Komatsu Hydraulic Excavators PC360LC-10, PC390LC-10, PC360LCi-11, PC390LCi-11 Repair Service Manuals
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Model:
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavators PC360LC-10, PC390LC-10, PC360LCi-11, PC390LCi-11, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Komatsu Hydraulic Excavators PC360LC-10, PC390LC-10, PC360LCi-11, PC390LCi-11 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
CEAM025404 - Hydraulic Excavator PC360LC-10, PC390LC-10 Operation & Maintenance Manual.pdf
CEBM025204 - Hydraulic Excavator PC360LC-10, PC390LC-10 Shop Manual.pdf
CEBM025205 - Hydraulic Excavator PC360LC-10, PC390LC-10 Shop Manual.pdf
CEBM031702 - Hydraulic Excavator PC360LCi-11, PC390LCi-11 Shop Manual.pdf
Total Pages: 8,075 pages
File Format: PDF
Language: English
CEAM025404 - Hydraulic Excavator PC360LC-10, PC390LC-10 Operation & Maintenance Manual...2
CEAM025404 PC360LC-10_PC390LC-10...2
INTRODUCTION...4
FOREWORD...5
BASIC MACHINE INTRODUCTION...7
Directions of Machine...7
Visibility from Operator’s Seat...7
Rollover Protective Structure (ROPS)...7
Breaking-In the New Machine...8
Product Information...9
Product Identification Number (Pin)/Machine Serial No. Plate...9
EPA* Regulations, Engine Number Plate...9
Service Meter Location...10
Your Machine Serial Numbers and Distributor...10
Engine Acronyms...10
TABLE OF CONTENTS...11
SAFETY...22
SAFETY LABELS...23
Location of Safety Labels...24
Safety Labels...25
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE...34
Precautions Before Starting Operation...34
Ensuring Safe Operation...34
Understanding the Machine...34
Preparations for Safe Operation...34
Precautions Regarding Safety-Related Equipment...34
Inspecting Machine...34
Clothing and Personal Protective Items...34
Keep Machine Clean...35
Keep Operator's Compartment Clean...35
Fire Extinguisher and First Aid Kit...35
Safety Equipment...35
If Problems are Found...35
Fire Prevention and Explosion Prevention...36
Action if Fire Occurs...37
Handrails and Steps...38
Mounting and Dismounting...38
No Persons on Attachments...38
Leaving Operator's Seat with Lock...39
Emergency Exit from Operator's Cab...39
Do Not Get Caught in Work Equipment...39
Precautions Related to Protective Structures...40
Falling Objects, Flying Objects and Intruding Objects Prevention...40
Unauthorized Modification...41
Precautions Related to Attachments and Options...41
Precautions Related to Cab Glass...41
Precautions When Running Engine Inside Building...41
Safety at Job Site...42
Working on Loose Ground...42
Distance to High Voltage Cables...43
Ensure Good Visibility...43
Signalman's Signal and Signs...43
Asbestos Dust Hazard Prevention...44
SAFETY MACHINE OPERATION...45
Starting Engine...45
Checks Before Starting Engine...45
Safety Rules for Starting Engine...46
Starting Engine in Cold Weather...46
Starting Engine with Booster Cables...46
Operation...47
Checks Before Operation...47
Safety Rules for Changing Machine Directions...47
Safety Rules for Traveling...48
Traveling on Slopes...49
Operations on Slopes...50
Prohibited Operations...51
Operations on Snow or Frozen Surfaces...53
Parking Machine...53
TRANSPORTATION...54
Loading and Unloading...54
Shipping the Machine...54
TOWING...55
Safety Rules for Towing...55
LIFTING OBJECTS WITH BUCKET...56
Safety Rules for Lifting Objects...56
SAFETY MAINTENANCE INFORMATION...57
Warning Tag...57
Keep Work Place Clean and Tidy...57
Select Suitable Place for Inspection and Maintenance...57
Only Authorized Personnel...57
Appoint Leader When Working with Others...57
Stop Engine Before Carrying Out Maintenance...58
Precautions When Working at High Places...58
Two Workers for Maintenance When Engine is Running...59
Attachments...59
Work on Machine...60
Work Under the Machine...60
Proper Tools...60
Battery Disconnect Switch...61
Removing Battery Terminals...61
Welding...61
Battery...61
Battery Hazard Prevention...61
When Using Hammer...62
Precautions with High-temperature Coolant...62
Precautions with High-Temperature Oil...63
Safety Rules for High-Pressure Oil...63
Precaution for High Fuel Pressure...63
Safety Handling High-Pressure Hoses or Piping...63
Precaution for High Voltage...64
Noise...64
Safety First When Using High-Pressure Grease to Adjust Track Tension...64
Do Not Disassemble Recoil Springs...65
Accumulator...65
Handling Gas Spring...65
Precautions When Using...65
Precautions When Discarding...66
Compressed Air...66
Air Conditioner Maintenance...66
Waste Materials...66
Select Window Washer Fluid...66
Personnel...66
Periodic Replacement of Safety Critical Parts...67
OPERATION...68
MACHINE VIEW ILLUSTRATIONS...69
Overall Machine View...69
General View of Cab...71
General View of Controls and Gauges...72
Machine Monitor...73
EXPLANATION OF COMPONENTS...74
Machine Monitor...74
Basic Operation of Machine Monitor...75
Warning Display...80
Pilot Display, Meter Display...91
Gauges and Meter...98
Monitor Switches...102
Handling Function Switches...113
User Menu Selector Switch...118
User Menu...118
Machine Settings...130
Maintenance Screen Setting...136
Monitor Setting...137
Screen Adjustment...138
Screen Adjustment (Camera)...139
Clock Adjustment...140
Time...142
SWITCHES...147
Starting Switch...148
Fuel Control Dial...148
Cigarette Lighter...148
