Service manual Komatsu PC360LC-10, PC390LC-10 Hydraulic Excavator | CEBM025204

Komatsu PC360LC-10, PC390LC-10 Hydraulic Excavator CEBM025204 (Preview)

PC360-390LC-10 Shop Manual CEBM025204
00 FORWARD
– CONTENTS
– SAFETY
— Safety Notice
— Important Safety Notice
— General Precautions
— Preparations For Work
— Precautions During Work
– GENERAL
– HOW TO READ THE SHOP MANUAL
— Volumes
— Distribution And Updating
— Filing Method
— Revised Edition Mark
— Revisions
— Symbols
– HOISTING INSTRUCTIONS
— Hoisting
— Making Signs
— Precautions
— Precautions for Sling Work
— Precautions for Using Mobile Crane
— Precautions for Using Overhead Hoist Crane
— Selecting Wire Ropes
– HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
— Points to Remember When Handling Electric Equipment
— Points to Remember When Handling Hydraulic Equipment
– PUSH PULL COUPLER
— Type 1
— Disconnection
— Connection
— Type 2
— Disconnection
— Connection
— Type 3
— Disconnection
— Connection
– EXPLANATION OF MAINTENANCE STANDARD TERMS
– HANDLING OF FUEL SYSTEM DEVICES
– HANDLING OF INTAKE SYSTEM PARTS
– STANDARD TIGHTENING TORQUE
— Bolts And Nuts
— Tightening Torque Of Hose Nuts
— Tightening Torque Of Split Flange Bolts
— Tightening Torque For Flared Nuts
— Tightening Torques for Split Flanged Bolts
— Tightening Torques For O-ring Boss Piping Joints
— Table Of Tightening Torques For O-ring Boss Plugs
— Tightening Torque For Hoses (Taper Seal Type And Face Seal Type)
— Tightening Torque For Face Seal Joints
— For 102, 107, and 114 Engine Series (Bolts and Nuts)
— For 102, 107, and 114 Engine Series (Eye Joints)
— For 102, 107, and 114 Engine Series (Taper Screws)
– ELECTRIC WIRE CODE
— Classification By Thickness
— Classification By Color And Code
— How To Read Electric Wire Code
– PRECAUTIONS FOR OPERATIONS
— Precautions when Carrying Out Removal Work
— Precautions when Carrying Out Installation Work
— Precautions when Completing the Operation
– CONVERSION TABLES
— Method Of Using The Conversion Table
– COATING MATERIALS
– LIST OF ABBREVIATIONS
— List of Abbreviations Used in the Shop Manual
— List of Abbreviations Used in the Circuit Diagrams
01 GENERAL
– SPECIFICATION DIMENSION DRAWINGS
— Dimensions
— Working Ranges
– SPECIFICATIONS
— Engine
— Undercarriage
— Hydraulic System
– WEIGHT TABLE
– FUEL, COOLANT AND LUBRICANTS
— Lubrication Chart
10 STRUCTION AND FUNCTION
– ENGINE AND COOLING SYSTEM
— Engine Related Parts
— Cooling System
– POWER TRAIN
— Power Train
— Swing Circle
— Final Drive
— PC360LC-10
— PC390LC-10
– UNDERCARRIAGE AND FRAME
— Track Frame and Idler Cushion
– HYDRAULIC SYSTEM
— Hydraulic Component Layout
— Valve Control
— Hydraulic Tank
— Oil Filler Cap
— CLSS
— Structure of CLSS
— Basic principle
— Main Pump
— Operation
— LS Valve
— PC Valve
— LS(PC)-EPC Valve
— Control Valve
— Functions and Operation by Valve
— Hydraulic Circuit Diagram and Name of Valves
— Unload Valve
— Introduction of LS Pressure
— LS By-Pass Plug
— Pressure Compensation Valve
— Shuttle Valve In Pressure Compensation Valve
— Boom Regeneration Circuit
— Arm Regeneration Circuit
— Merge-Divider Valve
— LS Selector Valve
— Self-Pressure Reducing Valve
— Travel Junction Valve
— Travel PPC Shuttle Valve
— Boom Hydraulic Drift Prevention Valve
— Arm Hydraulic Drift Prevention Valve (If Equipped)
— Suction Safety Valve for Drift Prevention Valve
— Arm Quick Return Valve
— Variable Back Pressure Valve
— Main Relief Valve
— Suction 2-Stage Safety Valve
— Swing Motor
— Swing Holding Brake
— Relief Valve
— Swing 2-Stage Relief Valve
— Swing Motor Reverse Prevention Valve
— Travel Motor – Type KMV180ADT-2 (PC360LC-10)
— Operation of Travel Motor
— Operation of Parking Brake
— Brake Valve
— Counterbalance Valve
— Suction Safety Valve
— Travel Motor – Type KMV200ADT-2 (PC390LC-10)
— Operation of Travel Motor
— Parking Brake
— Brake Valve
— Safety Valve
— PPC Valve
— Work Equipment and Swing PPC Valve
— Travel PPC Valve
— 1st-Line Attachment PPC Valve (with EPC Valve) (If Equipped)
— EPC Valve (If Equipped)
— 2nd-Line Attachment PPC Valve (If Equipped)
— Solenoid Valve
— Attachment Circuit Selector Valve (If Equipped)
— Center Swivel Joint
— Accumulator
— PPC Accumulator
– WORK EQUIPMENT
— Work Equipment
— Work Equipment Shim
— Bucket Play Adjustment Shim
– CAB AND ITS ATTACHMENTS
— Cab Mount and Cab Tipping Stopper
— ROPS Cab
– ELECTRICAL SYSTEM
— Electrical Control System
— Machine Control System Diagram
— Engine Control Function
— Engine and Pump Combined Control Function
— Pump and Valve Control Function
— One-Touch Power Maximizing Function
— Machine Push-Up Function
