................ 445 IMU Sensor.................................................................................................................................................. 446 Intelligent Machine Control EPC Valve....................................................................................................................... 447 Stroke Sensor for Boom Cylinder............................................................................................................................. 450 Stroke Sensor for Arm Cylinder.............................................................................................................................. 452 Stroke and Reset Sensor for Bucket Cylinder................................................................................................................. 454 Reset Sensor for Boom Cylinder.............................................................................................................................. 457 Reset Sensor for Arm Cylinder............................................................................................................................... 458 Boom Spool Stroke Sensor.................................................................................................................................... 459 Arm Spool Stroke Sensor..................................................................................................................................... 461 Swing System........................................................................................................................................................ 463 Layout Drawing of Swing System.................................................................................................................................. 463 Swing Control System Diagram.................................................................................................................................... 466 Function of Swing Control System............................................................................................................................ 467 Component Parts of Swing System................................................................................................................................. 470 Swing Motor................................................................................................................................................. 470 Swing Machinery............................................................................................................................................. 483 Swing Circle................................................................................................................................................ 485 Travel System....................................................................................................................................................... 486 Layout Drawing of Travel System................................................................................................................................. 486 System Diagram of Travel Control System......................................................................................................................... 490 Function of Travel Control System........................................................................................................................... 491 Component Parts of Travel System................................................................................................................................ 492 Travel Motor................................................................................................................................................ 492 Final Drive................................................................................................................................................. 504 Travel PPC Valve............................................................................................................................................ 506 Center Swivel Joint......................................................................................................................................... 510 Undercarriage and Frame............................................................................................................................................. 512 Layout Drawing of Undercarriage................................................................................................................................. 512 Specifications of Undercarriage............................................................................................................................. 512 Work Equipment...................................................................................................................................................... 514 Structure of Work Equipment..................................................................................................................................... 514 Function of Work Equipment...................................................................................................................................... 515 Work Equipment Clearance Adjustment Shim........................................................................................................................ 516 Function of Work Equipment Clearance Adjustment Shim........................................................................................................ 516 Bucket Clearance Adjustment Shim................................................................................................................................ 517 Function of Bucket Clearance Adjustment Shim................................................................................................................ 517 CAB Related Parts................................................................................................................................................... 518 ROPS CAB........................................................................................................................................................ 518 Structure of ROPS CAB....................................................................................................................................... 518 Function of ROPS CAB........................................................................................................................................ 518 CAB Mount....................................................................................................................................................... 519 Structure of CAB Mount...................................................................................................................................... 519 Function of CAB Mount....................................................................................................................................... 519 CAB Tipping Stopper............................................................................................................................................. 520 Structure of CAB Tipping Stopper............................................................................................................................ 520 Function of CAB Tipping Stopper............................................................................................................................. 520 20 Standard Value Table................................................................................................................................................. 521 Table of Contents................................................................................................................................................... 522 Standard Value Table for Engine..................................................................................................................................... 523 Standard Value Table for Engine: PC360LCI-11.................................................................................................................... 523 Standard Value Table for Machine.................................................................................................................................... 528 Standard Value Table for Machine: PC360LCI-11................................................................................................................... 528 Machine Posture and Procedures to Measure Performance........................................................................................................... 551 Standard Value Table for Electricity................................................................................................................................ 555 Standard Value Table for Electricity............................................................................................................................ 555 30 Testing and Adjusting................................................................................................................................................ 565 Table of Contents................................................................................................................................................... 566 Precautions Before Work............................................................................................................................................. 570 Related Information on Testing and Adjusting........................................................................................................................ 571 Tools for Testing and Adjusting................................................................................................................................. 571 Sketch of Tools for Testing and Adjusting....................................................................................................................... 582 Engine and Cooling System........................................................................................................................................... 584 Examine Engine Speed............................................................................................................................................ 584 How to Examine Engine Speed................................................................................................................................. 584 Examine Boost Pressure.......................................................................................................................................... 588 How to Examine Boost Pressure on Machine Monitor............................................................................................................ 588 How to Examine Boost Pressure by Testing Tool............................................................................................................... 589 Examine Exhaust Gas Color....................................................................................................................................... 590 How to Examine Exhaust Gas Color with the Handy Smoke Checker............................................................................................... 590 How to Examine Exhaust Gas Color with Smoke Meter........................................................................................................... 591 Examine Mass Air Flow and Temperature Sensor.................................................................................................................... 592 How to Examine Mass Air Flow and Temperature Sensor......................................................................................................... 592 Examine and Adjust Valve Clearance.............................................................................................................................. 594 Check Valve Clearance....................................................................................................................................... 594 Adjust Valve Clearance...................................................................................................................................... 596 Examine Compression Pressure.................................................................................................................................... 597 How to Examine Compression Pressure......................................................................................................................... 597 Examine Blowby Pressure......................................................................................................................................... 600 How to Examine Blowby Pressure.............................................................................................................................. 600 Examine Engine Oil Pressure..................................................................................................................................... 602 How to Examine Engine Oil Pressure.......................................................................................................................... 602 Examine EGR Valve and VGT Oil Pressure.......................................................................................................................... 604 How to Examine EGR Valve and VGT Oil Pressure............................................................................................................... 604 Examine Fuel Pressure........................................................................................................................................... 606 How to Examine Fuel Pressure................................................................................................................................ 607 Examine Fuel Discharge, Return and Leakage...................................................................................................................... 613 How to Examine Fuel Discharge, Return, and Leakage.......................................................................................................... 614 Bleed Air from Fuel System...................................................................................................................................... 620 How to Bleed Air from Fuel System........................................................................................................................... 620 Examine Fuel Circuit for Leakage................................................................................................................................ 621 How to Examine Fuel System for Leakage...................................................................................................................... 621 Handle Cylinder Cut-out Mode Operation.......................................................................................................................... 623 Handle No-Injection Cranking Operation.......................................................................................................................... 624 Examine and Adjust Air Conditioner Compressor Belt Tension...................................................................................................... 625 How to Examine Air Conditioner Compressor Belt Tension...................................................................................................... 625 How to Adjust Air Conditioner Compressor Belt Tension....................................................................................................... 625 Examine Alternator Belt......................................................................................................................................... 626 How to Examine Alternator Belt.............................................................................................................................. 626 Examine Automatic Tensioner..................................................................................................................................... 627 How to Examine Automatic Tensioner.......................................................................................................................... 627 Write Correction for Ash in Soot Accumulation to Engine Controller.............................................................................................. 628 How to Write Correction for Ash in Soot Accumulation to Engine Controller................................................................................... 628 Examine SCR Related Functions................................................................................................................................... 629 Examine DEF Pump Raised Pressure............................................................................................................................ 633 Examine Injection Volume from DEF Injector.................................................................................................................. 636 Examine DEF Line Heater Relay 1............................................................................................................................. 641 Examine DEF Line Heater Relay 2............................................................................................................................. 644 Examine DEF Pump Heater Relay............................................................................................................................... 647 Examine DEF Tank Heater Valve............................................................................................................................... 650 Examine SCR Denitration Efficiency.......................................................................................................................... 653 Clean DEF Tank.................................................................................................................................................. 657 How to Clean DEF Tank....................................................................................................................................... 657 Clean DEF Pump.................................................................................................................................................. 661 How to Clean DEF Pump....................................................................................................................................... 661 Power Train......................................................................................................................................................... 667 Examine Swing Circle Bearing Clearance.......................................................................................................................... 667 How to Examine Swing Circle Bearing Clearance............................................................................................................... 667 Undercarriage and Frame............................................................................................................................................. 668 Examine and Adjust Track Tension................................................................................................................................ 668 How to Examine Track Tension................................................................................................................................ 668 How to Adjust Track Tension................................................................................................................................. 668 Hydraulic System.................................................................................................................................................... 670 Release Remained Pressure in Hydraulic Circuit.................................................................................................................. 670 How to Release Remained Pressure from Hydraulic Tank........................................................................................................ 670 How to Release Remained Pressure in Hydraulic Cylinder Circuit.............................................................................................. 670 How to Release Remained Pressure from Swing Motor Circuit................................................................................................... 674 How to Release Remained Pressure from Travel Motor Circuit.................................................................................................. 674 Examine and Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits................................................................................... 675 How to Examine Oil Pressure in Work Equipment, Swing, and Travel Circuits................................................................................... 676 How to Adjust Oil Pressure in Work Equipment, Swing, and Travel Circuits.................................................................................... 684 Examine Oil Pressure of Control Circuit......................................................................................................................... 687 Examine Oil Pressure in Control Circuit..................................................................................................................... 687 Examine and adjust oil pressure in pump PC control circuit...................................................................................................... 689 Examine PC Valve Outlet Pressure (Servo Piston Inlet Pressure).............................................................................................. 689 Examine PC-EPC Valve Outlet Pressure........................................................................................................................ 690 How to Adjust Oil Pressure in Pump PC Control Circuit....................................................................................................... 691 Examine and Adjust Oil Pressure in Pump LS Control Circuit...................................................................................................... 692 Examine LS Differential Pressure with Machine Monitor....................................................................................................... 692 Examine LS Differential Pressure by Testing Tool............................................................................................................ 693 How to Examine LS Valve Outlet Pressure (Servo Piston Inlet Pressure)....................................................................................... 695 How to Examine LS-EPC Valve Outlet Pressure................................................................................................................. 695 Adjust LS Valve............................................................................................................................................. 696 Examine Outlet Pressure of Solenoid Valve....................................................................................................................... 697 How to Examine Outlet Pressure of Solenoid Valve............................................................................................................ 697 Operating Condition of Solenoid Valve....................................................................................................................... 698 Examine PPC Valve Outlet Pressure............................................................................................................................... 700 Examine Outlet Pressure in PPC Valve........................................................................................................................ 700 Adjust Play of Work Equipment and Swing PPC Valves.............................................................................................................. 702 How to Adjust Play of Work Equipment and Swing PPC Valves................................................................................................... 702 Examine Pump Swash Plate Sensor................................................................................................................................. 703 How to Examine pump swash plate sensor...................................................................................................................... 703 Examine Parts Which Cause Hydraulic Drift of Work Equipment..................................................................................................... 704 How to Examine Parts Which Cause Hydraulic Drift of Boom Cylinder and Bucket Cylinder....................................................................... 704 How to Examine the Parts Which Cause Hydraulic Drift of Arm Cylinder........................................................................................ 704 How to Examine Parts that Cause Hydraulic Drift of PPC Valve................................................................................................ 705 Examine Oil Leakage............................................................................................................................................. 706 How to Examine Oil Leakage from Boom Cylinder............................................................................................................... 706 How to Examine Oil Leakage from Arm Cylinder................................................................................................................ 706 How to Examine Oil Leakage from Bucket Cylinder............................................................................................................. 707 How to Examine Oil Leakage from Swing Motor................................................................................................................. 707 How to Examine Oil Leakage from Travel Motor................................................................................................................ 708 Bleed Air from Hydraulic System................................................................................................................................. 709 How to Bleed Air from Hydraulic System...................................................................................................................... 711 Examine and Charge Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side)........................................................... 714 Examine Accumulator (Made by NOK) Nitrogen Gas Pressure for Attachment (Low Pressure Side).................................................................. 714 Examine and Charge Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side)........................................................................ 718 Examine Accumulator Nitrogen Gas Pressure for Attachment (High Pressure Side)............................................................................... 718 Replace Accumulator Bladder on High Pressure Side for Attachment Piping......................................................................................... 722 How to Replace Accumulator Bladder on High Pressure Side for Attachment Piping.............................................................................. 722 CAB Related Parts................................................................................................................................................... 729 Examine CAB Tipping Stopper..................................................................................................................................... 729 How to Examine Cab Tipping Stopper.......................................................................................................................... 729 How to Adjust Mirrors........................................................................................................................................... 730 Procedure to Adjust Regular Position of Machine Left Front Mirror (A)....................................................................................... 730 Procedure to Adjust Machine Right Front Mirror (B).......................................................................................................... 