Swing Lock Switch...149
Lamp Switch...149
Horn Switch...149
One Touch Power Max. Switch...150
Room Lamp Switch...150
Emergency Pump Drive Switch...150
Swing Brake Cancel Switch...151
Engine Shutdown Secondary Switch...151
Seat Heater Switch...152
Machine Push-Up Switch...152
CONTROL LEVERS AND PEDALS...153
Lock Lever...153
Travel Levers...154
Work Equipment Control Lever...155
ROOF WINDOW...156
WINDSHIELD...157
EMERGENCY ESCAPE HAMMER...163
DOOR LOCK...164
CAB DOOR HINGE...164
ENGINE HOOD...165
When Opening...165
When Closing...166
CAPS AND COVERS WITH LOCK...167
Open and Close Caps with Lock...167
Opening the Cap...167
Locking the Cap...167
Open and Close Covers with Lock...168
Opening the Cover (Locked Cover)...168
Locking the Cover...168
Lock and Unlock Engine Hood...168
Opening the Hood (Locked Hood)...168
Locking the Hood...168
Lock and Unlock Cab Door...169
Opening the Door (Locked Door)...169
Locking the Door...169
DRINK BOX...169
MAGAZINE BOX...169
CUP HOLDER...170
ASHTRAY...170
AIR CONDITIONER CONTROLS...171
Air Conditioner Control Panel...171
Method of Operation...175
Automatic Operation...175
Stopping Automatic Operation...176
Manual Operation...177
Stop Manual Operation...178
Operation with Cold Air to Face and Warm Air to Feet...179
Defroster Operation...181
Rules for Using Air Conditioner...183
Air Conditioner Maintenance...183
RADIO...184
Control Panel...184
Operation Method...186
Frequency Adjustment...186
Frequency Adjustment (Auto Presetting)...186
Preset Call...186
Preset Memory...186
Sound Adjustment (Balance)...186
Sound Adjustment (Treble)...186
Sound Adjustment (Bass)...187
Time Adjustment...187
Stowing Radio Antenna...187
AUXILIARY ELECTRIC POWER...188
24 V Power Source...188
12 V Power Source...188
FUSE...189
FUSIBLE LINK...190
TOOL BOX...190
GREASE GUN HOLDER...190
FIRE EXTINGUISHER...190
BATTERY DISCONNECT SWITCH...191
SYSTEM OPERATING LAMP...192
HANDLING KOMATSU DIESEL PARTICULATE FILTER (KDPF)...193
Operation Procedure of Manual Stationary Regeneration...196
Komatsu Diesel Particulate Filter (KDPF) Regeneration Disable Procedure...199
While Regeneration is not Being Performed: Setting for Regeneration Disable...199
While Regeneration is Being Performed: Stopping Regeneration...201
Re-enabling KDPF Regeneration...202
Handling Komatsu Closed Crankcase Ventilation (KCCV)...202
HANDLING MACHINES EQUIPPED WITH KOMTRAX...203
Basic Precautions...203
MACHINE OPERATIONS AND CONTROLS...204
Before Starting Engine...204
Walk-Around Checks...204
Checks Before Starting...206
Adjustments...214
Seat Belt Inspection...223
Seat Belt...224
Operations Before Starting Engine...225
STARTING ENGINE...228
Automatic Pre-Heating...228
Manual Pre-Heating...230
Turbo Protect Function...231
AFTER STARTING ENGINE...232
Checking of Engine Start Ability and Abnormal Noise...232
Check Engine Acceleration and Deceleration...232
Breaking-in the New Machine...233
Engine Warm Up...233
Canceling Automatic Warm-up Operation...235
Hydraulic System Warm-Up...236
Operation After Completion Of Warming-Up Operation...242
STOPPING THE ENGINE...244
MACHINE OPERATION...245
Preparations for Moving the Machine...245
Moving Machine Forward...246
Moving Machine Backward...247
Stopping Machine...248
STEERING THE MACHINE...249
Steering...249
Steering the Machine When Stopped...249
Changing Direction of the Machine...250
Counter-rotation Turn (Spin Turn)...250
SWINGING THE MACHINE...251
WORK EQUIPMENT CONTROLS AND OPERATIONS...253
WORKING MODE...255
Working Mode Switch...255
One-Touch Power Max. Switch...257
PROHIBITED OPERATIONS...258
GENERAL OPERATION INFORMATION...263
Traveling...263
High Speed Travel...263
Permissible Water Depth...263
TRAVELING ON SLOPES...265
ESCAPE FROM MUD...267
Track on One Side Stuck...267
Tracks on Both Sides Stuck...267
RECOMMENDED APPLICATIONS...268
Backhoe Work...268
Shovel Work...268
Ditching Work...268
Loading Work...269
BUCKET REPLACEMENT AND INVERSION...270
Replacement...270
Inversion...271
PARKING MACHINE...273
MACHINE INSPECTION AFTER DAILY WORK...275
LOCKING...275
TRANSPORTATION...276
Transportation Procedure...276
Loading and Unloading with Trailer...276
Loading...278
Securing Machine...280
Stowing Radio Antenna...282
Rear View Mirrors...282
Remove and Install Handrail...284
Unloading...285
LIFTING MACHINE...287
Standard Specification Machines...287
Machines with Lifting Hook...289
SPREAD AND NARROW TRACK FRAME GAUGE...290
Narrowing Gauge...290
Spreading Gauge...291
COLD WEATHER OPERATION...292
Cold Weather Operation Information...292
Fuel and Lubricants...292
Coolant...292
Battery...293
AFTER DAILY WORK COMPLETION...294
AFTER COLD WEATHER SEASON...294
LONG TERM STORAGE...295
Before Storage...295
During Storage...295
After Storage...296
Starting Machine After Long-Term Storage...296
TROUBLES AND ACTIONS...297
Running Out of Fuel...297
Procedure for Bleeding Air...297
Phenomena That are Not Failures...298
Towing the Machine...299
Lightweight Towing Hole...300
Severe Job Condition...300
Discharged Battery...301
Battery Removal and Installation...301
Battery Charges...302
Starting Engine with Booster Cables...303
OTHER TROUBLE...305
Electrical System...305
Chassis...306
Engine...307
Electronic Control System...309
Point of Contact to Telephone when Error Occurs...309
MAINTENANCE...310