— Auto-Deceleration Function
— Engine Automatic Warm-Up Function
— Overheat Prevention Function
— Turbocharger Protection Function
— Swing Control Function
— Quick Warm-Up Function
— Swing 2-Stage Relief Function
— Travel Control Function
— PPC Lock Function
— Attachment Flow Control Function
— System Component Part
— Engine Controller
— Pump Controller
— Fuel Control Dial
— Resister for PC-EPC valve
— CAN Terminating Resistor
— Engine Oil Pressure Switch
— PPC Oil Pressure Switch
– MACHINE MONITOR SYSTEM
— Machine Monitor
— Input and Output Signals
— Display
— Gauges
— Caution Monitor
— Pilot Monitor
— Switches
— Guidance ICON and Function Switch
— Operator Mode Function
— Service Mode Function
– KOMTRAX SYSTEM
— KOMTRAX terminal
— Input and Output Signals
– SENSORS
— Ambient Pressure Sensor
— Charge (Boost) Pressure and Temperature Sensor
— Coolant Temperature Sensor
— Ne (Crankshaft) Speed Sensor
— Bkup (Camshaft) Speed Sensor
— Common Rail Pressure Sensor
— Exhaust Manifold Pressure Sensor
— EGR Orifice Temperature Sensor
— EGR Valve Lift Sensor
— Turbo Speed Sensor
— KVGT Position Sensor
— Mass Air Flow and Temperature Sensor
— KDPF Differential Pressure and Outlet Pressure Sensor
— KDOC Inlet Temperature Sensor
— KDOC Outlet Temperature Sensor
— KDPF Outlet Temperature Sensor
— Crankcase Pressure Sensor
— Engine Oil Level Sensor
— Fuel Level Sensor
— Coolant Level Sensor
— Hydraulic Oil Temperature Sensor
— Front Pump Oil Pressure Sensor
— Rear Pump Oil Pressure Sensor
— PPC Oil Pressure Sensor
— Air Cleaner Clogging Sensor
— Front Pump Swash Plate Sensor
— Rear Pump Swash Plate Sensor
— Water-In-Fuel Sensor
20 STANDARD VALUE TABLES
– STANDARD SERVICE VALUE TABLES
— Standard Value Table for Engine Related Parts
— Standard Value Table for Chassis Related Parts
— Engine Speed
— Travel of Control Valve Spool
— Travel of Control Lever
— Operating Effort of Control Lever and Pedal
— Hydraulic Pressure
— Swing
— Travel
— Work Equipment
— Performance in Combined Operation
— Pump Swash Plate Sensor
— Main Pump
— Posture of Machine for Measuring Performance and Measurement Procedure
— Control Valve: Spool Stroke
— Swing 1: Overrun When Stopping Swing, Time Taken to Start Swing, Time Taken to Swing
— Swing 2: Hydraulic Drift of Swing
— Travel 1: Travel Speed, Idle Running (Without Load)
— Travel 2: Travel Speed (Actual Run), Travel Deviation
— Travel 3: Travel Deviation
— Travel 4: Hydraulic Drift of Travel
— Work Equipment 1: Hydraulic Drift of Work Equipment
— Work Equipment 2: Boom Speed
— Work Equipment 3: Arm Speed
— Work Equipment 4: Bucket Speed
— Work Equipment 5: Boom Time Lag
— Work Equipment 6: Arm Time Lag
— Work Equipment 7: Bucket Time Lag
30 TESTING AND ADJUSTING
– GENERAL INFORMATION
— Tools for Testing, Adjusting, and Troubleshooting
— Sketch of Tools for Testing and Adjusting
– ENGINE AND COOLING SYSTEM
— Checking Engine Speed
— Measuring Boost Pressure
— Measuring Exhaust Gas Color
— Measuring and Adjusting Valve Clearance
— Testing
— Adjustment
— Measuring Compression Pressure
— Measuring Blow-By Pressure
— Measuring Engine Oil Pressure
— Measuring EGR Valve and KVGT Oil Pressure
— Measuring Fuel Pressure
— Testing Low-Pressure Circuit (Main Fuel Filter Inlet Side)
— Testing Low-Pressure Circuit (Pressure Difference)
— Testing Return Circuit
— Testing the Negative Pressure Circuit (At Fuel Supply Connector)
— Testing the Negative Pressure Circuit (At Supply Pump)
— Testing Fuel Feed Pump Outlet Pressure (At Supply Pump)
— Measuring Fuel Delivery, Return and Leakage
— Testing Supply Pump Delivery
— Testing Supply Pump Return Rate
— Testing Leakage from Pressure Limiter
— Measuring Return Rate from Injector
— Testing Delivery of Fuel Feed Pump
— Bleeding Air from Fuel System
— Bleeding Air
— Checking Fuel Circuit for Leakage
— Handling Cylinder Cut-Out Mode Operation
— Handling No-Injection Cranking Operation
— Checking and Adjusting Air Conditioner Compressor Belt Tension
— Checking
— Adjusting
— Replacing Fan Belt
— Replacing Alternator Belt
– POWER TRAIN
— Testing Swing Circle Bearing Clearance
— Testing
– UNDERCARRIAGE AND FRAME
— Testing and Adjusting Track Shoe Tension
— Testing
— Adjusting
– HYDRAULIC SYSTEM
— Releasing Remaining Pressure from Hydraulic Circuit
— Measuring and Adjusting of Oil Pressure in Work Equipment, Swing, and Travel Circuits
— Testing
— Measuring Method by Using Machine Monitor
— Measuring Method by Using Oil Pressure Gauge
— Combination of Pump, Actuator, and Valve
— Measuring Unload Pressure
— Measuring Work Equipment Relief Pressure
— Measuring Swing Relief Pressure