731 Procedure to Adjust Regular Position of Machine Right Front Mirror (B)...................................................................................... 732 Procedure to Adjust Machine Right Side Mirror (C)........................................................................................................... 733 Electrical System................................................................................................................................................... 735 Set and Operate Machine Monitor................................................................................................................................. 735 Operator Mode............................................................................................................................................... 739 Function to Show Technician Identification Status Screen.................................................................................................... 739 Function to Show Operator Identification Input Screen....................................................................................................... 739 Examine Function by LCD (Liquid Crystal Display)............................................................................................................ 740 Examine Function of Service Meter........................................................................................................................... 740 Usage Limitation and Maintenance Password Change Function................................................................................................... 740 Service Mode................................................................................................................................................ 743 How to Operate Service Mode................................................................................................................................. 743 How to See Pre-defined Monitoring Information............................................................................................................... 745 How to Examine Self-Define Monitor Information.............................................................................................................. 752 Abnormality Record Menu..................................................................................................................................... 766 How to See Maintenance Record............................................................................................................................... 770 Maintenance Mode Setting.................................................................................................................................... 771 Set Phone Number Entry...................................................................................................................................... 775 Default Menu................................................................................................................................................ 777 Diagnostic Tests Menu....................................................................................................................................... 785 Adjustment Menu............................................................................................................................................. 795 No-Injection Cranking Operation............................................................................................................................. 812 KOMTRAX Settings Menu....................................................................................................................................... 814 Show Service Message........................................................................................................................................ 816 How to Start Up KOMTRAX Terminal................................................................................................................................ 818 Adjust Rearview Camera Angle.................................................................................................................................... 823 How to Adjust Rearview Camera Angle......................................................................................................................... 823 Adjust KomVision Camera Angle................................................................................................................................... 826 How to Adjust KomVision Camera Angle........................................................................................................................ 827 Adjust KomVision Related Function............................................................................................................................... 831 Setting of KomVision (Main Setting)......................................................................................................................... 832 Setting of KomVision (Camera Setting)....................................................................................................................... 834 Setting of KomVision (Camera Calibration)................................................................................................................... 837 KomVision screen - Check 12 m visibility.................................................................................................................... 850 Set Region of Bluetooth(R) Compatible Radio..................................................................................................................... 853 Set Region of Bluetooth(R) Compatible Radio................................................................................................................. 853 Handle Voltage Circuit of Engine Controller..................................................................................................................... 855 Handle Battery Disconnect Switch................................................................................................................................ 856 Examine Diodes.................................................................................................................................................. 857 Examine Diodes by Digital Tester............................................................................................................................ 857 How to Examine Diodes by Analog Tester...................................................................................................................... 857 ICT System.......................................................................................................................................................... 858 Set and Operate Control Box..................................................................................................................................... 858 How to Set the Starting Switch Interlock Function of the Control Box........................................................................................ 860 How to Select Excavator Model in the Control Box............................................................................................................ 863 Calibrate Intelligent Machine Control........................................................................................................................... 867 PPC Pressure Sensor Calibration............................................................................................................................. 870 Control Map Calibration..................................................................................................................................... 952 How to Examine the Intelligent Machine Control System.......................................................................................................1102 Calibrate IMU Sensor for Yaw Angle..........................................................................................................................1107 Calibrate IMU Sensor........................................................................................................................................1115 Procedure to be Done If an Error Occurs During Calibration of IMU Sensor....................................................................................1127 Work Equipment Cylinder Calibration.........................................................................................................................1128 If Error Occurs During Calibration of Work Equipment Cylinder...............................................................................................1140 General Calibration of Bucket Blade Edge Position, Boom Dimensions, Arm Dimensions, Bucket Link Dimensions, and GNSS Antenna Position with Total Station....1143 Calibration of Boom Dimensions and Arm Dimensions with Total Station........................................................................................1195 Calibration of Bucket Link Dimensions with Total Station....................................................................................................1215 Calibration of GNSS Antenna with Total Station..............................................................................................................1252 Input Range of the Measured Values in Calibration with Total Station........................................................................................1276 Examine the Input Values in Calibration with Total Station..................................................................................................1278 Procedure to be Done If an Error Occurs During Calibration with Total Station...............................................................................1278 Calibration of GNSS Antenna Without Total Station...........................................................................................................1280 Calibration of Bucket Blade Edge Position Without Total Station.............................................................................................1284 Input Range of the Measured Values in Calibration Without Total Station.....................................................................................1293 Procedure to be Done If an Error Occurs During Calibration Without Total Station............................................................................1294 Pm Clinic...........................................................................................................................................................1296 Pm Clinic Service...............................................................................................................................................1296 Pm Clinic Check Sheet: PC360LCI-11..........................................................................................................................1297 40 Troubleshooting......................................................................................................................................................1311 Table of Contents...................................................................................................................................................1312 Precautions Before Work.............................................................................................................................................1325 Related Information to Troubleshooting..............................................................................................................................1326 General Troubleshooting Points..................................................................................................................................1326 Troubleshooting Points for Urea SCR System......................................................................................................................1327 Sequence of Events in Troubleshooting...........................................................................................................................1341 Checks Before Troubleshooting...................................................................................................................................1343 Inspection Procedure Before Troubleshooting.....................................................................................................................1345 Walk-Around Check...........................................................................................................................................1345 Test in Accordance with Testing Procedure.......................................................................................................................1347 Examine Fuel Level and Type.................................................................................................................................1347 Examine for Impure Ingredient in Fuel.......................................................................................................................1347 Examine Fuel Prefilter......................................................................................................................................1348 Examine Water Separator, Drain Water and Sediment...........................................................................................................1348 How to Replace Fuel Prefilter Cartridge.....................................................................................................................1349 Examine Fuel Main Filter....................................................................................................................................1350 Examine Engine Oil Level (Oil Quantity in Oil Pan)..........................................................................................................1352 Examine Coolant Level (Reservoir Tank)......................................................................................................................1353 Examine Air Cleaner Clogging................................................................................................................................1354 Clean Outer Element.........................................................................................................................................1354 Replace Element.............................................................................................................................................1356 Examine Hydraulic Oil Level.................................................................................................................................1357 Examine Hydraulic Oil Strainer..............................................................................................................................1358 Examine Hydraulic Oil Filter................................................................................................................................1359 Examine Oil Level in Swing Machinery Case...................................................................................................................1360 Examine Oil Level in Damper Case............................................................................................................................1360 Examine Oil Level in Final Drive Case.......................................................................................................................1361 Bleed Air from Fuel System..................................................................................................................................1361 Bleed Air from Hydraulic System.............................................................................................................................1361 How to Examine Electric Equipment...........................................................................................................................1362 Preparation for Troubleshooting of Electrical System............................................................................................................1367 Preparation for Troubleshooting of Machine Monitor..........................................................................................................1367 Preparation for Troubleshooting of Engine Controller........................................................................................................1367 Preparation for Troubleshooting of ICT Sensor Controller....................................................................................................1368 Preparation for Troubleshooting of KOMTRAX Terminal.........................................................................................................1369 Preparation for Troubleshooting of KomVision Controller.....................................................................................................1369 Preparation for Troubleshooting of Control Box..............................................................................................................1369 Preparation for Troubleshooting of GNSS Receiver............................................................................................................1369 How to Disconnect and Connect Connector with a Special Lock.................................................................................................1370 Procedure for Troubleshooting...................................................................................................................................1374 Symptom and Troubleshooting Numbers.............................................................................................................................1377 Information Shown in Troubleshooting Table......................................................................................................................1382 Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness........................................................................................1384 Connector List and Layout.......................................................................................................................................1387 Connector Contact Connection Table..............................................................................................................................1407 T-Branch Box and T-Branch Adapter Table.........................................................................................................................1447 Fuse Location Table.............................................................................................................................................1453 Precautions When You Clean and Replace KDPF (KCSF and KDOC).....................................................................................................1456 Prepare Short Circuit Electrical Connector (For Failure Codes [CA1883] and [CA3135])............................................................................1460 Failure Code Table..............................................................................................................................................1462 Troubleshooting by Failure Code (Display of Code)...................................................................................................................1484 Failure Code [879AKA]...........................................................................................................................................1484 Failure Code [879AKB]...........................................................................................................................................1485 Failure Code [879BKA]...........................................................................................................................................1486 Failure Code [879BKB]...........................................................................................................................................1488 Failure Code [879CKA]...........................................................................................................................................1490 Failure Code [879CKB]...........................................................................................................................................1491 Failure Code [879DKZ]...........................................................................................................................................1492 Failure Code [879EMC]...........................................................................................................................................1494 Failure Code [879FMC]...........................................................................................................................................1495 Failure Code [879GKX]...........................................................................................................................................1496 Failure Code [989L00]...........................................................................................................................................1498 Failure Code [989M00]...........................................................................................................................................1499 Failure Code [989N00]...........................................................................................................................................1500 Failure Code [A1U0N3]...........................................................................................................................................1501 Failure Code [A1U0N4]...........................................................................................................................................1503 Failure Code [A900FR]...........................................................................................................................................1505 Failure Code [A900N6]...........................................................................................................................................1506 Failure Code [A900NY]...........................................................................................................................................1507 Failure Code [AA10NX]...........................................................................................................................................1508 Failure Code [AB00KE]...........................................................................................................................................1510 Failure Code [AQ10N3]...........................................................................................................................................1513 Failure Code [AS00N3]...........................................................................................................................................1515 Failure Code [AS00R2]...........................................................................................................................................1517 Failure Code [AS00R3]...........................................................................................................................................1518 Failure Code [AS00R4]...........................................................................................................................................1519 Failure Code [AS00R5]...........................................................................................................................................1520 Failure Code [AS00R6]...........................................................................................................................................1521 Failure Code [AS00ZK]...........................................................................................................................................1522 Failure Code [AS10KM]...........................................................................................................................................1523 Failure Code [AS10NR]...........................................................................................................................................1524 Failure Code [AS10NT]...........................................................................................................................................1525 Failure Code [B@BAZG]...........................................................................................................................................1526 Failure Code [B@BAZK]...........................................................................................................................................1527 Failure Code [B@BCNS]...........................................................................................................................................1529 Failure Code [B@BCQA]...........................................................................................................................................1530 Failure Code [B@BCZK]...........................................................................................................................................1532 Failure Code [B@HANS]...........................................................................................................................................1534 Failure Code [CA115]............................................................................................................................................1535 Failure Code [CA122]............................................................................................................................................1536 Failure Code [CA123]............................................................................................................................................1538 Failure Code [CA131]............................................................................................................................................1540 Failure Code [CA132]............................................................................................................................................1542 Failure Code [CA144]............................................................................................................................................1544 Failure Code [CA145]............................................................................................................................................1546 Failure Code [CA153]............................................................................................................................................1548 Failure Code [CA154]............................................................................................................................................1551 Failure Code [CA187]............................................................................................................................................1554 Failure Code [CA221]............................................................................................................................................1556 Failure Code [CA222]............................................................................................................................................1558 Failure Code [CA227]............................................................................................................................................1560 Failure Code [CA234]............................................................................................................................................1561 Failure Code [CA238]............................................................................................................................................1562 Failure Code [CA239]............................................................................................................................................1564 Failure Code [CA249]............................................................................................................................................1566 Failure Code [CA256]............................................................................................................................................1568 Failure Code [CA271]............................................................................................................................................1570 Failure Code [CA272]............................................................................................................................................1572 Failure Code [CA281]............................................................................................................................................1574 Failure Code [CA322]............................................................................................................................................1575 Failure Code [CA323]............................................................................................................................................1577 Failure Code [CA324]............................................................................................................................................1579 Failure Code [CA325]............................................................................................................................................1581 Failure Code [CA331]............................................................................................................................................1583 Failure Code [CA332]............................................................................................................................................1585 Failure Code [CA343]............................................................................................................................................1587 Failure Code [CA351]............................................................................................................................................1588 Failure Code [CA352]............................................................................................................................................1589 Failure Code [CA356]............................................................................................................................................1592 Failure Code [CA357]............................................................................................................................................1594 Failure Code [CA386]............................................................................................................................................1596 Failure Code [CA428]............................................................................................................................................1597 Failure Code [CA429]............................................................................................................................................1599 Failure Code [CA435]............................................................................................................................................1601 Failure Code [CA441]............................................................................................................................................1603 Failure Code [CA442]............................................................................................................................................1605 Failure Code [CA449]............................................................................................................................................1606 Failure Code [CA451]............................................................................................................................................1610 Failure Code [CA452]............................................................................................................................................1613 Failure Code [CA488]............................................................................................................................................1615 Failure Code [CA515]............................................................................................................................................1616 Failure Code [CA516]............................................................................................................................................1618 Failure Code [CA553]............................................................................................................................................1620 Failure Code [CA555]............................................................................................................................................1621 Failure Code [CA556]............................................................................................................................................1622 Failure Code [CA559]............................................................................................................................................1623 Failure Code [CA595]............................................................................................................................................1627 Failure Code [CA687]............................................................................................................................................1628 Failure Code [CA689]............................................................................................................................................1630 Failure Code [CA691]............................................................................................................................................1635 Failure Code [CA692]............................................................................................................................................1637 Failure Code [CA697]............................................................................................................................................1639 Failure Code [CA698]............................................................................................................................................1640 Failure Code [CA731]............................................................................................................................................1641 Failure Code [CA778]............................................................................................................................................1643 Failure Code [CA1117]...........................................................................................................................................1648 Failure Code [CA1664]...........................................................................................................................................1649 Failure Code [CA1669]...........................................................................................................................................1651 Failure Code [CA1673]...........................................................................................................................................1652 Failure Code [CA1677]...........................................................................................................................................1653 Failure Code [CA1678]...........................................................................................................................................1654 Failure Code [CA1682]...........................................................................................................................................1655 Failure Code [CA1683]...........................................................................................................................................1657 Failure Code [CA1684]...........................................................................................................................................1659 Failure Code [CA1686]...........................................................................................................................................1661 Failure Code [CA1691]...........................................................................................................................................1662 Failure Code [CA1694]...........................................................................................................................................1665 Failure Code [CA1695]...........................................................................................................................................1668 Failure Code [CA1696]...........................................................................................................................................1669 Failure Code [CA1712]...........................................................................................................................................1671 Failure Code [CA1713]...........................................................................................................................................1674 Failure Code [CA1714]...........................................................................................................................................1676 Failure Code [CA1715]...........................................................................................................................................1677 Failure Code [CA1776]...........................................................................................................................................1678 Failure Code [CA1777]...........................................................................................................................................1681 Failure Code [CA1843]...........................................................................................................................................1684 Failure Code [CA1844]...........................................................................................................................................1686 Failure Code [CA1879]...........................................................................................................................................1689 Failure Code [CA1881]...........................................................................................................................................1692 Failure Code [CA1883]...........................................................................................................................................1694 Failure Code [CA1885]...........................................................................................................................................1697 Failure Code [CA1887]...........................................................................................................................................1699 Failure Code [CA1921]...........................................................................................................................................1701 Failure Code [CA1922]...........................................................................................................................................1704 Failure Code [CA1942]...........................................................................................................................................1709 Failure Code [CA1993]...........................................................................................................................................1710 Failure Code [CA2185]...........................................................................................................................................1713 Failure Code [CA2186]...........................................................................................................................................1715 Failure Code [CA2249]...........................................................................................................................................1717 Failure Code [CA2265]...........................................................................................................................................1718 Failure Code [CA2266]...........................................................................................................................................1720 Failure Code [CA2271]...........................................................................................................................................1722 Failure Code [CA2272]...........................................................................................................................................1725 Failure Code [CA2288]...........................................................................................................................................1728 Failure Code [CA2311]...........................................................................................................................................1729 Failure Code [CA2349]...........................................................................................................................................1730 Failure Code [CA2353]...........................................................................................................................................1733 Failure Code [CA2357]...........................................................................................................................................1735 Failure Code [CA2381]...........................................................................................................................................1736 Failure Code [CA2382]...........................................................................................................................................1739 Failure Code [CA2383]...........................................................................................................................................1742 Failure Code [CA2386]...........................................................................................................................................1745 Failure Code [CA2387]...........................................................................................................................................1747 Troubleshooting Flowchart...................................................................................................................................1751 Failure Code [CA2555]...........................................................................................................................................1752 Failure Code [CA2556]...........................................................................................................................................1755 Failure Code [CA2637]...........................................................................................................................................1758 Failure Code [CA2639]...........................................................................................................................................1760 Failure Code [CA2771]...........................................................................................................................................1763 Failure Code [CA2777]...........................................................................................................................................1769 Failure Code [CA2976]...........................................................................................................................................1772 Failure Code [CA3133]...........................................................................................................................................1774 Failure Code [CA3134]...........................................................................................................................................1776 Failure Code [CA3135]...........................................................................................................................................1778 Failure Code [CA3142]...........................................................................................................................................1781 Failure Code [CA3143]...........................................................................................................................................1782 Failure Code [CA3144]...........................................................................................................................................1783 Failure Code [CA3146]...........................................................................................................................................1785 Failure Code [CA3147]...........................................................................................................................................1786 Failure Code [CA3148]...........................................................................................................................................1787 Failure Code [CA3151]...........................................................................................................................................1789 Failure Code [CA3165]...........................................................................................................................................1795 Failure Code [CA3229]...........................................................................................................................................1797 Failure Code [CA3231]...........................................................................................................................................1799 Failure Code [CA3232]...........................................................................................................................................1801 Failure Code [CA3235]...........................................................................................................................................1805 Failure Code [CA3239]...........................................................................................................................................1807 Failure Code [CA3241]...........................................................................................................................................1810 Failure Code [CA3242]...........................................................................................................................................1813 Failure Code [CA3251]...........................................................................................................................................1816 Failure Code [CA3253]...........................................................................................................................................1818 Failure Code [CA3254]...........................................................................................................................................1821 Failure Code [CA3255]...........................................................................................................................................1824 Failure Code [CA3256]...........................................................................................................................................1828 Failure Code [CA3311]...........................................................................................................................................1830 Failure Code [CA3312]...........................................................................................................................................1832 Failure Code [CA3313]...........................................................................................................................................1835 Failure Code [CA3314]...........................................................................................................................................1836 Failure Code [CA3315]...........................................................................................................................................1837 Failure Code [CA3316]...........................................................................................................................................1839 Failure Code [CA3317]...........................................................................................................................................1840 Failure Code [CA3318]...........................................................................................................................................1841 Failure Code [CA3319]...........................................................................................................................................1843 Failure Code [CA3321]...........................................................................................................................................1844 Failure Code [CA3322]...........................................................................................................................................1846 Failure Code [CA3419]...........................................................................................................................................1848 Failure Code [CA3421]...........................................................................................................................................1850 Failure Code [CA3497]...........................................................................................................................................1852 Failure Code [CA3498]...........................................................................................................................................1853 Failure Code [CA3543]...........................................................................................................................................1854 Failure Code [CA3545]...........................................................................................................................................1861 Failure Code [CA3547]...........................................................................................................................................1863 Failure Code [CA3558]...........................................................................................................................................1864 Failure Code [CA3559]...........................................................................................................................................1866 Failure Code [CA3562]...........................................................................................................................................1868 Failure Code [CA3563]...........................................................................................................................................1870 Failure Code [CA3567]...........................................................................................................................................1873 Failure Code [CA3568]...........................................................................................................................................1876 Failure Code [CA3571]...........................................................................................................................................1880 Failure Code [CA3572]...........................................................................................................................................1882 Failure Code [CA3574]...........................................................................................................................................1884 Failure Code [CA3575]...........................................................................................................................................1886 Failure Code [CA3577]...........................................................................................................................................1888 Failure Code [CA3578]...........................................................................................................................................1890 Failure Code [CA3582]...........................................................................................................................................1892 Failure Code [CA3583]...........................................................................................................................................1898 Failure Code [CA3596]...........................................................................................................................................1900 Failure Code [CA3649]...........................................................................................................................................1902 Failure Code [CA3681]...........................................................................................................................................1904 Failure Code [CA3682]...........................................................................................................................................1909 Failure Code [CA3713]...........................................................................................................................................1915 Failure Code [CA3717]...........................................................................................................................................1918 Failure Code [CA3718]...........................................................................................................................................1919 Failure Code [CA3725]...........................................................................................................................................1920 Failure Code [CA3741]...........................................................................................................................................1923 Failure Code [CA3748]...........................................................................................................................................1924 Failure Code [CA3751]...........................................................................................................................................1926 Failure Code [CA3755]...........................................................................................................................................1928 Failure Code [CA3866]...........................................................................................................................................1930 Failure Code [CA3867]...........................................................................................................................................1934 Failure Code [CA3868]...........................................................................................................................................1937 Failure Code [CA3899]...........................................................................................................................................1941 Failure Code [CA3911]...........................................................................................................................................1943 Failure Code [CA3912]...........................................................................................................................................1947 Failure Code [CA3932]...........................................................................................................................................1949 Failure Code [CA3933]...........................................................................................................................................1951 Failure Code [CA3934]...........................................................................................................................................1953 Failure Code [CA3935]...........................................................................................................................................1956 Failure Code [CA3936]...........................................................................................................................................1958 Failure Code [CA4151]...........................................................................................................................................1960 