MAINTENANCE INFORMATION...311
OUTLINE OF SERVICE...313
Handling Oil, Fuel, Coolant, and Performing Oil Clinic...313
Oil...313
Fuel...314
Coolant and Water for Dilution...314
Grease...314
Carrying Out KOWA (Komatsu Oil Wear Analysis)...315
Storing Oil and Fuel...316
Filters...316
Electric System Maintenance...316
WEAR PARTS...317
Wear Parts List...317
RECOMMENDED FUEL, COOLANT, AND LUBRICANT...318
Lubrication Chart...318
Fuel, Coolant, and Lubricants to Match the Ambient Temperature...320
KDPF (Komatsu Diesel Particulate Filter)...320
Recommended Brands, Recommended Quality for Products Other Than Komatsu Genuine Oil...321
TORQUE SPECIFICATIONS...322
Torque List...322
Torque of Bolts...322
Torque of Hose Nuts...322
Torque of Split Flange Bolts...323
Torque for Flared Nuts...323
Torque for O-ring Boss Piping Joints...324
Torque for O-ring Boss Plugs...324
Torque for Hoses (Taper Seal Type and Face Seal Type)...325
SAFETY CRITICAL PARTS...326
Safety Critical Parts List...327
MAINTENANCE SCHEDULE...328
Maintenance Schedule Table...328
Maintenance Interval for Hydraulic Breaker...330
MAINTENANCE PROCEDURE...331
Initial 10 Hours Maintenance...331
Initial 250 Hours Maintenance (Only After the First 250 Hours)...331
Initial 500 Hours Maintenance (Only After the First 500 Hours)...331
When Required...332
Check, Clean and Replace Air Cleaner Element...332
Clean Inside of Cooling System...339
Check and Tighten Track Shoe Bolts...345
Check and Adjust Track Tension...346
Replace Bucket Teeth (Vertical Pin Type)...348
Replace Bucket Teeth (Horizontal Pin Type)...351
Replace Bucket Side Cutter, Shroud...352
Adjust Bucket Clearance...354
Check Window Washer Fluid Level, Add Fluid...355
Check and Maintain Air Conditioner...356
Wash Washable Floor...357
Set Machine at Angle...360
Check Gas Spring...361
Bleeding Air From Hydraulic System...362
Check Before Starting...364
Every 50 Hours Maintenance...365
Lubrication...365
Every 250 Hours Maintenance...366
Check Level of Battery Electrolyte...366
Check Air Conditioner Compressor Belt Tension, Adjust...368
Lubricate Swing Circle...369
Every 500 Hours Maintenance...370
Lubricating...370
Change Oil in Engine Oil Pan, Replace Engine Oil Filter Cartridge...372
Replace Fuel Pre-Filter Cartridge...374
Check Swing Pinion Grease Level, Add Grease...377
Clean and Inspect Radiator Fins, Oil Cooler Fins, Aftercooler Fins, Fuel Cooler Fins, and Condenser Fins...378
Clean Air Conditioner Fresh/Recirc Filters...380
Replace Breather Element in Hydraulic Tank...382
Replace Additional Breather Element in Hydraulic Tank...383
Check Oil Level in Swing Machinery Case, Add Oil...384
Check Oil Level in Final Drive Case, Add Oil...385
Every 1000 Hours Maintenance...386
Replace Hydraulic Oil Filter Element...386
Change Oil in Swing Machinery Case...387
Check Oil Level in Damper Case, Add Oil...388
Replace Fuel Main Filter Cartridge...389
Check all Tightening Points of Engine Exhaust Pipe Clamps...392
Check Fan Belt Tension and Replace Fan Belt...392
Check Nitrogen Gas Charge Pressure in Accumulator (for Breaker)...392
Every 2000 Hours Maintenance...393
Change Oil In Final Drive Case...393
Clean Hydraulic Tank Strainer...394
Check Charge Pressure of Nitrogen Gas In Accumulator (For Control Circuit)...395
Function of Accumulator...395
Check Function of Accumulator...395
Method of Releasing Pressure in Hydraulic Circuit...397
Check Alternator...398
Check Engine Valve Clearance, Adjust...398
Replace Komatsu Closed Crankcase Ventilation (KCCV) Filter Element...399
Every 4000 Hours Maintenance...402
Check Water Pump...402
Check Vibration Damper...402
Check Starting Motor...402
Replace Accumulator (For Control Circuit)...403
Check for Missing Fuel Spray Prevention Cap, Hardening of Rubber...404
Check Operating Condition of Compressor...404
Every 4500 Hours Maintenance...404
Clean Komatsu Diesel Particulate Filter (KDPF)...404
Replace Komatsu Closed Crankcase Ventilation (KCCV) Hose...404
Every 5000 Hours Maintenance...405
Change Oil in Hydraulic Tank...405
Every 8000 Hours Maintenance...407
Replace Fuel Spray Prevention Cap...407
Replace High-Pressure Piping Clamp...407
SPECIFICATIONS...408
SPECIFICATIONS...409
Dimensions...409
Working Ranges...410
OPTIONS, ATTACHMENTS...412
GENERAL PRECAUTIONS FOR SAFETY...413
Precautions When Selecting...413
Read the Operation and Maintenance Manual Thoroughly...413
Precautions When Removing or Installing...413
Precautions When Using...413
BUCKET WITH HOOK...414
Hook Condition...414
Safety Rules for Lifting Operations...414
CHANGING DIRECTION OF THE MACHINE...415
Straight Travel (Optional)...416
CHANGING MACHINE CONTROL PATTERN...417
Control Pattern Change Procedure...417
MACHINE READY FOR ATTACHMENT...419
Locations...419
Stop Valve...419
Selector Valve...420
Attachment Control Pedal...420
Lock Pin...420
Breaker Circuit Additional Oil Filter...421
Accumulator...422
HYDRAULIC CIRCUIT...423
Switching Hydraulic Circuit...423
Switching Between Breaker and General Attachment...423
Hydraulic Circuit Connection...424
Oil Flow Path...425
Replace Additional Breaker Filter Element...426
ATTACHMENT REMOVAL AND INSTALLATION...429
Removal...429
Installation...431
ATTACHMENT OPERATIONS...433
When Using Breaker...433
When Using General Attachment Such as Crusher...435
LONG TERM STORAGE...436