— Measuring Travel Relief Pressure
— Work After Finishing Measurement
— Adjusting
— Adjusting Work Equipment and Travel Relief Pressure
— Adjusting Boom LOWER Relief Pressure (On the Side Where High Pressure is Set)
— Adjusting Boom LOWER Relief Pressure (On the Side Where Low Pressure is Set)
— Adjusting Swing Relief Pressure
— Measuring Oil Pressure in Control Circuit
— Measuring with Machine Monitor
— Measuring with Oil Pressure Gauge
— Measuring and Adjusting Oil Pressure in Pump PC Control Circuit
— Testing
— Measuring PC Valve Output Pressure (Servo Piston Inlet Pressure) With Machine Monitor
— Measuring PC-EPC Valve Output Pressure With the Machine Monitor
— Measuring PC Valve Output Pressure (Servo Piston Inlet Pressure) With Oil Pressure Gauge
— Measuring PC-EPC Valve Output Pressure With Oil Pressure Gauge
— Adjusting
— Measuring and Adjusting Oil Pressure in Pump LS Control Circuit
— Testing
— Measuring LS Valve Output Pressure (Servo Piston Inlet Pressure) With Machine Monitor
— Measuring LS Differential Pressure with the Machine Monitor
— Measuring LS-EPC Valve Output Pressure with the Machine Monitor
— Measuring LS Valve Output Pressure (Servo Piston Inlet Pressure) with Oil Pressure Gauge
— Measuring LS Differential Pressure with Oil Pressure Gauge
— Measuring LS-EPC Valve Output Pressure with Oil Pressure Gauge
— Adjusting
— Measuring Solenoid Valve Output Pressure
— Testing
— Measuring with Machine Monitor
— Measuring with Oil Pressure Gauge
— Operating Condition
— Measuring PPC Valve Output Pressure
— Testing
— Measuring with Machine Monitor
— Measuring with Oil Pressure Gauge
— Adjusting Play of Work Equipment and Swing PPC Valves
— Adjusting
— Testing Pump Swash Plate Sensor
— Testing Output Voltage of Pump Swash Plate Sensor
— Isolating the Parts Causing Hydraulic Drift in Work Equipment
— Measuring Oil Leakage
— Bleeding Air From Hydraulic Circuit
– CAB AND ITS ATTACHMENTS
— Checking Cab Tipping Stopper
— Adjusting Mirrors
– ELECTRICAL SYSTEM
— Special Functions of Machine Monitor
— Upper Part of machine monitor (display portion)
— Upper Part of Machine Monitor (Switch Portion)
— Lower Part of Machine Monitor (Switch Portion)
— Ordinary Functions and Special Functions of Machine Monitor
— Operator Mode (Outline)
— Service Mode
— Angle Adjustment of Rear View Camera
— Handling Voltage Circuit of Engine Controller
— Handling Battery Disconnect Switch
— Testing Diodes
– PM CLINIC
— PM Clinic Service
— Check Items Related to Engine
— Check Items Related to Oil Pressure
— Check Sheet
40 TROUBLESHOOTING
– GENERAL INFORMATION ON TROUBLESHOOTING
— Points to Remember When Troubleshooting
— Sequence of Events in Troubleshooting
— Checks Before Troubleshooting
— Testing Procedure Before Troubleshooting
— Walk-Around Check
— Checking in Accordance with Checking Procedure
— Preparation Work for Troubleshooting of Electrical System
— Preparation Work
— Classification and Procedure for Troubleshooting
— Classification of Troubleshooting
— Procedure for Troubleshooting
— Symptom of Probable Failure and Troubleshooting No.
— Information Mentioned in Troubleshooting Table
– Diagnostic Procedure for Wiring Harness Open Circuit of Pressure Sensor System
— Connector list
— Layout of connectors
— Connection Table for Connector Pin Numbers
— T-Branch Box and T-Branch Adapter Table
— Fuse List and Location
— Connection Table of Fuse Box
— Locations of Fusible Links
— Location of Fuse Box and Fuse Numbers
— Precautions for Cleaning and Replacing KDPF (KCSF, KDOC)
– FAILURE CODE (DISPLAY OF CODE)
— Failure Codes Table
— 879AKA – A/C Inner Sensor Open Circuit
— 879AKB – A/C Inner Sensor Short Circuit
— 879BKA – A/C Outer Sensor Open Circuit
— 879BKB – A/C Outer Sensor Short Circuit
— 879CKA – Ventilating Sensor Open Circuit
— 879CKB – Ventilating Sensor Short Circuit
— 879DKZ – Sunlight Sensor Open or Short Circuit
— 879EMC – Ventilation Damper Abnormality
— 879FMC – Air Mix Damper Abnormality
— 879GKX – Refrigerant Abnormality
— 989L00 – Engine Controller Lock Caution 1
— 989M00 – Engine Controller Lock Caution 2
— 989N00 – Engine Controller Lock Caution 3
— A1U0N3 – KDPF Dry Request (HC Release) 1
— A1U0N4 – KDPF Dry Request (HC Release) 2
— AA10NX – Air Cleaner Clogging
— AB00KE – Charge Voltage Low
— B@BAZG – Engine Oil Pressure Low
— B@BAZK – Eng Oil Level Low
— B@BCNS – Engine Coolant Overheat
— B@BCZK – Radiator Coolant Level Low
— B@HANS – Hyd Oil Overheat
— CA115 – Eng Ne and Bkup Speed Sens Error
— CA122 – Chg Air Press Sensor High Error
— CA123 – Chg Air Press Sensor Low Error
— CA131 – Throttle Sensor High Error