Failure Code [CA4152]...........................................................................................................................................1964 Failure Code [CA4155]...........................................................................................................................................1968 Failure Code [CA4156]...........................................................................................................................................1970 Failure Code [CA4157]...........................................................................................................................................1973 Failure Code [CA4158]...........................................................................................................................................1975 Failure Code [CA4159]...........................................................................................................................................1976 Failure Code [CA4161]...........................................................................................................................................1977 Failure Code [CA4162]...........................................................................................................................................1980 Failure Code [CA4163]...........................................................................................................................................1983 Failure Code [CA4164]...........................................................................................................................................1985 Failure Code [CA4165]...........................................................................................................................................1987 Failure Code [CA4166]...........................................................................................................................................1989 Failure Code [CA4168]...........................................................................................................................................1991 Failure Code [CA4169]...........................................................................................................................................1994 Failure Code [CA4171]...........................................................................................................................................1996 Failure Code [CA4249]...........................................................................................................................................1999 Failure Code [CA4251]...........................................................................................................................................2001 Failure Code [CA4259]...........................................................................................................................................2003 Failure Code [CA4261]...........................................................................................................................................2006 Failure Code [CA4277]...........................................................................................................................................2009 Failure Code [CA4281]...........................................................................................................................................2013 Failure Code [CA4459]...........................................................................................................................................2016 Failure Code [CA4461]...........................................................................................................................................2018 Failure Code [CA4658]...........................................................................................................................................2021 Failure Code [CA4731]...........................................................................................................................................2025 Failure Code [CA4732]...........................................................................................................................................2026 Failure Code [CA4739]...........................................................................................................................................2027 Failure Code [CA4768]...........................................................................................................................................2028 Failure Code [CA4769]...........................................................................................................................................2030 Failure Code [CA4842]...........................................................................................................................................2033 Failure Code [CA4952]...........................................................................................................................................2037 Failure Code [CA5115]...........................................................................................................................................2039 Failure Code [CA5179]...........................................................................................................................................2042 Failure Code [CA5181]...........................................................................................................................................2044 Failure Code [CA5383]...........................................................................................................................................2046 Failure Code [D110KB]...........................................................................................................................................2048 Failure Code [D19JKZ]...........................................................................................................................................2050 Failure Code [D811MC]...........................................................................................................................................2052 Failure Code [D862KA]...........................................................................................................................................2053 Failure Code [D8ALKA]...........................................................................................................................................2054 Failure Code [D8ALKB]...........................................................................................................................................2056 Failure Code [D8AQKR]...........................................................................................................................................2058 Failure Code [DA20MC]...........................................................................................................................................2066 Failure Code [DA22KK]...........................................................................................................................................2067 Failure Code [DA25KP]...........................................................................................................................................2070 Failure Code [DA29KQ]...........................................................................................................................................2073 Failure Code [DA2LKA]...........................................................................................................................................2075 Failure Code [DA2LKB]...........................................................................................................................................2077 Failure Code [DA2QKR]...........................................................................................................................................2079 Failure Code [DA2RKR]...........................................................................................................................................2088 Failure Code [DAF0MB]...........................................................................................................................................2097 Failure Code [DAF0MC]...........................................................................................................................................2098 Failure Code [DAF8KB]...........................................................................................................................................2099 Failure Code [DAF9KQ]...........................................................................................................................................2101 Failure Code [DAFGMC]...........................................................................................................................................2102 Failure Code [DAFLKA]...........................................................................................................................................2103 Failure Code [DAFLKB]...........................................................................................................................................2105 Failure Code [DAFQKR]...........................................................................................................................................2107 Failure Code [DAZ9KQ]...........................................................................................................................................2115 Failure Code [DAZQKR]...........................................................................................................................................2116 Failure Code [DB2QKR]...........................................................................................................................................2124 Failure Code [DB2RKR]...........................................................................................................................................2132 Failure Code [DB90MC]...........................................................................................................................................2140 Failure Code [DB92KK]...........................................................................................................................................2141 Failure Code [DB95KP]...........................................................................................................................................2143 Failure Code [DB96KP]...........................................................................................................................................2147 Failure Code [DB99KQ]...........................................................................................................................................2151 Failure Code [DB9LKA]...........................................................................................................................................2154 Failure Code [DB9LKB]...........................................................................................................................................2156 Failure Code [DB9QKR]...........................................................................................................................................2158 Failure Code [DB9RKR]...........................................................................................................................................2167 Failure Code [DBP0KM]...........................................................................................................................................2176 Failure Code [DBP0KT]...........................................................................................................................................2177 Failure Code [DBPQKR]...........................................................................................................................................2178 Failure Code [DBR0MC]...........................................................................................................................................2188 Failure Code [DBR2KK]...........................................................................................................................................2189 Failure Code [DBR5KP]...........................................................................................................................................2192 Failure Code [DBR6KP]...........................................................................................................................................2194 Failure Code [DBR9KQ]...........................................................................................................................................2196 Failure Code [DBRLKA]...........................................................................................................................................2199 Failure Code [DBRLKB]...........................................................................................................................................2201 Failure Code [DBRQKR]...........................................................................................................................................2203 Failure Code [DBRRKR]...........................................................................................................................................2212 Failure Code [DBRSKB]...........................................................................................................................................2221 Failure Code [DBRTKB]...........................................................................................................................................2223 Failure Code [DBUSKR]...........................................................................................................................................2225 Failure Code [DD20MA]...........................................................................................................................................2229 Failure Code [DDNRKA]...........................................................................................................................................2232 Failure Code [DDNRKY]...........................................................................................................................................2234 Failure Code [DDNS00]...........................................................................................................................................2236 Failure Code [DGH2KB]...........................................................................................................................................2238 Failure Code [DHA4KA]...........................................................................................................................................2240 Failure Code [DHAAMA]...........................................................................................................................................2242 Failure Code [DHACMA]...........................................................................................................................................2244 Failure Code [DHPAMA]...........................................................................................................................................2246 Failure Code [DHPBMA]...........................................................................................................................................2249 Failure Code [DHS3MA]...........................................................................................................................................2252 Failure Code [DHS4MA]...........................................................................................................................................2255 Failure Code [DHS8MA]...........................................................................................................................................2258 Failure Code [DHS9MA]...........................................................................................................................................2261 Failure Code [DHSAMA]...........................................................................................................................................2264 Failure Code [DHSBMA]...........................................................................................................................................2267 Failure Code [DHSCMA]...........................................................................................................................................2270 Failure Code [DHSDMA]...........................................................................................................................................2273 Failure Code [DHSFMA]...........................................................................................................................................2276 Failure Code [DHSGMA]...........................................................................................................................................2279 Failure Code [DHSHMA]...........................................................................................................................................2282 Failure Code [DHSJMA]...........................................................................................................................................2285 Failure Code [DHZAMA]...........................................................................................................................................2288 Failure Code [DHZCL8]...........................................................................................................................................2292 Failure Code [DK80KM]...........................................................................................................................................2293 Failure Code [DK80KR]...........................................................................................................................................2294 Failure Code [DK80KT]...........................................................................................................................................2300 Failure Code [DKG1KM]...........................................................................................................................................2301 Failure Code [DKG1L8]...........................................................................................................................................2302 Failure Code [DKR0MA]...........................................................................................................................................2303 Failure Code [DKR1MA]...........................................................................................................................................2306 Failure Code [DKT0KM]...........................................................................................................................................2309 Failure Code [DKT0L8]...........................................................................................................................................2310 Failure Code [DKT1KA]...........................................................................................................................................2311 Failure Code [DKT1KB]...........................................................................................................................................2313 Failure Code [DKT2KA]...........................................................................................................................................2315 Failure Code [DKT2KB]...........................................................................................................................................2317 Failure Code [DKT4KM]...........................................................................................................................................2319 Failure Code [DKT4L8]...........................................................................................................................................2320 Failure Code [DKT5KA]...........................................................................................................................................2321 Failure Code [DKT5KB]...........................................................................................................................................2323 Failure Code [DKT6KA]...........................................................................................................................................2325 Failure Code [DKT6KB]...........................................................................................................................................2327 Failure Code [DKT8KA]...........................................................................................................................................2329 Failure Code [DKT8KB]...........................................................................................................................................2331 Failure Code [DKT9KA]...........................................................................................................................................2333 Failure Code [DKT9KB]...........................................................................................................................................2335 Failure Code [DKTAKA]...........................................................................................................................................2337 Failure Code [DKTAKB]...........................................................................................................................................2339 Failure Code [DKTAMB]...........................................................................................................................................2341 Failure Code [DKTBKX]...........................................................................................................................................2342 Failure Code [DKTBMC]...........................................................................................................................................2344 Failure Code [DKTEMB]...........................................................................................................................................2345 Failure Code [DKTFKX]...........................................................................................................................................2347 Failure Code [DKTFMC]...........................................................................................................................................2349 Failure Code [DKTJMB]...........................................................................................................................................2350 Failure Code [DKU1MA]...........................................................................................................................................2352 Failure Code [DKU2MA]...........................................................................................................................................2353 Failure Code [DKUGKA]...........................................................................................................................................2354 Failure Code [DKUGKB]...........................................................................................................................................2356 Failure Code [DKUGKY]...........................................................................................................................................2358 Failure Code [DKUHKA]...........................................................................................................................................2360 Failure Code [DKUHKB]...........................................................................................................................................2362 Failure Code [DKUHKY]...........................................................................................................................................2364 Failure Code [DKULKA]...........................................................................................................................................2366 Failure Code [DKULKB]...........................................................................................................................................2368 Failure Code [DKULKY]...........................................................................................................................................2370 Failure Code [DKV0KA]...........................................................................................................................................2372 Failure Code [DKV0KY]...........................................................................................................................................2375 Failure Code [DKV1KA]...........................................................................................................................................2377 Failure Code [DKV1KY]...........................................................................................................................................2379 Failure Code [DKV2KA]...........................................................................................................................................2381 Failure Code [DKV2KY]...........................................................................................................................................2383 Failure Code [DKV3KA]...........................................................................................................................................2385 Failure Code [DKV3KY]...........................................................................................................................................2387 Failure Code [DKV4MA]...........................................................................................................................................2389 Failure Code [DKV5MA]...........................................................................................................................................2392 Failure Code [DKV6MA]...........................................................................................................................................2395 Failure Code [DKV7MA]...........................................................................................................................................2398 Failure Code [DKV8MA]...........................................................................................................................................2401 Failure Code [DKV9MA]...........................................................................................................................................2404 Failure Code [DKVAMA]...........................................................................................................................................2407 Failure Code [DKVBKA]...........................................................................................................................................2410 Failure Code [DKVBKB]...........................................................................................................................................2412 Failure Code [DKVBKY]...........................................................................................................................................2414 Failure Code [DKVCKA]...........................................................................................................................................2416 Failure Code [DKVCKB]...........................................................................................................................................2418 Failure Code [DKVCKY]...........................................................................................................................................2420 Failure Code [DKVDKA]...........................................................................................................................................2422 Failure Code [DKVDKB]...........................................................................................................................................2424 Failure Code [DKVDKY]...........................................................................................................................................2426 Failure Code [DKVDMA]...........................................................................................................................................2428 Failure Code [DR10KA]...........................................................................................................................................2429 Failure Code [DR21KX]...........................................................................................................................................2432 Failure Code [DR31KX]...........................................................................................................................................2434 Failure Code [DUMBKA]...........................................................................................................................................2436 Failure Code [DUMBKB]...........................................................................................................................................2438 Failure Code [DV20KB]...........................................................................................................................................2440 Failure Code [DW43KA]...........................................................................................................................................2442 Failure Code [DW43KB]...........................................................................................................................................2444 Failure Code [DW43KY]...........................................................................................................................................2446 Failure Code [DW45KA]...........................................................................................................................................2448 Failure Code [DW45KB]...........................................................................................................................................2451 Failure Code [DW45KY]...........................................................................................................................................2454 Failure Code [DW4CKY]...........................................................................................................................................2456 Failure Code [DW4FKA]...........................................................................................................................................2457 Failure Code [DW4FKB]...........................................................................................................................................2460 Failure Code [DW4FKY]...........................................................................................................................................2462 Failure Code [DW4GKA]...........................................................................................................................................2465 Failure Code [DW4GKB]...........................................................................................................................................2468 Failure Code [DW4GKY]...........................................................................................................................................2470 Failure Code [DW4SKA]...........................................................................................................................................2472 Failure Code [DW4SKB]...........................................................................................................................................2474 Failure Code [DW4SKY]...........................................................................................................................................2476 Failure Code [DW91KA]...........................................................................................................................................2478 Failure Code [DW91KB]...........................................................................................................................................2480 Failure Code [DW91KY]...........................................................................................................................................2482 Failure Code [DWA2KA]...........................................................................................................................................2484 Failure Code [DWA2KB]...........................................................................................................................................2486 Failure Code [DWA2KY]...........................................................................................................................................2488 Failure Code [DWK0KA]...........................................................................................................................................2490 Failure Code [DWK0KB]...........................................................................................................................................2492 Failure Code [DWK0KY]...........................................................................................................................................2494 Failure Code [DWK2KA]...........................................................................................................................................2496 Failure Code [DWK2KB]...........................................................................................................................................2498 Failure Code [DWK2KY]...........................................................................................................................................2500 Failure Code [DWK8KA]...........................................................................................................................................2502 Failure Code [DWK8KB]...........................................................................................................................................2504 Failure Code [DWK8KY]...........................................................................................................................................2506 Failure Code [DWPUKA]...........................................................................................................................................2508 Failure Code [DWPUKB]...........................................................................................................................................2510 Failure Code [DWPUKY]...........................................................................................................................................2512 Failure Code [DXA8KA]...........................................................................................................................................2514 Failure Code [DXA8KB]...........................................................................................................................................2517 Failure Code [DXA9KA]...........................................................................................................................................2519 Failure Code [DXA9KB]...........................................................................................................................................2522 Failure Code [DXE0KA]...........................................................................................................................................2524 Failure Code [DXE0KB]...........................................................................................................................................2526 Failure Code [DXE4KA]...........................................................................................................................................2528 Failure Code [DXE4KB]...........................................................................................................................................2530 Failure Code [DXE4KY]...........................................................................................................................................2532 Failure Code [DXE5KA]...........................................................................................................................................2533 Failure Code [DXE5KB]...........................................................................................................................................2535 Failure Code [DXE6KA]...........................................................................................................................................2537 Failure Code [DXE6KB]...........................................................................................................................................2539 Failure Code [DXE7KA]...........................................................................................................................................2541 Failure Code [DXE7KB]...........................................................................................................................................2543 Failure Code [DXE7KY]...........................................................................................................................................2545 Failure Code [DXE8KA]...........................................................................................................................................2547 Failure Code [DXE8KB]...........................................................................................................................................2549 Failure Code [DXE8KY]...........................................................................................................................................2551 Failure Code [DXE9KA]...........................................................................................................................................2553 Failure Code [DXE9KB]...........................................................................................................................................2555 Failure Code [DXE9KY]...........................................................................................................................................2557 Failure Code [DXEAKA]...........................................................................................................................................2559 Failure Code [DXEAKB]...........................................................................................................................................2561 Failure Code [DXEAKY]...........................................................................................................................................2563 Failure Code [DXEKKA]...........................................................................................................................................2565 Failure Code [DXEKKB]...........................................................................................................................................2567 Failure Code [DXEKKY]...........................................................................................................................................2569 Failure Code [DXELKA]...........................................................................................................................................2571 Failure Code [DXELKB]...........................................................................................................................................2573 Failure Code [DXELKY]...........................................................................................................................................2575 Failure Code [DY20KA]...........................................................................................................................................2577 Failure Code [DY20MA]...........................................................................................................................................2580 Failure Code [DY2CKB]...........................................................................................................................................2582 Failure Code [DY2DKB]...........................................................................................................................................2585 Failure Code [DY2EKB]...........................................................................................................................................2587 Troubleshooting of Electrical System (E-Mode).......................................................................................................................2589 E-1 Engine Does Not Start (Engine Does Not Crank)...............................................................................................................2589 E-2 Manual Preheating System Does Not Operate...................................................................................................................2595 E-3 Automatic Preheating System Does Not Operate................................................................................................................2598 E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On.......................................................................................2600 E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing................................................................................2602 E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Engine Oil Level Monitor Comes On in Yellow...........................................2605 E-7 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow.....................................2606 E-8 Engine Coolant Temperature Monitor Comes On While Engine is in Operation....................................................................................2607 E-9 Hydraulic Oil Temperature Monitor Comes On in White While Engine Runs.......................................................................................2608 E-10 Air Cleaner Clogging Monitor Comes On in Yellow While Engine Runs..........................................................................................2609 E-11 Charge Level Monitor Comes On in Red While Engine is in Operation..........................................................................................2610 E-12 Fuel Level Monitor Comes On in Red While Engine Runs.......................................................................................................2611 E-13 Water Separator Monitor Comes On in Red While Engine Runs..................................................................................................2612 E-14 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation............................................................................2613 E-15 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation...................................................................................2614 E-16 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation.............................................................................2615 E-17 Fuel Gauge Display Does Not Move from Minimum or Maximum...................................................................................................2616 E-18 Display of Fuel Gauge is Different from Actual Fuel Level..................................................................................................2618 E-19 Coolant Temperature Gauge Display Does Not Move from Minimum or Maximum....................................................................................2619 E-20 Display of Coolant Temperature Gauge is Different from Actual Coolant Temperature..........................................................................2620 E-21 Hydraulic Oil Temperature Gauge Display Does Not Move from Minimum or Maximum..............................................................................2621 E-22 Display of Hydraulic Oil Temperature Gauge is Different from Actual Oil Temperature........................................................................2623 E-23 Some Areas of Machine Monitor Screen are Not Shown.........................................................................................................2624 E-24 Function Switch Does Not Operate...........................................................................................................................2625 E-25 Automatic Warm-up System Does Not Work (in Cold Weather)...................................................................................................2626 E-26 When Auto-Decelerator Switch is Operated, Auto-Decelerator Monitor Does Not Come On or Does Not Go Out.....................................................2627 E-27 Auto-Decelerator is Not Operated or Canceled with Lever....................................................................................................2628 E-28 When Working Mode Switch is Operated, Working Mode Selection Screen is Not Shown...........................................................................2629 E-29 When Working Mode is Changed, Setting of Engine and Hydraulic Pump is Not Changed..........................................................................2630 E-30 When Travel Speed Switch is Operated, Travel Speed Monitor Does Not Change.................................................................................2631 E-31 When Travel Speed Selection is Changed, Actual Travel Speed Does Not Change................................................................................2632 E-32 Alarm Buzzer Cannot be Canceled............................................................................................................................2634 E-33 Service Meter is Not Shown, While Starting Switch is in OFF Position.......................................................................................2635 E-34 Service Mode Cannot be Selected............................................................................................................................2636 E-35 All of Work Equipment, Swing, and Travel Mechanism Do Not Move.............................................................................................2637 E-36 All Work Equipment, Swing and Travel Do Not Lock...........................................................................................................2639 E-37 When Swing Brake Cancel Switch is Set to Cancel Position, Machine Cannot Swing.............................................................................2640 E-38 When Swing Brake Cancel Switch is Set to Normal Position, Swing Holding Brake Does Not Operate.............................................................2643 E-39 One-Touch Power Maximizing Function Does Not Operate Correctly or Monitor Does Not Show....................................................................2645 E-40 One-Touch Power Maximizing Function is Not Cancelled.......................................................................................................2647 E-41 Alarm Does Not Sound During Travel.........................................................................................................................2648 E-42 Alarm Does Not Stop When Machine Stops.....................................................................................................................2650 E-43 Horn Does Not Sound........................................................................................................................................2651 E-44 Horn Does Not Stop.........................................................................................................................................2655 E-45 When Wiper Switch is Operated, Wiper Monitor Does Not Come On or Go Out....................................................................................2657 E-46 When Wiper Switch is Operated, Windshield Wiper Does Not Operate...........................................................................................2658 E-47 Window Washer Does Not Operate When Window Washer Switch is Operated.......................................................................................2660 E-48 "Boom RAISE" is Not Shown Correctly with Monitoring Function...............................................................................................2661 E-49 "Boom LOWER" is Not Shown Correctly with Monitoring Function...............................................................................................2662 E-50 "Arm OUT" is Not Shown Correctly with Monitoring Function..................................................................................................2663 E-51 "Arm IN" is Not Shown Correctly with Monitoring Function...................................................................................................2664 E-52 "Bucket DUMP" is Not Shown Correctly with Monitoring Function..............................................................................................2665 E-53 "Bucket CURL" is Not Shown Correctly with Monitoring Function..............................................................................................2666 E-54 "Swing" is Not Shown Correctly with Monitoring Function....................................................................................................2667 E-55 "Travel" is Not Shown Correctly with Monitoring Function...................................................................................................2668 E-56 Service is Not Shown Correctly with Monitoring Function....................................................................................................2669 E-57 Attachment Hydraulic Circuit Cannot be Changed.............................................................................................................2671 E-58 KOMTRAX System Does Not Operate Correctly..................................................................................................................2672 E-59 Machine Push-Up Function is Not Canceled...................................................................................................................2673 E-60 Machine Push-Up Function Does Not Operate..................................................................................................................2675 E-61 Control Box Shows Message [GPS Receiver Not Connected !] and [Slope Sensor Not Connected !], and Then Shuts Down...........................................2676 E-62 Control Box Shows Message [GPS Receiver Not Connected!]....................................................................................................2681 E-63 Control Box Shows Message [Waiting for Radio Link].........................................................................................................2685 E-64 Control Box Shows Message [Tilt Bucket Sensor Offline!]....................................................................................................2686 E-65 Control Box Shows Message [Waiting for Satellites...]......................................................................................................2687 E-66 Control Box Shows Message [Komatsu controller not connected!] Show Production..............................................................................2688 E-67 Control Box Shows Message [Sensors are Invalid]............................................................................................................2691 E-68 Control Box Shows Message [Waiting to Initialize....]......................................................................................................2694 E-69 Control Box Shows Message [Initialize....].................................................................................................................2695 E-70 Control Box Shows Message [No GPS Localization]............................................................................................................2696 E-71 Control Box Shows Message [Low Precisions...]..............................................................................................................2697 E-72 Control Box Shows Message [Out of Design Area].............................................................................................................2698 E-73 Control Box Shows Message [Avoidance Area Breach!].