Specifications...436
ATTACHMENT GUIDE...437
Attachment Combinations...437
TRACK SHOES SELECTION...439
BUCKET TEETH SELECTION...440
Selection Guide for Horizontal or Vertical Pin Type Tooth...440
RECOMMENDED ATTACHMENT OPERATIONS...441
Hydraulic Breaker...441
Prohibited Usage...443
Correct Position for Greasing Breaker...445
CEBM025204 - Hydraulic Excavator PC360LC-10, PC390LC-10 Shop Manual...446
PC360-390LC-10 Shop Manual CEBM025204...446
00 FORWARD...0
CONTENTS...447
SAFETY...464
Safety Notice...464
Important Safety Notice...464
General Precautions...464
Preparations For Work...466
Precautions During Work...466
GENERAL...469
HOW TO READ THE SHOP MANUAL...471
Volumes...471
Distribution And Updating...471
Filing Method...471
Revised Edition Mark...471
Revisions...471
Symbols...471
HOISTING INSTRUCTIONS...472
Hoisting...472
Making Signs...472
Precautions...472
Precautions for Sling Work...472
Precautions for Using Mobile Crane...473
Precautions for Using Overhead Hoist Crane...473
Selecting Wire Ropes...475
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS...476
Points to Remember When Handling Electric Equipment...476
Points to Remember When Handling Hydraulic Equipment...487
PUSH PULL COUPLER...489
Type 1...489
Disconnection...489
Connection...489
Type 2...490
Disconnection...490
Connection...490
Type 3...491
Disconnection...491
Connection...491
EXPLANATION OF MAINTENANCE STANDARD TERMS...492
HANDLING OF FUEL SYSTEM DEVICES...493
HANDLING OF INTAKE SYSTEM PARTS...494
STANDARD TIGHTENING TORQUE...495
Bolts And Nuts...495
Tightening Torque Of Hose Nuts...496
Tightening Torque Of Split Flange Bolts...496
Tightening Torque For Flared Nuts...496
Tightening Torques for Split Flanged Bolts...497
Tightening Torques For O-ring Boss Piping Joints...497
Table Of Tightening Torques For O-ring Boss Plugs...497
Tightening Torque For Hoses (Taper Seal Type And Face Seal Type)...498
Tightening Torque For Face Seal Joints...498
For 102, 107, and 114 Engine Series (Bolts and Nuts)...498
For 102, 107, and 114 Engine Series (Eye Joints)...499
For 102, 107, and 114 Engine Series (Taper Screws)...499
ELECTRIC WIRE CODE...500
Classification By Thickness...500
Classification By Color And Code...500
How To Read Electric Wire Code...501
PRECAUTIONS FOR OPERATIONS...504
Precautions when Carrying Out Removal Work...504
Precautions when Carrying Out Installation Work...505
Precautions when Completing the Operation...506
CONVERSION TABLES...507
Method Of Using The Conversion Table...507
COATING MATERIALS...513
LIST OF ABBREVIATIONS...515
List of Abbreviations Used in the Shop Manual...515
List of Abbreviations Used in the Circuit Diagrams...519
01 GENERAL...520
SPECIFICATION DIMENSION DRAWINGS...521
Dimensions...521
Working Ranges...522
SPECIFICATIONS...523
Engine...523
Undercarriage...523
Hydraulic System...524
WEIGHT TABLE...527
FUEL, COOLANT AND LUBRICANTS...529
Lubrication Chart...531
10 STRUCTION AND FUNCTION...532
ENGINE AND COOLING SYSTEM...535
Engine Related Parts...535
Cooling System...537
POWER TRAIN...539
Power Train...539
Swing Circle...541
Final Drive...543
PC360LC-10...543
PC390LC-10...545
UNDERCARRIAGE AND FRAME...547
Track Frame and Idler Cushion...547
HYDRAULIC SYSTEM...549
Hydraulic Component Layout...549
Valve Control...551
Hydraulic Tank...553
Oil Filler Cap...554
CLSS...555
Structure of CLSS...555
Basic principle...556
Main Pump...559
Operation...563
LS Valve...565
PC Valve...571
LS(PC)-EPC Valve...578
Control Valve...581
Functions and Operation by Valve...593
Hydraulic Circuit Diagram and Name of Valves...593
Unload Valve...597
Introduction of LS Pressure...598
LS By-Pass Plug...599
Pressure Compensation Valve...600
Shuttle Valve In Pressure Compensation Valve...603
Boom Regeneration Circuit...605
Arm Regeneration Circuit...607
Merge-Divider Valve...609
LS Selector Valve...612
Self-Pressure Reducing Valve...613
Travel Junction Valve...617
Travel PPC Shuttle Valve...621
Boom Hydraulic Drift Prevention Valve...623
Arm Hydraulic Drift Prevention Valve (If Equipped)...626
Suction Safety Valve for Drift Prevention Valve...629
Arm Quick Return Valve...631
Variable Back Pressure Valve...633
Main Relief Valve...635
Suction 2-Stage Safety Valve...637
Swing Motor...639
Swing Holding Brake...641
Relief Valve...643
Swing 2-Stage Relief Valve...645
Swing Motor Reverse Prevention Valve...646
Travel Motor - Type KMV180ADT-2 (PC360LC-10)...649
Operation of Travel Motor...652
Operation of Parking Brake...654
Brake Valve...655
Counterbalance Valve...656
Suction Safety Valve...658
Travel Motor - Type KMV200ADT-2 (PC390LC-10)...661
Operation of Travel Motor...664
Parking Brake...667
Brake Valve...669
Safety Valve...671
PPC Valve...675
Work Equipment and Swing PPC Valve...675
Travel PPC Valve...681
1st-Line Attachment PPC Valve (with EPC Valve) (If Equipped)...685
EPC Valve (If Equipped)...687
2nd-Line Attachment PPC Valve (If Equipped)...691
Solenoid Valve...693
Attachment Circuit Selector Valve (If Equipped)...697
Center Swivel Joint...699
Accumulator...701
PPC Accumulator...701
WORK EQUIPMENT...703
Work Equipment...703
Work Equipment Shim...704
Bucket Play Adjustment Shim...704
CAB AND ITS ATTACHMENTS...705
Cab Mount and Cab Tipping Stopper...705
ROPS Cab...707
ELECTRICAL SYSTEM...709
Electrical Control System...709