— CA132 – Throttle Sensor Low Error
— CA144 – Coolant Temp Sens High Error
— CA145 – Coolant Temp Sens Low Error
— CA153 – Chg Air Temp Sensor High Error
— CA154 – Chg Air Temp Sensor Low Error
— CA187 – Sensor 2 Supply Volt Low Error
— CA221 – Ambient Press Sensor High Error
— CA222 – Ambient Press Sensor Low Error
— CA227 – Sensor 2 Supply Volt High Error
— CA234 – Eng Overspeed
— CA238 – Ne Speed Sensor Supply Volt Error
— CA239 – Ne Speed Sens Supply Volt High Error
— CA271 – IMV/PCV1 Short Error
— CA272 – IMV/PCV1 Open Error
— CA281 – Pump Press Balance Error
— CA295 – Ambient Press Sens In Range Error
— CA322 – Inj #1 (L#1) Open/Short Error
— CA323 – Inj #5 (L#5) Open/Short Error
— CA324 – Inj #3 (L#3) Open/Short Error
— CA325 – Inj #6 (L#6) Open/Short Error
— CA331 – Inj #2 (L#2) Open/Short Error
— CA332 – Inj #4 (L#4) Open/Short Error
— CA343 – ECM Critical Internal Failure
— CA351 – Injectors Drive Circuit Error
— CA352 – Sensor 1 Supply Volt Low Error
— CA356 – Mass Air Flow Sensor High Error
— CA357 – Mass Air Flow Sensor Low Error
— CA386 – Sensor 1 Supply Volt High Error
— CA428 – Water in Fuel Sensor High Error
— CA429 – Water in Fuel Sensor Low Error
— CA435 – Eng Oil Press Sw Error
— CA441 – Battery Voltage Low Error
— CA442 – Battery Voltage High Error
— CA449 – Rail Press Very High Error
— CA451 – Rail Press Sensor High Error
— CA452 – Rail Press Sensor Low Error
— CA488 – Chg Air Temp High Torque Derate
— CA515 – Rail Press Sens Sup Volt High Error
— CA516 – Rail Press Sens Sup Volt Low Error
— CA553 – Rail Press High Error 1
— CA555 – Crankcase Press High Error 1
— CA556 – Crankcase Press High Error 2
— CA559 – Rail Press Low Error 1
— CA595 – Turbo Speed High Error 2
— CA687 – Turbo Speed Low Error
— CA689 – Eng Ne Speed Sensor Error
— CA691 – Intake Air Temp Sens High Error
— CA692 – Intake Air Temp Sens Low Error
— CA697 – ECM Int Temp Sensor High Error
— CA698 – ECM Int Temp Sensor Low Error
— CA731 – Eng Bkup Speed Sens Phase Error
— CA778 – Eng Bkup Speed Sensor Error
— CA1117 – Persistent Data Lost Error
— CA1664 – KDOC Malfunction
— CA1691 – Regeneration Ineffective
— CA1695 – Sensor 5 Supply Volt High Error
— CA1696 – Sensor 5 Supply Volt Low Error
— CA1843 – Crankcase Press Sens High Error
— CA1844 – Crankcase Press Sens Low Error
— CA1879 – KDPF Differential P Sensor High Error
— CA1881 – KDPF Differential P Sensor Low Error
— CA1883 – KDPF Differential P Sens In Range Error
— CA1921 – KDPF Soot Load High Error 1
— CA1922 – KDPF Soot Load High Error 2
— CA1942 – Crankcase Press Sens In Range Error
— CA1993 – KDPF Differential Pressure Low Error
— CA2185 – Throt Sensor Sup Volt High Error
— CA2186 – Throt Sensor Sup Volt Low Error
— CA2249 – Rail Press Very Low Error
— CA2265 – Fuel Feed Pump Open Error
— CA2266 – Fuel Feed Pump Short Error
— CA2271 – EGR Valve Pos Sens High Error
— CA2272 – EGR Valve Pos Sens Low Error
— CA2288 – Turbo Speed High Error 1
— CA2311 – IMV Solenoid Error
— CA2349 – EGR Valve Solenoid Open Error
— CA2353 – EGR Valve Solenoid Short Error
— CA2357 – EGR Valve Servo Error
— CA2373 – Exhaust Manifold Press Sens High error
— CA2374 – Exhaust Manifold Press Sens Low Error
— CA2375 – EGR Orifice Temp Sens High Error
— CA2376 – EGR Orifice Temp Sens Low Error
— CA2381 – KVGT Pos Sens High Error
— CA2382 – KVGT Pos Sens Low Error
— CA2383 – KVGT Solenoid Open Error
— CA2386 – KVGT Solenoid Short Error
— CA2387 – KVGT Valve Servo Error
— CA2554 – Exh Manifold Press Sens In Range Error
— CA2555 – Grid Htr Relay Open Circuit Error
— CA2556 – Grid Htr Relay Volt High Error
— CA2637 – KDOC Blocked
— CA2639 – Manual Stationary Regeneration Request
— CA2961 – EGR Orifice Temp High Error 1
— CA2973 – Chg Air Press Sensor In Range Error
— CA3133 – KDPF Outlet Press Sens High Error
— CA3134 – KDPF Outlet Press Sens Low Error
— CA3135 – KDPF Outlet Press Sens In Range Error
— CA3251 – KDOC Inlet Temp High Error
— CA3253 – KDOC Temp Error – Non Regeneration
— CA3254 – KDOC Outlet Temp High Error 1
— CA3255 – KDPF Temp Error – Non Regeneration
— CA3256 – KDPF Outlet Temp High Error 1
— CA3311 – KDOC Outlet Temp High Error 2
— CA3312 – KDPF Outlet Temp High Error 2
— CA3313 – KDOC Inlet Temp Sensor Low Error
— CA3314 – KDOC Inlet Temp Sens High Error
— CA3315 – KDOC Inlet Temp Sens In Range Error
— CA3316 – KDOC Outlet Temp Sens Low Error
— CA3317 – KDOC Outlet Temp Sens High Error
— CA3318 – KDOC Outlet Temp Sens In Range Error
— CA3319 – KDPF Outlet Temp Sens High Error
— CA3321 – KDPF Outlet Temp Sens Low Error
— CA3322 – KDPF Outlet Temp Sens In Range Error
— CA3419 – Mass Air Flow (MAF) Sensor Sup Volt High Error