........................................................................................................2699 E-74 Control Box Cannot be Turned on............................................................................................................................2700 E-75 Control Box Does Not Show Intelligent Machine Control Screen...............................................................................................2701 E-76 Control Box Does Not Show Hydraulic Excavator Image........................................................................................................2702 E-77 Control Box Does Not Show Design Surface...................................................................................................................2703 E-78 Control Box Touch Panel Does Not Respond...................................................................................................................2704 E-79 Control Box Touch Panel is Inaccurate......................................................................................................................2705 E-80 When You Examine and Adjust Bucket Blade Edge Position, Value is Different Largely.........................................................................2706 E-81 "Semi-Auto Mode" is Not Shown When Auto/Manual Switch is Pushed............................................................................................2708 E-82 "Semi-Automatic Mode" is Shown but Auto Grade Assist Function Does Not Operate.............................................................................2709 E-83 "Semi-Automatic Mode" is Shown but Auto Stop Control Does Not Work.........................................................................................2710 E-84 Blade Edge Position on Design Surface is Not Accurate When Auto Grade Assist Function is on................................................................2711 E-85 Blade Edge Stop Position is Not Accurate for Design Surface When Auto Stop Control Function is on..........................................................2713 E-86 Facing Angle Compass Does Not Become Perpendicular to Target...............................................................................................2715 E-87 NG Occurs Frequently in IMU Calibration Diagnosis..........................................................................................................2716 E-88 Cushion for Boom Raise End Does Not Work or is Weak........................................................................................................2717 E-89 Cushion for Arm IN End Does Not Work or is Weak............................................................................................................2718 Troubleshooting for Hydraulic and Mechanical Systems (H Mode).......................................................................................................2721 Information Shown in Troubleshooting Table (H-Mode).............................................................................................................2721 System Chart of Hydraulic and Mechanical Systems................................................................................................................2722 Failure Mode and Cause Table....................................................................................................................................2724 H-1 All Work Equipment, Swing and Travel Do Not Work............................................................................................................2735 H-2 All Work Equipment, Swing and Travel Lack Speed and Power...................................................................................................2736 H-3 Fine Control Performance or Response is Unsatisfactory......................................................................................................2739 H-4 Unusual Noise is Heard from Around Hydraulic Pump...........................................................................................................2740 H-5 Engine Speed Drops Largely or Engine Stops..................................................................................................................2741 H-6 Speed or Power of Boom is Low...............................................................................................................................2743 H-7 Arm Speed or Power is Low...................................................................................................................................2749 H-8 Bucket Speed or Power is Low................................................................................................................................2754 H-9 Work Equipment Does Not Move in Single Operation............................................................................................................2758 H-10 Hydraulic Drift of Boom is Large...........................................................................................................................2759 H-11 Hydraulic Drift of Arm is Large............................................................................................................................2761 H-12 Hydraulic Drift of Bucket is Large.........................................................................................................................2763 H-13 When Single Work Equipment is Released Hydraulically, Other Work Equipment Moves...........................................................................2764 H-14 Time Lag of Work Equipment is Large........................................................................................................................2765 H-15 One-Touch Power Maximizing Function Does Not Operate.......................................................................................................2766 H-16 Machine Push-Up Function Does Not Operate..................................................................................................................2767 H-17 Attachment Circuit Cannot be Changed.......................................................................................................................2768 H-18 Oil Flow in Attachment Circuit Cannot be Changed...........................................................................................................2769 H-19 In Mixed Operation of Work Equipment, Work Equipment with Heavier Load Moves Slower........................................................................2770 H-20 In Mixed Operation of Swing and Travel, Travel Speed Drops Largely.........................................................................................2771 H-21 In Mixed Operation of Swing and Boom Raise, Boom Raise Speed is Low........................................................................................2772 H-22 Machine Does Not Travel Straight...........................................................................................................................2773 H-23 Machine is Not Steered Correctly or Steering Power is Low..................................................................................................2775 H-24 Travel Speed is Low........................................................................................................................................2778 H-25 One of Tracks Does Not Run.................................................................................................................................2780 H-26 Travel Speed Does Not Change, or Travel Speed is Too Slow or Fast..........................................................................................2782 H-27 Machine Does Not Swing to Right or Left....................................................................................................................2783 H-28 Upper Structure Swings Only to Right or Left...............................................................................................................2784 H-29 Swing Acceleration or Swing Speed is Low in Two Directions of Right and Left...............................................................................2785 H-30 Swing Acceleration or Swing Speed is Low in Only One Direction.............................................................................................2786 H-31 Upper Structure Overruns Too Much When It Stops Swing Operation (Right and Left)...........................................................................2787 H-32 Upper Structure Overruns Too Much When It Stops Swing Operation (Only One Direction).......................................................................2788 H-33 Shock is Large When Upper Structure Stops Swing Operation..................................................................................................2789 H-34 There is Large Unusual Noise When It Stops Swing Operation.................................................................................................2790 H-35 Swing Drift on a Slope is Large (While Swing Parking Brake is Applied).....................................................................................2791 H-36 Swing Drift on a Slope is Large (While Swing Parking Brake is Released)....................................................................................2792 Troubleshooting of Engine (S-Mode)..................................................................................................................................2793 Information Shown in Troubleshooting Table (S-Mode).............................................................................................................2793 S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position......................................................................................2794 S-2 Engine Cranks but No Exhaust Smoke Comes Out................................................................................................................2795 S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start)....................................................................2796 S-4 Engine Startability is Unsatisfactory.......................................................................................................................2798 S-5 Engine Does Not Pick Up Smoothly............................................................................................................................2800 S-6 Engine Stops During Operation...............................................................................................................................2802 S-7 Engine Runs Rough or is Not Stable..........................................................................................................................2804 S-8 Engine Lacks Power..........................................................................................................................................2805 S-9 KDPF Becomes Clogged in a Short Time........................................................................................................................2807 S-10 Engine Oil Consumption is Excessive........................................................................................................................2809 S-11 Oil Becomes Dirty Quickly..................................................................................................................................2810 S-12 Fuel Consumption is Excessive..............................................................................................................................2811 S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant.......................................................................................................2812 S-14 Oil Pressure Drops.........................................................................................................................................2813 S-15 Fuel Mixes Into Engine Oil.................................................................................................................................2815 S-16 Water Mixes Into Engine Oil (Milky)........................................................................................................................2816 S-17 Coolant Temperature Increases Too High (Overheating).......................................................................................................2817 S-18 Unusual Noise is Heard.....................................................................................................................................2818 S-19 Vibration is Excessive.....................................................................................................................................2819 S-20 Air Cannot be Bled from Fuel Circuit.......................................................................................................................2820 S-21 Active Regeneration is Done Frequently.....................................................................................................................2821 S-22 Active Regeneration Continues Long.........................................................................................................................2823 S-23 White Smoke is Exhausted During Active Regeneration........................................................................................................2824 S-24 DEF Consumption is Excessive...............................................................................................................................2825 S-25 There is Unusual Smell (Irritating Odor)...................................................................................................................2827 S-26 Foreign Materials Enter DEF (DEF Increases)................................................................................................................2828 50 Disassembly and Assembly.............................................................................................................................................2829 Table of Contents...................................................................................................................................................2830 Precautions Before Work.............................................................................................................................................2836 Related Information on Disassembly and Assembly.....................................................................................................................2837 How to Read This Manual.........................................................................................................................................2837 Coating Materials List..........................................................................................................................................2838 Special Tool List...............................................................................................................................................2843 Sketches of Special Tools.......................................................................................................................................2858 Engine and Cooling System...........................................................................................................................................2867 Remove and Install Supply Pump Assembly.........................................................................................................................2867 Remove Supply Pump Assembly.................................................................................................................................2867 Install Supply Pump Assembly................................................................................................................................2872 Remove and Install Injector Assembly............................................................................................................................2880 How to Remove Injector Assembly.............................................................................................................................2880 How to Install Injector Assembly............................................................................................................................2887 Remove and Install Cylinder Head Assembly.......................................................................................................................2899 How to Remove Cylinder Head Assembly........................................................................................................................2900 How to Install Cylinder Head Assembly.......................................................................................................................2909 Remove and Install EGR Valve Assembly...........................................................................................................................2927 Remove EGR Valve Assembly...................................................................................................................................2927 Install EGR Valve Assembly..................................................................................................................................2928 Remove and Install EGR Cooler Assembly..........................................................................................................................2930 How to Remove EGR Cooler Assembly...........................................................................................................................2930 How to Install EGR Cooler Assembly..........................................................................................................................2931 Remove and Install Starter Assembly.............................................................................................................................2934 Remove Starting Motor Assembly..............................................................................................................................2934 Install Starting Motor Assembly.............................................................................................................................2935 Remove and Install Alternator Belt..............................................................................................................................2936 Remove Alternator Belt......................................................................................................................................2936 Install Alternator Belt.....................................................................................................................................2939 Remove and Install Radiator Assembly............................................................................................................................2942 How to Remove Radiator Assembly.............................................................................................................................2942 How to Install Radiator Assembly............................................................................................................................2944 Remove and Install Hydraulic Oil Cooler Assembly................................................................................................................2946 How to Remove Hydraulic Oil Cooler Assembly.................................................................................................................2946 How to Install Hydraulic Oil Cooler Assembly................................................................................................................2948 Remove and Install Aftercooler Assembly.........................................................................................................................2951 Remove Aftercooler Assembly.................................................................................................................................2951 Install Aftercooler Assembly................................................................................................................................2952 Remove and Install Engine and Main Pump Assembly................................................................................................................2954 Remove Engine and Main Pump Assembly........................................................................................................................2955 Install Engine and Main Pump Assembly.......................................................................................................................2967 Remove and Install Engine Front Oil Seal........................................................................................................................2982 How to Remove Engine Front Oil Seal.........................................................................................................................2982 How to Install Engine Front Oil Seal........................................................................................................................2986 Remove and Install Engine Rear Oil Seal.........................................................................................................................2990 How to Remove Engine Rear Oil Seal..........................................................................................................................2991 How to Install Engine Rear Oil Seal.........................................................................................................................2992 Remove and Install Engine Hood Assembly.........................................................................................................................2999 How to Remove Engine Hood Assembly..........................................................................................................................2999 How to Install Engine Hood Assembly.........................................................................................................................3001 Remove and Install Fuel Tank Assembly...........................................................................................................................3004 Remove Fuel Tank Assembly...................................................................................................................................3004 Install Fuel Tank Assembly..................................................................................................................................3009 Remove and Install DEF Tank Assembly............................................................................................................................3013 How to Remove DEF Tank Assembly.............................................................................................................................3013 How to Install DEF Tank Assembly............................................................................................................................3019 Remove and Install DEF Tank Sensor Flange Assembly..............................................................................................................3024 How to Remove DEF Tank Sensor Flange Assembly...............................................................................................................3024 How to Install DEF Tank Sensor Flange Assembly..............................................................................................................3031 Remove and Install DEF Tank Sensor..............................................................................................................................3037 Remove DEF Tank Sensor......................................................................................................................................3037 Install DEF Tank Sensor.....................................................................................................................................3037 Remove and Install DEF Tank Strainer............................................................................................................................3044 Remove DEF Tank Strainer....................................................................................................................................3044 Install DEF Tank Strainer...................................................................................................................................3044 Remove and Install DEF Tank Filler Port Filter..................................................................................................................3045 Remove DEF Tank Filler Port Filter..........................................................................................................................3045 Install DEF Tank Filler Port Filter.........................................................................................................................3047 Remove and Install KDPF Assembly................................................................................................................................3050 How to Remove KDPF Assembly.................................................................................................................................3050 How to Install KDPF Assembly................................................................................................................................3053 Disassemble and Assemble KDPF Assembly..........................................................................................................................3058 Disassemble KDPF Assembly...................................................................................................................................3059 Assemble KDPF Assembly......................................................................................................................................3062 Remove and Install SCR Assembly.................................................................................................................................3067 How to Remove SCR Assembly..................................................................................................................................3067 How to Install SCR Assembly.................................................................................................................................3070 Remove and Install KDPF and SCR Assembly........................................................................................................................3073 How to Remove KDPF and SCR Assembly.........................................................................................................................3074 Install KDPF and SCR Assembly...............................................................................................................................3081 Remove and Install KDPF and SCR Assembly Bracket................................................................................................................3088 Remove KDPF and SCR Assembly Bracket........................................................................................................................3088 Install KDPF and SCR Assembly Bracket.......................................................................................................................3091 Remove and Install Bellows Pipe Assembly........................................................................................................................3096 How to Remove Bellows Pipe Assembly.........................................................................................................................3096 How to Install Bellows Pipe Assembly........................................................................................................................3099 Remove and Install KCCV Assembly................................................................................................................................3103 Remove KCCV Assembly........................................................................................................................................3103 Install KCCV Assembly.......................................................................................................................................3104 Remove and Install DEF Mixing Tube..............................................................................................................................3106 Remove DEF Mixing Tube......................................................................................................................................3106 Install DEF Mixing Tube.....................................................................................................................................3110 Remove and Install DEF Injector.................................................................................................................................3114 Remove DEF Injector.........................................................................................................................................3114 Install DEF Injector........................................................................................................................................3117 Remove and Install DEF Pump.....................................................................................................................................3121 Remove DEF Pump.............................................................................................................................................3121 Install DEF Pump............................................................................................................................................3124 Remove and Install DEF Hose.....................................................................................................................................3127 Remove DEF Hose.............................................................................................................................................3128 Install DEF Hose............................................................................................................................................3134 Remove and Install Air Cleaner Assembly.........................................................................................................................3142 Remove Air Cleaner Assembly.................................................................................................................................3142 Install Air Cleaner Assembly................................................................................................................................3144 Remove and Install Air Conditioner Compressor Assembly..........................................................................................................3146 Remove Air Conditioner Compressor Assembly..................................................................................................................3146 How to Install Air Conditioner Compressor Assembly..........................................................................................................3147 Remove and Install Air Conditioner Condenser Assembly...........................................................................................................3149 How to Remove Air Conditioner Condenser Assembly............................................................................................................3149 How to Install Air Conditioner Condenser