Machine Control System Diagram...709
Engine Control Function...711
Engine and Pump Combined Control Function...713
Pump and Valve Control Function...719
One-Touch Power Maximizing Function...721
Machine Push-Up Function...723
Auto-Deceleration Function...725
Engine Automatic Warm-Up Function...727
Overheat Prevention Function...729
Turbocharger Protection Function...730
Swing Control Function...731
Quick Warm-Up Function...733
Swing 2-Stage Relief Function...733
Travel Control Function...735
PPC Lock Function...737
Attachment Flow Control Function...739
System Component Part...741
Engine Controller...741
Pump Controller...745
Fuel Control Dial...749
Resister for PC-EPC valve...750
CAN Terminating Resistor...751
Engine Oil Pressure Switch...752
PPC Oil Pressure Switch...753
MACHINE MONITOR SYSTEM...755
Machine Monitor...757
Input and Output Signals...758
Display...761
Gauges...763
Caution Monitor...765
Pilot Monitor...769
Switches...771
Guidance ICON and Function Switch...773
Operator Mode Function...777
Service Mode Function...779
KOMTRAX SYSTEM...781
KOMTRAX terminal...782
Input and Output Signals...783
SENSORS...785
Ambient Pressure Sensor...785
Charge (Boost) Pressure and Temperature Sensor...786
Coolant Temperature Sensor...787
Ne (Crankshaft) Speed Sensor...787
Bkup (Camshaft) Speed Sensor...788
Common Rail Pressure Sensor...788
Exhaust Manifold Pressure Sensor...789
EGR Orifice Temperature Sensor...789
EGR Valve Lift Sensor...790
Turbo Speed Sensor...791
KVGT Position Sensor...792
Mass Air Flow and Temperature Sensor...793
KDPF Differential Pressure and Outlet Pressure Sensor...793
KDOC Inlet Temperature Sensor...794
KDOC Outlet Temperature Sensor...794
KDPF Outlet Temperature Sensor...795
Crankcase Pressure Sensor...795
Engine Oil Level Sensor...796
Fuel Level Sensor...797
Coolant Level Sensor...798
Hydraulic Oil Temperature Sensor...798
Front Pump Oil Pressure Sensor...799
Rear Pump Oil Pressure Sensor...800
PPC Oil Pressure Sensor...801
Air Cleaner Clogging Sensor...802
Front Pump Swash Plate Sensor...803
Rear Pump Swash Plate Sensor...805
Water-In-Fuel Sensor...807
20 STANDARD VALUE TABLES...808
STANDARD SERVICE VALUE TABLES...809
Standard Value Table for Engine Related Parts...809
Standard Value Table for Chassis Related Parts...811
Engine Speed...811
Travel of Control Valve Spool...811
Travel of Control Lever...812
Operating Effort of Control Lever and Pedal...812
Hydraulic Pressure...813
Swing...814
Travel...815
Work Equipment...817
Performance in Combined Operation...819
Pump Swash Plate Sensor...819
Main Pump...819
Posture of Machine for Measuring Performance and Measurement Procedure...821
Control Valve: Spool Stroke...821
Swing 1: Overrun When Stopping Swing, Time Taken to Start Swing, Time Taken to Swing...821
Swing 2: Hydraulic Drift of Swing...821
Travel 1: Travel Speed, Idle Running (Without Load)...821
Travel 2: Travel Speed (Actual Run), Travel Deviation...822
Travel 3: Travel Deviation...822
Travel 4: Hydraulic Drift of Travel...822
Work Equipment 1: Hydraulic Drift of Work Equipment...822
Work Equipment 2: Boom Speed...823
Work Equipment 3: Arm Speed...823
Work Equipment 4: Bucket Speed...823
Work Equipment 5: Boom Time Lag...823
Work Equipment 6: Arm Time Lag...824
Work Equipment 7: Bucket Time Lag...824
30 TESTING AND ADJUSTING...826
GENERAL INFORMATION...831
Tools for Testing, Adjusting, and Troubleshooting...831
Sketch of Tools for Testing and Adjusting...838
ENGINE AND COOLING SYSTEM...841
Checking Engine Speed...841
Measuring Boost Pressure...843
Measuring Exhaust Gas Color...847
Measuring and Adjusting Valve Clearance...849
Testing...849
Adjustment...852
Measuring Compression Pressure...855
Measuring Blow-By Pressure...865
Measuring Engine Oil Pressure...867
Measuring EGR Valve and KVGT Oil Pressure...871
Measuring Fuel Pressure...873
Testing Low-Pressure Circuit (Main Fuel Filter Inlet Side)...875
Testing Low-Pressure Circuit (Pressure Difference)...876
Testing Return Circuit...877
Testing the Negative Pressure Circuit (At Fuel Supply Connector)...879
Testing the Negative Pressure Circuit (At Supply Pump)...880
Testing Fuel Feed Pump Outlet Pressure (At Supply Pump)...881
Measuring Fuel Delivery, Return and Leakage...882
Testing Supply Pump Delivery...883
Testing Supply Pump Return Rate...885
Testing Leakage from Pressure Limiter...887
Measuring Return Rate from Injector...888
Testing Delivery of Fuel Feed Pump...889
Bleeding Air from Fuel System...890
Bleeding Air...890
Checking Fuel Circuit for Leakage...891
Handling Cylinder Cut-Out Mode Operation...892
Handling No-Injection Cranking Operation...892
Checking and Adjusting Air Conditioner Compressor Belt Tension...893
Checking...893
Adjusting...893
Replacing Fan Belt...894
Replacing Alternator Belt...895
POWER TRAIN...897
Testing Swing Circle Bearing Clearance...897
Testing...897
UNDERCARRIAGE AND FRAME...899
Testing and Adjusting Track Shoe Tension...899
Testing...899
Adjusting...899
HYDRAULIC SYSTEM...901
Releasing Remaining Pressure from Hydraulic Circuit...901
Measuring and Adjusting of Oil Pressure in Work Equipment, Swing, and Travel Circuits...903
Testing...903
Measuring Method by Using Machine Monitor...903
Measuring Method by Using Oil Pressure Gauge...905
Combination of Pump, Actuator, and Valve...907
Measuring Unload Pressure...907