— CA3421 – Mass Air Flow (MAF) Sensor Sup Volt Low Error
— CA3741 – Rail Press Valve Trip Error
— D110KB – Battery Relay Output Voltage
— D19JKZ – Personal Code Relay Abnormality
— D811MC – KOMTRAX Error
— D862KA – GPS Antenna Open Circuit
— D8AQKR – CAN2 Discon (KOMTRAX)
— DA20MC – Pump Controller
— DA22KK – Pump Solenoid Power Low Error
— DA25KP – 5 V Sensor 1 Power Abnormality
— DA29KQ – Model Selection Abnormality
— DA2QKR – CAN2 Discon ( Pump Con)
— DA2RKR – CAN1 Discon ( Pump Con)
— DAF0MB – Monitor Memory Error
— DAF0MC – Monitor Error
— DAF8KB – Camera Power Supply Short Circuit
— DAF9KQ – Model Selection Abnormality
— DAFGMC – GPS Module Error
— DAFQKR – CAN2 Discon
— DAZ9KQ – A/C Model Selection Abnormality
— DAZQKR – CAN2 Discon (AC)
— DB2QKR – CAN2 Discon (Engine Con)
— DB2RKR – CAN1 Discon (Engine Con)
— DGH2KB – Hyd Oil Sensor Short Circuit
— DHA4KA – Air Cleaner Clog Sensor Open Circuit
— DHPAMA – F Pump Press Sensor Abnormality
— DHPBMA – R Pump Press Sensor Abnormality
— DHS3MA – Arm In PPC Press Sensor Abnormality
— DHS4MA – Bucket Curl PPC Press Sensor Abnormality
— DHS8MA – Boom Raise PPC Press Sensor Abnormality
— DHS9MA – Boom Lower PPC Press Sensor Abnormality
— DHSAMA – Swing RH PPC Press Sensor Abnormality
— DHSBMA – Swing LH PPC Press Sensor Abnormality
— DHSCMA – Arm Out PPC Press Sensor Abnormality
— DHSDMA – Bucket Dump PPC Press Sensor Abnormality
— DHSFMA – Travel Fwd LH PPC Press Sensor Abnormality
— DHSGMA – Travel Fwd RH PPC Press Sensor Abnormality
— DHSHMA – Travel Rev LH PPC Press Sensor Abnormality
— DHSJMA – Travel Rev RH PPC Press Sensor Abnormality
— DKR0MA – F Pump Swash Plate Sensor Abnormality
— DKR1MA – R Pump Swash Plate Sensor Abnormality
— DV20KB – Travel Alarm Short Circuit
— DW43KA – Travel Speed Sol Open Circuit
— DW43KB – Travel Speed Sol Short Circuit
— DW45KA – Swing Brake Sol Open Circuit
— DW45KB – Swing Brake Sol Short Circuit
— DW91KA – Travel Junction Sol Open Circuit
— DW91KB – Travel Junction Sol Short Circuit
— DWA2KA – Attachment Sol Open Circuit
— DWA2KB – Attachment Sol Short Circuit
— DWK0KA – 2-Stage Relief Sol Open Circuit
— DWK0KB – 2-Stage Relief Sol Short Circuit
— DWK2KA – Variable Back Press Sol Open Circuit
— DWK2KB – Variable Back Press Sol Short Circuit
— DWK8KA – Swing Press C/O Sol Open Circuit
— DWK8KB – Swing Press C/O Sol Short Circuit
— DXA8KA – PC-EPC (F) Sol Open Circuit
— DXA8KB – PC-EPC (F) Sol Short Circuit
— DXA9KA – PC-EPC (R) Sol Open Circuit
— DXA9KB – PC-EPC (R) Sol Short Circuit
— DXE0KA – LS-EPC Sol Open Circuit
— DXE0KB – LS-EPC Sol Short Circuit
— DXE4KA – Attachment Flow EPC Open Circuit
— DXE4KB – Attachment Flow EPC Short Circuit
— DXE5KA – Merge-divide Main Sol Open Circuit
— DXE5KB – Merge-divide Main Sol Short Circuit
— DXE6KA – Merge-divide LS Sol Open Circuit
— DXE6KB – Merge-divide LS Sol Short Circuit
— DY20KA – Wiper Working Abnormality
— DY20MA – Wiper Parking Abnormality
— DY2CKB – Washer Drive Short Circuit
— DY2DKB – Wiper Drive (Fwd) Short Circuit
— DY2EKB – Wiper Drive (Rev) Short Circuit
– ELECTRICAL SYSTEM (E-MODE)
— E-1 Engine Does Not Start (Engine Does Not Rotate)
— E-2 Manual Pre-Heating System Does Not Work
— E-3 Automatic Pre-Heating System Does Not Work
— E-4 Pre-Heating Monitor Does Not Light Up When Pre-Heater is Operated
— E-5 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing
— E-6 When Starting Switch is Turned to ON Position (Before Starting Engine), Engine Oil Level Monitor Lights Up in Yellow
— E-7 When Starting Switch is Turned to ON Position (Before Starting Engine), Radiator Coolant Level Monitor Lights Up in Yellow
— E-8 Coolant Temperature Monitor Lights Up in White While Engine is Running
— E-9 Hydraulic Oil Temperature Monitor Lights Up in White While Engine is Running
— E-10 Charge Level Monitor Lights Up While Engine is Running
— E-11 Fuel Level Monitor Lights Up in Red While Engine is Running
— E-12 Air Cleaner Clogging Monitor Lights Up in Yellow While Engine is Running
— E-13 Engine Coolant Temperature Monitor Lights Up in Red While Engine is Running
— E-14 Hydraulic Oil Temperature Monitor Lights Up in Red While Engine is Running
— E-15 Engine Oil Pressure Monitor Lights Up in Red While Engine is Running
— E-16 Fuel Gauge Display Does Not Move from Minimum or Maximum
— E-17 Display of Fuel Gauge Differs from Actual Fuel Level
— E-18 Coolant Temperature Gauge Indicate Either Min or Max and Does Not Move
— E-20 Hydraulic Oil Temperature Gauge Indicate Either Min or Max and Does Not Move
— E-21 Hydraulic Oil Temperature Gauge Differs from Actual oil Temperature