Assembly...........................................................................................................3150 Power Train.........................................................................................................................................................3151 Remove and Install Travel Motor and Final Drive Assembly........................................................................................................3151 Remove Travel Motor and Final Drive Assembly................................................................................................................3151 Install Travel Motor and Final Drive Assembly...............................................................................................................3152 Disassemble and Assemble Final Drive Assembly...................................................................................................................3154 Disassemble Final Drive Assembly............................................................................................................................3155 Assemble Final Drive Assembly...............................................................................................................................3159 Remove and Install Swing Motor and Swing Machinery Assembly.....................................................................................................3167 Remove Swing Motor and Swing Machinery Assembly.............................................................................................................3167 Install Swing Motor and Swing Machinery Assembly............................................................................................................3168 Disassemble and Assemble Swing Machinery Assembly...............................................................................................................3170 Disassemble Swing Machinery Assembly........................................................................................................................3170 Assemble Swing Machinery Assembly...........................................................................................................................3173 Remove and Install Swing Circle Assembly........................................................................................................................3181 Remove Swing Circle Assembly................................................................................................................................3181 Install Swing Circle Assembly...............................................................................................................................3181 Undercarriage and Frame.............................................................................................................................................3183 Separate and Connect Track Assembly.............................................................................................................................3183 Separate Track Assembly.....................................................................................................................................3183 Install Track Assembly......................................................................................................................................3185 Remove and Install Sprocket.....................................................................................................................................3188 Remove Sprocket.............................................................................................................................................3188 Install Sprocket............................................................................................................................................3188 Remove and Install Idler and Idler Cushion Assembly.............................................................................................................3190 Remove Idler and Idler Cushion Assembly.....................................................................................................................3190 Install Idler and Idler Cushion Assembly....................................................................................................................3191 Disassemble and Assemble Idler Assembly.........................................................................................................................3192 Disassemble Idler Assembly..................................................................................................................................3192 Assemble Idler Assembly.....................................................................................................................................3193 Disassemble and Assemble Idler Cushion Assembly.................................................................................................................3197 Disassemble Idler Cushion Assembly..........................................................................................................................3198 Assemble Idler Cushion Assembly.............................................................................................................................3198 Disassemble and Assemble Track Roller Assembly..................................................................................................................3200 Disassemble Track Roller Assembly...........................................................................................................................3201 Assemble Track Roller Assembly..............................................................................................................................3202 Disassemble and Assemble Carrier Roller Assembly................................................................................................................3204 Disassemble Carrier Roller Assembly.........................................................................................................................3204 Assemble Carrier Roller Assembly............................................................................................................................3205 Remove and Install Revolving Frame Assembly.....................................................................................................................3208 Remove Revolving Frame Assembly.............................................................................................................................3208 Install Revolving Frame Assembly............................................................................................................................3211 Remove and Install Counterweight Assembly.......................................................................................................................3215 Remove Counterweight Assembly...............................................................................................................................3215 Install Counterweight Assembly..............................................................................................................................3216 Hydraulic System....................................................................................................................................................3219 Remove and Install Center Swivel Joint Assembly.................................................................................................................3219 Remove Center Swivel Joint Assembly.........................................................................................................................3219 Install Center Swivel Joint Assembly........................................................................................................................3220 Disassemble and Assemble Center Swivel Joint Assembly...........................................................................................................3223 Disassemble Center Swivel Joint Assembly....................................................................................................................3224 Assemble Center Swivel Joint Assembly.......................................................................................................................3225 Remove and Install Hydraulic Tank Assembly......................................................................................................................3226 Remove Hydraulic Tank Assembly..............................................................................................................................3226 How to Install Hydraulic Tank Assembly......................................................................................................................3231 Remove and Install Main Pump Assembly...........................................................................................................................3236 Remove Main Pump Assembly...................................................................................................................................3236 Install Main Pump Assembly..................................................................................................................................3239 Remove and Install Junction Block Assembly for Intelligent Machine Control......................................................................................3242 Remove Junction Block Assembly for Intelligent Machine Control..............................................................................................3242 Install Junction Block Assembly for Intelligent Machine Control.............................................................................................3244 Remove and Install Pressure Sensor for Intelligent Machine Control..............................................................................................3247 How to Remove Pressure Sensor for Intelligent Machine Control...............................................................................................3247 How to Install Pressure Sensor for Intelligent Machine Control..............................................................................................3249 Remove and Install Boom Spool Stroke Sensor.....................................................................................................................3253 How to Remove Boom Spool Stroke Sensor......................................................................................................................3253 How to Install Boom Spool Stroke Sensor.....................................................................................................................3253 Remove and Install Arm Spool Stroke Sensor......................................................................................................................3255 How to Remove Arm Spool Stroke Sensor.......................................................................................................................3255 How to Install Arm Spool Stroke Sensor......................................................................................................................3257 Remove and Install Junction Block Bypass Adapter for Intelligent Machine Control................................................................................3259 How to Remove Junction Block Bypass Adapter for Intelligent Machine Control.................................................................................3259 How to Remove Junction Block Bypass Adapter for Intelligent Machine Control.................................................................................3261 Remove and Install Control Valve Assembly.......................................................................................................................3263 How to Remove Control Valve Assembly........................................................................................................................3263 How to Install Control Valve Assembly.......................................................................................................................3269 Disassemble and Assemble Control Valve Assembly.................................................................................................................3275 Replace Pressure Compensation Valve Seal Ring...............................................................................................................3276 Assemble Control Valve Assembly.............................................................................................................................3277 Remove and Install ATT Bypass Solenoid..........................................................................................................................3282 Remove ATT Bypass Solenoid..................................................................................................................................3282 Install ATT Bypass Solenoid.................................................................................................................................3285 Disassemble and Assemble Work Equipment PPC Valve Assembly......................................................................................................3287 Disassemble Work Equipment PPC Valve Assembly...............................................................................................................3287 How to Assemble Work Equipment PPC Valve Assembly...........................................................................................................3288 Disassemble and Assemble Travel PPC Valve Assembly..............................................................................................................3290 Disassemble Travel PPC Valve Assembly.......................................................................................................................3290 How to Assemble Travel PPC Valve Assembly...................................................................................................................3291 Work Equipment......................................................................................................................................................3293 Remove and Install Bucket Assembly..............................................................................................................................3293 How to Remove Bucket Assembly...............................................................................................................................3293 How to Install Bucket Assembly..............................................................................................................................3293 Remove and Install Arm Assembly.................................................................................................................................3295 Remove Arm Assembly.........................................................................................................................................3295 How to Install Arm Assembly.................................................................................................................................3298 Remove and Install Work Equipment Assembly......................................................................................................................3301 Remove Work Equipment Assembly..............................................................................................................................3301 Install Work Equipment Assembly.............................................................................................................................3305 Disassemble and Assemble Stroke Sensing Boom Cylinder Assembly..................................................................................................3310 How to Disassemble Stroke Sensing Boom Cylinder Assembly....................................................................................................3311 How to Assemble Stroke Sensing Boom Cylinder Assembly.......................................................................................................3316 Disassemble and Assemble Stroke Sensing Arm Cylinder Assembly...................................................................................................3323 How to Disassemble Stroke Sensing Arm Cylinder Assembly.....................................................................................................3324 How to Assemble Stroke Sensing Arm Cylinder Assembly........................................................................................................3329 Disassemble and Assemble Stroke Sensing Bucket Cylinder Assembly................................................................................................3338 How to Disassemble Stroke and Reset Sensing Bucket Cylinder Assembly........................................................................................3339 How to Assemble Stroke and Reset Sensing Bucket Cylinder Assembly...........................................................................................3344 CAB Related Parts...................................................................................................................................................3355 Remove and Install Operator Cab Assembly........................................................................................................................3355 How to Remove Operator Cab Assembly.........................................................................................................................3355 Install Operator CAB Assembly...............................................................................................................................3365 Remove and Install Operator Cab Glass (Adhered Glass)...........................................................................................................3374 Remove Operator CAB Glass (Adhered Glass)...................................................................................................................3376 Install Operator CAB Glass (Adhered Glass)..................................................................................................................3376 Remove and Install Front Window Assembly........................................................................................................................3386 Remove Front Window Assembly................................................................................................................................3386 Install Front Window Assembly...............................................................................................................................3389 Remove and Install Floor Frame Assembly.........................................................................................................................3395 How to Remove Floor Frame Assembly..........................................................................................................................3395 How to Install Floor Frame Assembly.........................................................................................................................3402 Remove and Install Air Conditioner Unit Assembly................................................................................................................3409 Remove Air Conditioner Unit Assembly........................................................................................................................3409 Install Air Conditioner Unit Assembly.......................................................................................................................3416 Remove and Install Operator Seat................................................................................................................................3424 Remove Operator's Seat......................................................................................................................................3424 Install Operator's Seat.....................................................................................................................................3426 How to Remove and Install Seat Belt.............................................................................................................................3430 How to Remove Seat Belt.....................................................................................................................................3430 How to Install Seatbelt.....................................................................................................................................3430 Remove and Install Work Equipment Control Lever Assembly........................................................................................................3432 How to Remove Work Equipment Control Lever Assembly.........................................................................................................3432 How to Install Work Equipment Control Lever Assembly........................................................................................................3438 Remove and Install Front Wiper Assembly.........................................................................................................................3447 Remove Front Wiper Assembly.................................................................................................................................3447 Install Front Wiper Assembly................................................................................................................................3453 Electrical System...................................................................................................................................................3462 Remove and Install Engine Controller Assembly...................................................................................................................3462 Remove Engine Controller Assembly...........................................................................................................................3462 Install Engine Controller Assembly..........................................................................................................................3464 Remove and Install Pump Controller Assembly.....................................................................................................................3468 Remove Pump Controller Assembly.............................................................................................................................3468 Install Pump Controller Assembly............................................................................................................................3472 Remove and Install Work Equipment Controller Assembly...........................................................................................................3478 Remove Work Equipment Controller Assembly...................................................................................................................3478 Install Work Equipment Controller Assembly..................................................................................................................3479 Remove and Install KomVision Controller Assembly................................................................................................................3482 Remove KomVision Controller Assembly........................................................................................................................3482 Install KomVision Controller Assembly.......................................................................................................................3483 Remove and Install Machine Monitor Assembly.....................................................................................................................3485 Remove Machine Monitor Assembly.............................................................................................................................3485 Install Machine Monitor Assembly............................................................................................................................3488 Remove and Install Pump Swash Plate Sensor......................................................................................................................3492 Remove Pump Swash Plate Sensor..............................................................................................................................3492 Install Pump Swash Plate Sensor.............................................................................................................................3492 Remove and Install Mass Air Flow and Temperature Sensor.........................................................................................................3494 How to Remove Mass Air Flow and Temperature Sensor..........................................................................................................3494 How to Install Mass Air Flow and Temperature Sensor.........................................................................................................3495 Remove and Install KCCV Crankcase Pressure Sensor...............................................................................................................3496 How to Remove KCCV Crankcase Pressure Sensor................................................................................................................3496 How to Install KCCV Crankcase Pressure Sensor...............................................................................................................3497 Remove and Install SCR Temperature Sensor.......................................................................................................................3498 Remove SCR Temperature Sensor...............................................................................................................................3498 Install SCR Temperature Sensor..............................................................................................................................3499 Remove and Install Rearview Camera..............................................................................................................................3501 Remove Rearview Camera......................................................................................................................................3501 Install Rearview Camera.....................................................................................................................................3502 Remove and Install KomVision Camera.............................................................................................................................3504 Remove KomVision Camera.....................................................................................................................................3504 Install KomVision Camera....................................................................................................................................3505 Remove and Install KOMTRAX Terminal Assembly....................................................................................................................3507 Remove KOMTRAX Terminal Assembly............................................................................................................................3507 Install KOMTRAX Terminal Assembly...........................................................................................................................3510 Remove and Install ICT Sensor Controller Assembly...............................................................................................................3514 Remove ICT Sensor Controller Assembly.......................................................................................................................3514 Install ICT Sensor Controller Assembly......................................................................................................................3516 Remove and Install Junction Harness of Control Box..............................................................................................................3520 How to Remove Junction Harness of Control