Measuring Work Equipment Relief Pressure...907
Measuring Swing Relief Pressure...908
Measuring Travel Relief Pressure...908
Work After Finishing Measurement...908
Adjusting...909
Adjusting Work Equipment and Travel Relief Pressure...909
Adjusting Boom LOWER Relief Pressure (On the Side Where High Pressure is Set)...910
Adjusting Boom LOWER Relief Pressure (On the Side Where Low Pressure is Set)...911
Adjusting Swing Relief Pressure...912
Measuring Oil Pressure in Control Circuit...913
Measuring with Machine Monitor...913
Measuring with Oil Pressure Gauge...917
Measuring and Adjusting Oil Pressure in Pump PC Control Circuit...919
Testing...920
Measuring PC Valve Output Pressure (Servo Piston Inlet Pressure) With Machine Monitor...920
Measuring PC-EPC Valve Output Pressure With the Machine Monitor...923
Measuring PC Valve Output Pressure (Servo Piston Inlet Pressure) With Oil Pressure Gauge...927
Measuring PC-EPC Valve Output Pressure With Oil Pressure Gauge...931
Adjusting...933
Measuring and Adjusting Oil Pressure in Pump LS Control Circuit...934
Testing...935
Measuring LS Valve Output Pressure (Servo Piston Inlet Pressure) With Machine Monitor...935
Measuring LS Differential Pressure with the Machine Monitor...939
Measuring LS-EPC Valve Output Pressure with the Machine Monitor...943
Measuring LS Valve Output Pressure (Servo Piston Inlet Pressure) with Oil Pressure Gauge...945
Measuring LS Differential Pressure with Oil Pressure Gauge...949
Measuring LS-EPC Valve Output Pressure with Oil Pressure Gauge...953
Adjusting...954
Measuring Solenoid Valve Output Pressure...955
Testing...956
Measuring with Machine Monitor...956
Measuring with Oil Pressure Gauge...957
Operating Condition...959
Measuring PPC Valve Output Pressure...961
Testing...961
Measuring with Machine Monitor...961
Measuring with Oil Pressure Gauge...962
Adjusting Play of Work Equipment and Swing PPC Valves...964
Adjusting...964
Testing Pump Swash Plate Sensor...965
Testing Output Voltage of Pump Swash Plate Sensor...965
Isolating the Parts Causing Hydraulic Drift in Work Equipment...967
Measuring Oil Leakage...969
Bleeding Air From Hydraulic Circuit...973
CAB AND ITS ATTACHMENTS...977
Checking Cab Tipping Stopper...977
Adjusting Mirrors...979
ELECTRICAL SYSTEM...983
Special Functions of Machine Monitor...983
Upper Part of machine monitor (display portion)...984
Upper Part of Machine Monitor (Switch Portion)...984
Lower Part of Machine Monitor (Switch Portion)...984
Ordinary Functions and Special Functions of Machine Monitor...984
Operator Mode (Outline)...987
Service Mode...1007
Angle Adjustment of Rear View Camera...1075
Handling Voltage Circuit of Engine Controller...1077
Handling Battery Disconnect Switch...1078
Testing Diodes...1079
PM CLINIC...1081
PM Clinic Service...1081
Check Items Related to Engine...1083
Check Items Related to Oil Pressure...1084
Check Sheet...1085
40 TROUBLESHOOTING...1092
GENERAL INFORMATION ON TROUBLESHOOTING...1101
Points to Remember When Troubleshooting...1101
Sequence of Events in Troubleshooting...1103
Checks Before Troubleshooting...1105
Testing Procedure Before Troubleshooting...1107
Walk-Around Check...1107
Checking in Accordance with Checking Procedure...1109
Preparation Work for Troubleshooting of Electrical System...1115
Preparation Work...1115
Classification and Procedure for Troubleshooting...1120
Classification of Troubleshooting...1120
Procedure for Troubleshooting...1120
Symptom of Probable Failure and Troubleshooting No...1124
Information Mentioned in Troubleshooting Table...1128
Diagnostic Procedure for Wiring Harness Open Circuit of Pressure Sensor System...1130
Connector list...1133
Layout of connectors...1138
Connection Table for Connector Pin Numbers...1144
T-Branch Box and T-Branch Adapter Table...1179
Fuse List and Location...1183
Connection Table of Fuse Box...1183
Locations of Fusible Links...1184
Location of Fuse Box and Fuse Numbers...1184
Precautions for Cleaning and Replacing KDPF (KCSF, KDOC)...1185
FAILURE CODE (DISPLAY OF CODE)...1188
Failure Codes Table...1188
879AKA - A/C Inner Sensor Open Circuit...1195
879AKB - A/C Inner Sensor Short Circuit...1195
879BKA - A/C Outer Sensor Open Circuit...1195
879BKB - A/C Outer Sensor Short Circuit...1195
879CKA - Ventilating Sensor Open Circuit...1195
879CKB - Ventilating Sensor Short Circuit...1195
879DKZ - Sunlight Sensor Open or Short Circuit...1195
879EMC - Ventilation Damper Abnormality...1196
879FMC - Air Mix Damper Abnormality...1196
879GKX - Refrigerant Abnormality...1196
989L00 - Engine Controller Lock Caution 1...1197
989M00 - Engine Controller Lock Caution 2...1197
989N00 - Engine Controller Lock Caution 3...1198
A1U0N3 - KDPF Dry Request (HC Release) 1...1199
A1U0N4 - KDPF Dry Request (HC Release) 2...1201
AA10NX - Air Cleaner Clogging...1203
AB00KE - Charge Voltage Low...1205
B@BAZG - Engine Oil Pressure Low...1207
B@BAZK - Eng Oil Level Low...1209
B@BCNS - Engine Coolant Overheat...1211
B@BCZK - Radiator Coolant Level Low...1213
B@HANS - Hyd Oil Overheat...1215
CA115 - Eng Ne and Bkup Speed Sens Error...1216
CA122 - Chg Air Press Sensor High Error...1217
CA123 - Chg Air Press Sensor Low Error...1219
CA131 - Throttle Sensor High Error...1221
CA132 - Throttle Sensor Low Error...1223
CA144 - Coolant Temp Sens High Error...1225