— E-22 Machine Monitor Does Not Display Partially
— E-23 Function Switch Does Not Work
— E-24 Automatic Pre-Heating System Does Not Work (In Cold Weather)
— E-25 Auto-Deceleration Monitor Does Not Light Up or Does Not Go Out When Auto-Deceleration Switch is Operated
— E-26 Auto-Deceleration is Not Actuated or Canceled When Lever is Operated
— E-27 Working Mode Selector Screen Selection Screen is Not Displayed When Working Mode Switch is Operated
— E-28 Engine or Hydraulic Pump Setting Does Not Change When Working Mode is Changed
— E-29 Travel Speed Monitor Does Not Change When Travel Speed Switch is Operated
— E-32 Travel Speed Does Not Change When Travel Speed is Shifted
— E-31 Alarm Buzzer Does Not Stop Sounding
— E-32 When Starting Switch is Turned OFF, Service Meter is Not Displayed
— E-33 Machine Monitor Service Mode Cannot be Selected
— E-34 Any of Work Equipment, Swing and Travel Does Not Work
— E-35 Any of Work Equipment, Swing and Travel Can Not be Locked
— E-36 Machine Can Not Swing While Swing Brake Cancel Switch is Canceled
— E-37 Swing Brake Does Not Operate While Swing Brake Cancel Switch is set to NORMAL position
— E-38 One-Touch Power Maximizing Function Does Not Work Or Pilot Monitor is Not Displayed
— E-39 One-Touch Power Maximizing Function Cannot be Released
— E-40 Travel Alarm Does Not Sound When Machine Travels
— E-41 Travel Alarm Does Not Stop Sounding When Machine Stops
— E-42 Horn Does Not Sound
— E-43 Horn Does Not Stop Sounding
— E-44 Wiper Monitor Does Not Light Up or Go Out When Wiper Switch is Operated
— E-45 Wiper Does Not Operate When Wiper Switch is Operated
— E-46 Window Washer Does Not Operate When Window Washer Switch is Operated
— E-47 Boom LOWER Indication is Not Displayed Properly With Monitoring Function
— E-48 Arm DUMP Indication is Not Displayed Properly With Monitoring Function
— E-49 Arm IN Indication is Not Displayed Properly With Monitoring Function
— E-50 BooM RAISE Indication is Not Displayed Properly With Monitoring Function
— E-51 Bucket CURL Indication is Not Displayed Properly With Monitoring Function
— E-52 Bucket DUMP Indication is Not Displayed Properly With Monitoring Function
— E-53 Swing Indication is Not Displayed Properly With Monitoring Function
— E-54 Travel Indication is Not Displayed Properly With Monitoring Function
— E-55 Attachment is Not Displayed Properly With Monitoring Function
— E-56 Attachment Hydraulic Circuit Cannot be Changed
— E-57 KOMTRAX System Does Not Work Properly
— E-58 Machine Push-up Function is Not Canceled
– HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)
— Information Mentioned in Troubleshooting Table (H Mode)
— Failure Mode and Cause Table
— H-1 All of Work Equipment, Swing and Travel Operation Lacks Speed or Power
— H-2 Engine Speed Lowers Significantly or Engine Stalls
— H-3 Any of Work Equipment, Swing and Travel Does Not Work
— H-4 Unusual Sound is Heard from Around Hydraulic Pump
— H-5 Fine Control Performance or Response is Poor
— H-6 Boom Operation Lacks Speed or Power
— H-7 Arm Operation Lacks Speed or Power
— H-8 Bucket Operation Lacks Speed or Power
— H-9 Work Equipment Does Not Move in Single Operation
— H-10 Hydraulic Drift of Boom is Large
— H-11 Hydraulic Drift of Arm is Large
— H-12 Hydraulic Drift of Bucket is Large
— H-13 Time Lag of Work Equipment is Large
— H-14 When Part of Work Equipment is Relieved Singly, Other Parts of Work Equipment Move
— H-15 One-Touch Power Maximizing Function Does Not Work
— H-16 Machine Push Up Function Does Not Work
— H-17 In Combined Operation of Work Equipment, Equipment Having Heavier Load Moves Slower
— H-18 In Combined Operations of Swing and Boom RAISE, Boom Rising Speed is Low
— H-19 In Combined Operations of Swing and Travel, Travel Speed Drops Largely
— H-20 Machine Does Not Travel Straight
— H-21 Travel Speed is Too Low
— H-22 Machine is hard to Steer or Travel Power is Low
— H-23 Travel Speed Does Not Change, or Travel Speed is Too Low or High
— H-24 One of Tracks Dose Not Run
— H-25 Upper Structure Does Not Swing to the Right or Left
— H-26 Upper Structure Swing Only to the Right or Left
— H-27 Swing Acceleration is Poor or Swing Speed is Low (Either Right and Left)
— H-28 Swing Aceleration is Poor or Swing Speed is Low in Only One Direction
— H-29 Upper Structure Overruns Excessively When it Stops Swinging (Both Right and Left)
— H-30 Upper Structure Overruns Excessively When it Stops Swinging (Either Right or Left)
— H-31 Shock is Large When Upper Structure Stops Swinging
— H-32 Large Unusual Noise is Heard When Upper Structure Stops Swinging