Box...............................................................................................................3520 How to Install Junction Harness of Control Box..............................................................................................................3523 Remove and Install Control Box Harness..........................................................................................................................3526 Remove Control Box Harness..................................................................................................................................3526 Install Control Box Harness.................................................................................................................................3527 Remove and Install GNSS Receiver................................................................................................................................3529 Remove GNSS Receiver........................................................................................................................................3529 Install GNSS Receiver.......................................................................................................................................3530 Remove and Install Network Modem................................................................................................................................3531 How to Remove Network Modem.................................................................................................................................3531 How to Install Network Modem................................................................................................................................3531 Remove and Install GNSS Receiver Antenna........................................................................................................................3532 How to Remove GNSS Receiver Antenna.........................................................................................................................3532 How to Install GNSS Receiver Antenna........................................................................................................................3532 Remove and Install Network Modem Antenna........................................................................................................................3534 Remove Network Modem Antenna................................................................................................................................3534 Install Network Modem Antenna...............................................................................................................................3534 Remove and Install GNSS Antenna.................................................................................................................................3536 Remove GNSS Antenna.........................................................................................................................................3536 Install GNSS Antenna........................................................................................................................................3537 Remove and Install IMU Sensor...................................................................................................................................3538 Remove IMU Sensor...........................................................................................................................................3538 Install IMU Sensor..........................................................................................................................................3538 60 Maintenance Standard.................................................................................................................................................3541 Table of Contents...................................................................................................................................................3542 Engine and Cooling System...........................................................................................................................................3543 Maintenance Standard for Engine Mount...........................................................................................................................3543 Maintenance Standard for Cooling System.........................................................................................................................3545 Power Train.........................................................................................................................................................3547 Maintenance Standard for Swing Circle...........................................................................................................................3547 Maintenance Standard for Swing Machinery........................................................................................................................3548 Maintenance Standard for Final Drive............................................................................................................................3550 Maintenance Standard for Sprocket...............................................................................................................................3552 Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing..............................................................................................3553 Undercarriage and Frame.............................................................................................................................................3554 Maintenance Standard for Track Frame and Idler Cushion..........................................................................................................3554 Maintenance Standard for Idler..................................................................................................................................3556 Maintenance Standard for Track Roller...........................................................................................................................3558 Maintenance Standard for Carrier Roller.........................................................................................................................3560 Maintenance Standard for Track Shoes............................................................................................................................3561 Maintenance Standard for Triple Shoes...........................................................................................................................3564 Hydraulic System....................................................................................................................................................3565 Maintenance Standard for Hydraulic Tank.........................................................................................................................3565 Maintenance Standard for Main Pump..............................................................................................................................3566 Maintenance Standard for Swing Motor............................................................................................................................3568 Maintenance Standard for Travel Motor...........................................................................................................................3571 Maintenance Standard for Control Valve..........................................................................................................................3574 Maintenance Standard for Work Equipment and Swing PPC Valve.....................................................................................................3586 Maintenance Standard for Travel PPC Valve.......................................................................................................................3589 Maintenance Standard for 1st-Line Attachment PPC Valve (with EPC Valve).........................................................................................3592 Maintenance Standard for EPC Valve of 1st-Line Attachment PPC Valve.........................................................................................3594 Maintenance Standard for 2nd-Line Attachment PPC Valve..........................................................................................................3595 Maintenance Standard for Solenoid Valve.........................................................................................................................3597 Maintenance Standard for Attachment Circuit Selector Valve......................................................................................................3598 Maintenance Standard for Center Swivel Joint....................................................................................................................3599 Work Equipment......................................................................................................................................................3600 Maintenance Standard for Work Equipment Linkage.................................................................................................................3600 Dimensions of Arm...........................................................................................................................................3605 Dimensions of Bucket........................................................................................................................................3607 Maintenance Standard for Boom Cylinder..........................................................................................................................3609 Maintenance Standard for Stroke Sensing Boom Cylinder...........................................................................................................3610 Maintenance Standard for Stroke Sensing Arm Cylinder............................................................................................................3612 Maintenance Standard for Stroke and Reset Sensing Bucket Cylinder...............................................................................................3614 Maintenance Standard for Stroke Sensor for Boom Cylinder........................................................................................................3616 Maintenance Standard for Stroke Sensor for Arm Cylinder.........................................................................................................3617 Maintenance Standard for Stroke and Reset Sensor for Bucket Cylinder............................................................................................3618 80 Appendix.............................................................................................................................................................3619 Table of Contents...................................................................................................................................................3620 Precautions Before Work.............................................................................................................................................3622 Air Conditioner System..............................................................................................................................................3623 Precautions for Refrigerant.....................................................................................................................................3623 Air Conditioner Component.......................................................................................................................................3624 Specifications of Air Conditioner...............................................................................................................................3626 Structure and Function of Refrigeration Cycle...................................................................................................................3627 Outline of Refrigeration Cycle..................................................................................................................................3628 Component Parts of Air Conditioner System...........................................................................................................................3630 Air Conditioner Unit............................................................................................................................................3630 Configuration Diagram of Air Conditioner Unit...............................................................................................................3630 Function of Air Conditioner Unit............................................................................................................................3632 Component Parts of Air Conditioner Unit.........................................................................................................................3634 Function of Evaporator as Air Conditioner Unit Component....................................................................................................3635 Function of Heater Core as Air Conditioner Unit Component...................................................................................................3635 Function of Evaporator Temperature Sensor as Air Conditioner Unit Component.................................................................................3635 Function of Servo Motor as Air Conditioner Unit Component...................................................................................................3635 Structure of Expansion Valve as Air Conditioner Unit Component..............................................................................................3636 Function of Expansion Valve as Air Conditioner Unit Component...............................................................................................3636 Operate Expansion Valve as Air Conditioner Unit Component...................................................................................................3636 Function of Dual Pressure Switch............................................................................................................................3637 Air Conditioner Controller......................................................................................................................................3638 Structure of Air Conditioner Controller.....................................................................................................................3638 Compressor......................................................................................................................................................3639 Structure of Compressor.....................................................................................................................................3639 Specifications of Compressor................................................................................................................................3639 Function of Compressor......................................................................................................................................3639 Condenser.......................................................................................................................................................3640 Structure of Condenser......................................................................................................................................3640 Specifications of Condenser.................................................................................................................................3640 Function of Condenser.......................................................................................................................................3640 Receiver Drier..................................................................................................................................................3641 Structure of Receiver Dryer.................................................................................................................................3641 Specifications of Receiver Dryer............................................................................................................................3641 Function of Receiver Dryer..................................................................................................................................3641 Air Conditioner Related Sensors.................................................................................................................................3642 Structure of Sunlight Sensor................................................................................................................................3642 Function of Sunlight Sensor.................................................................................................................................3642 Structure of Outside Temperature Sensor.....................................................................................................................3642 Function of Outside Air Temperature Sensor..................................................................................................................3642 Explanation of Procedure for Test of and Troubleshooting of Air Conditioner.........................................................................................3644 Circuit Diagram and Configuration of Connector Pins of Air Conditioner..............................................................................................3646 System Diagram of Air Conditioner...................................................................................................................................3648 Input and Output Signals of Air Conditioner Controller..........................................................................................................3649 Function of Air Conditioner Controller......................................................................................................................3650 Locations of Air Conditioner Parts and Layout of Connectors.........................................................................................................3651 Examine Air Leakage (Duct)..........................................................................................................................................3655 How to Examine Air Leakage (Duct)...............................................................................................................................3655 Examine Air Conditioner with Self-Diagnosis Function................................................................................................................3656 Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor.............................................................................3657 Examine Vent (Mode) Changeover......................................................................................................................................3658 How to Examine Vent (Mode) Changeover...........................................................................................................................3658 Examine Fresh/Recirc Air Changeover.................................................................................................................................3659 How to Examine Fresh/Recirc Air Changeover......................................................................................................................3659 Examine Sunlight Sensor.............................................................................................................................................3660 How to Examine Sunlight Sensor..................................................................................................................................3660 Examine Refrigerant (Dual) Pressure Switch..........................................................................................................................3661 How to Examine Refrigerant (Dual) Pressure Switch...............................................................................................................3661 Examine Relay.......................................................................................................................................................3662 How to Examine Relay............................................................................................................................................3662 Air Conditioner Troubleshooting Chart 1.............................................................................................................................3663 Air Conditioner Troubleshooting Chart 2.............................................................................................................................3664 Information Shown in Troubleshooting Table..........................................................................................................................3667 Failure Code [879AKA]...............................................................................................................................................3668 Failure Code [879AKB]...............................................................................................................................................3669 Failure Code [879BKA]...............................................................................................................................................3670 Failure Code [879BKB]...............................................................................................................................................3672 Failure Code [879CKA]...............................................................................................................................................3674 Failure Code [879CKB]...............................................................................................................................................3675 Failure Code [879DKZ]...............................................................................................................................................3676 Failure Code [879EMC]...............................................................................................................................................3678 Failure Code [879FMC]...............................................................................................................................................3679 Failure Code [879GKX]...............................................................................................................................................3680 A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate)......................................................................................3682 A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled).......................................................................................3684 A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal)..............................................................................3687 A-4 Troubleshooting for Fresh/Recirc Air Changeover.................................................................................................................3689 Troubleshooting by Gauge Pressure...................................................................................................................................3691 Connect Service Tool................................................................................................................................................3694 How to Connect Service Tool.....................................................................................................................................3694 Precautions for Disconnection and Connection of Air Conditioner Piping..............................................................................................3696 Handle Compressor Oil...............................................................................................................................................3698 90 Circuit Diagrams.....................................................................................................................................................3701 Table of Contents...................................................................................................................................................3702 Hydraulic Circuit Diagram...........................................................................................................................................3703 Symbols Used in Hydraulic Circuit Diagram.......................................................................................................................3703 Hydraulic Circuit Diagram (1/3).................................................................................................................................3707 Hydraulic Circuit Diagram (2/3).................................................................................................................................3709 Hydraulic Circuit Diagram (3/3).................................................................................................................................3711 Electrical Circuit Diagram..........................................................................................................................................3713 Symbols Used in Electric Circuit Diagram........................................................................................................................3713 Electrical Circuit Diagram (1/14)...............................................................................................................................3717 Electrical Circuit Diagram (2/14)...............................................................................................................................3719 Electrical Circuit Diagram (3/14)...............................................................................................................................3721 Electrical Circuit Diagram (4/14)...............................................................................................................................3723 Electrical Circuit Diagram (5/14)...............................................................................................................................3725 Electrical Circuit Diagram (6/14)...............................................................................................................................3727 Electrical Circuit Diagram (7/14)...............................................................................................................................3729 Electrical Circuit Diagram (8/14)...............................................................................................................................3731 Electrical Circuit Diagram (9/14)...............................................................................................................................3733 Electrical Circuit Diagram (10/14)..............................................................................................................................3735 Electrical Circuit Diagram (11/14)..............................................................................................................................3737 Electrical Circuit Diagram (12/14)..............................................................................................................................3739 Electrical Circuit Diagram (13/14)..............................................................................................................................3741 Electrical Circuit Diagram (14/14)..............................................................................................................................3743 Index....................................................................................................................................................................3745
DESCRIPTION:
KOMATSU PC360LCi-11 HYDRAULIC EXCAVATOR SHOP MANUAL SEN06601-16 – 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.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
S.S 25/12/24