CA145 - Coolant Temp Sens Low Error...1227
CA153 - Chg Air Temp Sensor High Error...1229
CA154 - Chg Air Temp Sensor Low Error...1231
CA187 - Sensor 2 Supply Volt Low Error...1233
CA221 - Ambient Press Sensor High Error...1235
CA222 - Ambient Press Sensor Low Error...1237
CA227 - Sensor 2 Supply Volt High Error...1239
CA234 - Eng Overspeed...1240
CA238 - Ne Speed Sensor Supply Volt Error...1241
CA239 - Ne Speed Sens Supply Volt High Error...1243
CA271 - IMV/PCV1 Short Error...1245
CA272 - IMV/PCV1 Open Error...1247
CA281 - Pump Press Balance Error...1249
CA295 - Ambient Press Sens In Range Error...1250
CA322 - Inj #1 (L#1) Open/Short Error...1251
CA323 - Inj #5 (L#5) Open/Short Error...1253
CA324 - Inj #3 (L#3) Open/Short Error...1255
CA325 - Inj #6 (L#6) Open/Short Error...1257
CA331 - Inj #2 (L#2) Open/Short Error...1259
CA332 - Inj #4 (L#4) Open/Short Error...1261
CA343 - ECM Critical Internal Failure...1263
CA351 - Injectors Drive Circuit Error...1264
CA352 - Sensor 1 Supply Volt Low Error...1265
CA356 - Mass Air Flow Sensor High Error...1267
CA357 - Mass Air Flow Sensor Low Error...1269
CA386 - Sensor 1 Supply Volt High Error...1272
CA428 - Water in Fuel Sensor High Error...1273
CA429 - Water in Fuel Sensor Low Error...1275
CA435 - Eng Oil Press Sw Error...1277
CA441 - Battery Voltage Low Error...1279
CA442 - Battery Voltage High Error...1281
CA449 - Rail Press Very High Error...1282
CA451 - Rail Press Sensor High Error...1285
CA452 - Rail Press Sensor Low Error...1287
CA488 - Chg Air Temp High Torque Derate...1289
CA515 - Rail Press Sens Sup Volt High Error...1291
CA516 - Rail Press Sens Sup Volt Low Error...1293
CA553 - Rail Press High Error 1...1295
CA555 - Crankcase Press High Error 1...1296
CA556 - Crankcase Press High Error 2...1297
CA559 - Rail Press Low Error 1...1298
CA595 - Turbo Speed High Error 2...1302
CA687 - Turbo Speed Low Error...1303
CA689 - Eng Ne Speed Sensor Error...1305
CA691 - Intake Air Temp Sens High Error...1309
CA692 - Intake Air Temp Sens Low Error...1311
CA697 - ECM Int Temp Sensor High Error...1313
CA698 - ECM Int Temp Sensor Low Error...1314
CA731 - Eng Bkup Speed Sens Phase Error...1315
CA778 - Eng Bkup Speed Sensor Error...1317
CA1117 - Persistent Data Lost Error...1321
CA1664 - KDOC Malfunction...1323
CA1691 - Regeneration Ineffective...1325
CA1695 - Sensor 5 Supply Volt High Error...1329
CA1696 - Sensor 5 Supply Volt Low Error...1331
CA1843 - Crankcase Press Sens High Error...1333
CA1844 - Crankcase Press Sens Low Error...1335
CA1879 - KDPF Differential P Sensor High Error...1337
CA1881 - KDPF Differential P Sensor Low Error...1339
CA1883 - KDPF Differential P Sens In Range Error...1341
CA1921 - KDPF Soot Load High Error 1...1345
CA1922 - KDPF Soot Load High Error 2...1347
CA1942 - Crankcase Press Sens In Range Error...1351
CA1993 - KDPF Differential Pressure Low Error...1352
CA2185 - Throt Sensor Sup Volt High Error...1353
CA2186 - Throt Sensor Sup Volt Low Error...1355
CA2249 - Rail Press Very Low Error...1357
CA2265 - Fuel Feed Pump Open Error...1359
CA2266 - Fuel Feed Pump Short Error...1361
CA2271 - EGR Valve Pos Sens High Error...1363
CA2272 - EGR Valve Pos Sens Low Error...1367
CA2288 - Turbo Speed High Error 1...1370
CA2311 - IMV Solenoid Error...1371
CA2349 - EGR Valve Solenoid Open Error...1372
CA2353 - EGR Valve Solenoid Short Error...1374
CA2357 - EGR Valve Servo Error...1376
CA2373 - Exhaust Manifold Press Sens High error...1377
CA2374 - Exhaust Manifold Press Sens Low Error...1379
CA2375 - EGR Orifice Temp Sens High Error...1381
CA2376 - EGR Orifice Temp Sens Low Error...1383
CA2381 - KVGT Pos Sens High Error...1385
CA2382 - KVGT Pos Sens Low Error...1387
CA2383 - KVGT Solenoid Open Error...1391
CA2386 - KVGT Solenoid Short Error...1393
CA2387 - KVGT Valve Servo Error...1395
CA2554 - Exh Manifold Press Sens In Range Error...1396
CA2555 - Grid Htr Relay Open Circuit Error...1397
CA2556 - Grid Htr Relay Volt High Error...1399
CA2637 - KDOC Blocked...1401
CA2639 - Manual Stationary Regeneration Request...1403
CA2961 - EGR Orifice Temp High Error 1...1405
CA2973 - Chg Air Press Sensor In Range Error...1406
CA3133 - KDPF Outlet Press Sens High Error...1407
CA3134 - KDPF Outlet Press Sens Low Error...1409
CA3135 - KDPF Outlet Press Sens In Range Error...1411
CA3251 - KDOC Inlet Temp High Error...1415
CA3253 - KDOC Temp Error - Non Regeneration...1419
CA3254 - KDOC Outlet Temp High Error 1...1421
CA3255 - KDPF Temp Error - Non Regeneration...1424
CA3256 - KDPF Outlet Temp High Error 1...1425
CA3311 - KDOC Outlet Temp High Error 2...1426
CA3312 - KDPF Outlet Temp High Error 2...1427
CA3313 - KDOC Inlet Temp Sensor Low Error...1431
CA3314 - KDOC Inlet Temp Sens High Error...1435
CA3315 - KDOC Inlet Temp Sens In Range Error...1439
CA3316 - KDOC Outlet Temp Sens Low Error...1443
CA3317 - KDOC Outlet Temp Sens High Error...1447
CA3318 - KDOC Outlet Temp Sens In Range Error...1451
CA3319 - KDPF Outlet Temp Sens High Error...1455
CA3321 - KDPF Outlet Temp Sens Low Error...1459
CA3322 - KDPF Outlet Temp Sens In Range Error...1463
CA3419 - Mass Air Flow (MAF) Sensor Sup Volt High Error...1467
CA3421 - Mass Air Flow (MAF) Sensor Sup Volt Low Error...1469
CA3741 - Rail Press Valve Trip Error...1471
D110KB - Battery Relay Output Voltage...1473
D19JKZ - Personal Code Relay Abnormality...1475