— H-33 When Swing Holding Brake is Applied, Hydraulic Drift of Swing is Large
— H-34 When Swing Holding Brake is Released, Hydraulic Drift Of Swing is Large
— H-35 When additional attachment is installed, attachment circuit is not switched
— H-36 Oil Flow in Attachment Circuit Cannot be Controlled
– ENGINE (S-MODE)
— Information Mentioned in Troubleshooting Table (S-Mode)
— S-1 When Starting Switch is Turned to START Position, Engine Does Not Crank
— S-2 When Engine Cranks, Exhaust Smoke Does Not Come Out
— S-3 Fuel is Being Injected But Engine Does Not Start (Incomplete Combustion: Engine Cranks but Does Not Start)
— S-4 Startability is Poor
— S-5 Engine Does Not Pick Up Smoothly
— S-6 Engine Stops During Operation
— S-7 Engine Runs Rough or is Unstable
— S-8 Engine Lacks Power
— S-9 Exhaust Smoke is Black (KDPF Clogs Up Early)
— S-10 Engine Oil Consumption is Excessive
— S-11 Oil Becomes Contaminated Early
— S-12 Fuel Consumption is Excessive
— S-13 Oil is in Coolant (or Coolant Spurts or Coolant Level Goes Down)
— S-14 Oil Pressure Drops
— S-15 Fuel is Contaminated in Engine Oil
— S-16 Coolant Mixes in Engine Oil (Oil Becomes Cloudy White)
— S-17 Coolant Temperature Rises Too High (Overheating)
— S-18 Unusual Noise is Heard
— S-19 Vibration is Excessive
— S-20 Air Cannot be Bled from Fuel Circuit
— S-21 Automatic Regeneration is Operated Frequently
— S-22 Active Regeneration is Operated for Long
— S-23 White Smoke Comes Out in the Process of Active Regeneration
50 DISASSEMBLY AND ASSEMBLY
– HOW TO READ THIS SECTION
— Removal and Installation of Assemblies
— Special Tools
— Removal
— Installation
— Disassembly and Assembly of Assemblies
— Special Tools
— Disassembly
— Assembly
— Coating Materials List
– SPECIAL TOOLS LIST
— Sketches of Special Tools
– CONNECTOR REPAIR PROCEDURES
— Stripping Insulation
— Wire Inspection
— Contact Terminal Removal (HD30 Type)
— Crimping Contact Terminal (HD30 Type)
— Insertion of Contact Terminal (HD30 Type)
— Contact Terminal Removal (DT Type)
— Crimping Contact Terminal (DT Type)
— Insertion of Contact Terminal (DT Type)
– ENGINE AND COOLING SYSTEM
— Supply Pump Assembly
— Removal
— Installation
— Fuel Injector Assembly
— Removal
— Installation
— Cylinder Head Assembly
— Removal
— Installation
— Radiator Assembly
— Removal
— Installation
— Hydraulic Oil Cooler Assembly
— Removal
— Installation
— Aftercooler Assembly
— Removal
— Installation
— Engine and Main Pump Assembly
— Removal
— Installation
— Engine Front Oil Seal
— Removal
— Installation
— Engine Rear Oil Seal
— Removal
— Installation
— Fuel Tank Assembly
— Removal
— Installation
— Engine Hood Assembly
— Removal
— Installation
— KDPF Assembly
— Removal
— Installation
— Disassembly
— Assembly
— KCCV Assembly
— Removal
— Installation
— Air Cleaner Assembly
— Removal
— Installation
— Air Conditioner Compressor Assembly
— Removal
— Installation
— Air Conditioner Condenser Assembly
— Removal
— Installation
– POWER TRAIN
— Travel Motor and Final Drive Assembly
— Removal
— Installation
— Final Drive (PC360LC-10)
— Disassembly
— Assembly
— Final Drive (PC390LC-10)
— Removal
— Installation
— Disassembly
— Assembly
— Swing Motor and Swing Machinery Assembly (PC360LC-10)
— Removal
— Installation
— Swing Motor and Swing Machinery (PC390LC-10)
— Removal
— Installation
— Swing Machinery (PC360LC-10)
— Disassembly
— Assembly
— Swing Machinery (PC390LC-10)
— Disassembly
— Assembly
— Swing Circle Assembly (PC360LC-10)
— Removal
— Installation
— Swing Circle Assembly (PC390LC-10)
— Removal
— Installation
– UNDERCARRIAGE AND FRAME
— Track Shoe Assembly
— Separation
— Installation
— Sprocket
— Removal
— Installation
— Idler and Idler Cushion Assembly
— Removal
— Installation
— Idler
— Disassembly
— Assembly
— Idler Cushion (PC360LC-10)
— Disassembly
— Assembly
— Idler Cushion (PC390LC-10)
— Disassembly
— Assembly
— Track Roller
— Disassembly
— Assembly
— Carrier Roller
— Disassembly
— Assembly
— Revolving Frame Assembly
— Removal
— Installation
— Counterweight Assembly
— Removal
— Installation
– HYDRAULIC SYSTEM
— Center Swivel Joint Assembly
— Removal
— Installation
— Disassembly
— Disassembly
— Assembly
— Hydraulic Tank Assembly
— Removal
— Installation
— Main Pump Assembly
— Removal
— Installation
— Control Valve Assembly
— Removal
— Installation
— Disassembly
— Replacing Procedures of Pressure Compensation Valve Seal
— Assembly
— Work Equipment PPC Valve
— Disassembly
— Assembly
— Travel PPC Valve
— Disassembly
— Assembly
– WORK EQUIPMENT
— Bucket Assembly
— Removal
— Installation
— Arm Assembly
— Removal
— Installation
— Work Equipment Assembly
— Removal
— Installation
— Work Equipment Cylinder
— Disassembly
— Assembly
– CAB AND ITS ATTACHMENTS
— Operator’s Cab Assembly
— Removal
— Installation
— Operator Cab Glass (Fixed Glass)
— Removal
— Installation
— Front Window Assembly
— Removal
— Installation
— Floor Frame Assembly
— Removal
— Installation
— Air Conditioner Unit Assembly
— Removal
— Installation
— Operator’s Seat
— Removal
— Installation
— Seat Belt
— Removal
— Installation
— Front Wiper Assembly
— Removal
— Installation
– ELECTRIC SYSTEM
— Engine Controller Assembly
— Removal
— Installation
— Pump Controller Assembly
— Removal
— Installation
— Machine Monitor Assembly
— Removal
— Installation
— Pump Swash Plate Sensor
— Removal
— Installation
— Mass Air Flow and Temperature Sensor
— Removal
— Installation
— KOMTRAX Terminal Assembly
— Removal
— Installation
60 MAINTENANCE STANDARD
– ENGINE AND COOLING SYSTEM
— Engine Mounts
— Cooling System
– POWER TRAIN
— Swing Circle
— Swing Machinery
— Final Drive
— PC360LC-10
— PC390LC-10
— Sprocket
— PC360LC-10
— PC390LC-10
– UNDERCARRIAGE AND FRAME
— Track Frame and Idler Cushion
— Idler
— PC360LC-10
— PC390LC-10
— Track Roller
— PC360LC-10
— PC390LC-10
— Carrier Roller
— PC360LC-10
— PC390LC-10
— Track Shoe
— PC360LC-10
— PC390LC-10
— Triple Grouser Shoe
— PC360LC-10
— PC390LC-10
– HYDRAULIC SYSTEM
— Hydraulic Tank
— Main Pump
— Control Valve
— General View
— Sectional View (1/5)
— Sectional View (2/5)
— Sectional View (3/5)
— Sectional View (4/5)
— Sectional View (5/5)
— Swing Motor
— Travel Motor
— PPC Valve
— Work Equipment and Swing PPC Valve
— Travel PPC Valve
— 1st-Line Attachment PPC Valve (with EPC Valve)
— EPC Valve
— 2nd-Line Attachment PPC Valve
— Solenoid Valve
— Attachment Circuit Selector Valve
— Center Swivel Joint
– WORK EQUIPMENT
— Dimensions of Components
— Dimensions of Arm
— Boom Cylinder
— Arm Cylinder
— Bucket Cylinder
80 AIR CONDITIONER
– AIR CONDITIONER
— Precautions for Refrigerant
— Air Conditioner Component
— Structure and Function of Refrigeration System
— Overview of Refrigeration System
— Air Conditioner Unit
— Function
— Functions of Major Components
— Dual Pressure Switch
— Air Conditioner Controller
— Air Conditioner Compressor
— Air Conditioner Condenser
— Receiver Drier
— Sunlight Sensor
— Outside Air Temperature Sensor
— Procedure for Testing and Troubleshooting
— Basic Inspection and Troubleshooting Sequence
— Air Conditioner Circuit Diagram and Arrangement of Connector Pins
— System Diagram
— Air Conditioner Controller Input and Output Signals
— Parts and Connectors Layout
— Layout of Air Conditioner Related Parts and Connectors
— Testing Air Leakage (Duct)
— Testing with Self-Diagnosis Function
— How to Enter Air Conditioner “Electrical Systems” Screen in Service Mode of the Machine Monitor
— Testing Vent (Mode) Changeover
— Testing FRESH/RECIRC Air Changeover
— Testing Sunlight Sensor
— Testing (Dual) Pressure Switch for Refrigerant
— Testing Relay
— Troubleshooting Chart 1
— Troubleshooting Chart 2
— Information Mentioned in Troubleshooting Table
— Information in Troubleshooting Table
— Failure Code List Related to Air Conditioner
— 879AKA – A/C Inner Sensor Open Circuit
— 879AKB – A/C Inner Sensor Short Circuit
— 879BKA – A/C Outer Sensor Open Circuit
— 879BKB – A/C Outer Sensor Short Circuit
— 879CKA – Ventilating Sensor Open Circuit
— 879CKB – Ventilating Sensor Short Circuit
— 879DKZ – Sunlight Sensor Open or Short Circuit
— 879EMC – Ventilation Damper Abnormality
— 879FMC – Air Mix Damper Abnormality
— 879GKX – Refrigerant Abnormality
— A-1 Troubleshooting for Power Supply System (The Air Conditioner Does Not Operate)
— A-2 Troubleshooting of Compressor System (Air is Not Cooled)
— A-3 Troubleshooting of Blower Motor System (Air Does Not Come Out or Air Flow is Normal)
— A-4 Troubleshooting for FRESH/RECIRC Air Changeover
— Troubleshooting with Gauge Pressure
— [Measurement Condition for Pressure]
— Testing Refrigerant Pressure
— Check
— Precautions for Disconnecting and Connecting Refrigerant Piping
— Disconnection
— Connection
— Tightening Torque for Joint Portion of Refrigerant Piping
— Handling of Compressor Oil
— Oil Level Control of Compressor
— Refilling of Compressor Oil
90 DIAGRAMS AND SCHEMATICS
– HYDRAULIC SYSTEM
— Hydraulic Circuit Symbols
— Hydraulic Circuit Diagram
– ELECTRICAL SYSTEM
— Electrical Symbols
— Air Conditioner Electrical Diagram
— Electrical Circuit Diagram (1/6)
— Electrical Circuit Diagram (2/6)
— Electrical Circuit Diagram (3/6)
— Electrical Circuit Diagram (4/6)
— Electrical Circuit Diagram (5/6)
— Electrical Circuit Diagram (6/6)