D811MC - KOMTRAX Error...1478
D862KA - GPS Antenna Open Circuit...1478
D8AQKR - CAN2 Discon (KOMTRAX)...1479
DA20MC - Pump Controller...1480
DA22KK - Pump Solenoid Power Low Error...1481
DA25KP - 5 V Sensor 1 Power Abnormality...1484
DA29KQ - Model Selection Abnormality...1487
DA2QKR - CAN2 Discon ( Pump Con)...1489
DA2RKR - CAN1 Discon ( Pump Con)...1492
DAF0MB - Monitor Memory Error...1493
DAF0MC - Monitor Error...1494
DAF8KB - Camera Power Supply Short Circuit...1495
DAF9KQ - Model Selection Abnormality...1497
DAFGMC - GPS Module Error...1498
DAFQKR - CAN2 Discon...1499
DAZ9KQ - A/C Model Selection Abnormality...1500
DAZQKR - CAN2 Discon (AC)...1501
DB2QKR - CAN2 Discon (Engine Con)...1505
DB2RKR - CAN1 Discon (Engine Con)...1511
DGH2KB - Hyd Oil Sensor Short Circuit...1517
DHA4KA - Air Cleaner Clog Sensor Open Circuit...1519
DHPAMA - F Pump Press Sensor Abnormality...1520
DHPBMA - R Pump Press Sensor Abnormality...1523
DHS3MA - Arm In PPC Press Sensor Abnormality...1527
DHS4MA - Bucket Curl PPC Press Sensor Abnormality...1531
DHS8MA - Boom Raise PPC Press Sensor Abnormality...1535
DHS9MA - Boom Lower PPC Press Sensor Abnormality...1539
DHSAMA - Swing RH PPC Press Sensor Abnormality...1543
DHSBMA - Swing LH PPC Press Sensor Abnormality...1547
DHSCMA - Arm Out PPC Press Sensor Abnormality...1551
DHSDMA - Bucket Dump PPC Press Sensor Abnormality...1555
DHSFMA - Travel Fwd LH PPC Press Sensor Abnormality...1559
DHSGMA - Travel Fwd RH PPC Press Sensor Abnormality...1563
DHSHMA - Travel Rev LH PPC Press Sensor Abnormality...1567
DHSJMA - Travel Rev RH PPC Press Sensor Abnormality...1571
DKR0MA - F Pump Swash Plate Sensor Abnormality...1575
DKR1MA - R Pump Swash Plate Sensor Abnormality...1579
DV20KB - Travel Alarm Short Circuit...1583
DW43KA - Travel Speed Sol Open Circuit...1585
DW43KB - Travel Speed Sol Short Circuit...1587
DW45KA - Swing Brake Sol Open Circuit...1589
DW45KB - Swing Brake Sol Short Circuit...1593
DW91KA - Travel Junction Sol Open Circuit...1597
DW91KB - Travel Junction Sol Short Circuit...1599
DWA2KA - Attachment Sol Open Circuit...1601
DWA2KB - Attachment Sol Short Circuit...1603
DWK0KA - 2-Stage Relief Sol Open Circuit...1605
DWK0KB - 2-Stage Relief Sol Short Circuit...1607
DWK2KA - Variable Back Press Sol Open Circuit...1609
DWK2KB - Variable Back Press Sol Short Circuit...1611
DWK8KA - Swing Press C/O Sol Open Circuit...1613
DWK8KB - Swing Press C/O Sol Short Circuit...1615
DXA8KA - PC-EPC (F) Sol Open Circuit...1617
DXA8KB - PC-EPC (F) Sol Short Circuit...1619
DXA9KA - PC-EPC (R) Sol Open Circuit...1621
DXA9KB - PC-EPC (R) Sol Short Circuit...1625
DXE0KA - LS-EPC Sol Open Circuit...1627
DXE0KB - LS-EPC Sol Short Circuit...1629
DXE4KA - Attachment Flow EPC Open Circuit...1631
DXE4KB - Attachment Flow EPC Short Circuit...1633
DXE5KA - Merge-divide Main Sol Open Circuit...1635
DXE5KB - Merge-divide Main Sol Short Circuit...1637
DXE6KA - Merge-divide LS Sol Open Circuit...1639
DXE6KB - Merge-divide LS Sol Short Circuit...1641
DY20KA - Wiper Working Abnormality...1643
DY20MA - Wiper Parking Abnormality...1647
DY2CKB - Washer Drive Short Circuit...1649
DY2DKB - Wiper Drive (Fwd) Short Circuit...1651
DY2EKB - Wiper Drive (Rev) Short Circuit...1653
ELECTRICAL SYSTEM (E-MODE)...1655
E-1 Engine Does Not Start (Engine Does Not Rotate)...1655
E-2 Manual Pre-Heating System Does Not Work...1663
E-3 Automatic Pre-Heating System Does Not Work...1667
E-4 Pre-Heating Monitor Does Not Light Up When Pre-Heater is Operated...1669
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing...1671
E-6 When Starting Switch is Turned to ON Position (Before Starting Engine), Engine Oil Level Monitor Lights Up in Yellow...1674
E-7 When Starting Switch is Turned to ON Position (Before Starting Engine), Radiator Coolant Level Monitor Lights Up in Yellow...1674
E-8 Coolant Temperature Monitor Lights Up in White While Engine is Running...1675
E-9 Hydraulic Oil Temperature Monitor Lights Up in White While Engine is Running...1675
E-10 Charge Level Monitor Lights Up While Engine is Running...1676
E-11 Fuel Level Monitor Lights Up in Red While Engine is Running...1676
E-12 Air Cleaner Clogging Monitor Lights Up in Yellow While Engine is Running...1676
E-13 Engine Coolant Temperature Monitor Lights Up in Red While Engine is Running...1677
E-14 Hydraulic Oil Temperature Monitor Lights Up in Red While Engine is Running...1677
E-15 Engine Oil Pressure Monitor Lights Up in Red While Engine is Running...1678
E-16 Fuel Gauge Display Does Not Move from Minimum or Maximum...1679
E-17 Display of Fuel Gauge Differs from Actual Fuel Level...1681
E-18 Coolant Temperature Gauge Indicate Either Min or Max and Does Not Move...1682
E-20 Hydraulic Oil Temperature Gauge Indicate Either Min or Max and Does Not Move...1685
E-21 Hydraulic Oil Temperature Gauge Differs from Actual oil Temperature...1687
E-22 Machine Monitor Does Not Display Partially...1688
E-23 Function Switch Does Not Work...1688
E-24 Automatic Pre-Heating System Does Not Work (In Cold Weather)...1689
E-25 Auto-Deceleration Monitor Does Not Light Up or Does Not Go Out When Auto-Deceleration Switch is Operated...1690
E-26 Auto-Deceleration is Not Actuated or Canceled When Lever is Operated...1691
E-27 Working Mode Selector Screen Selection Screen is Not Displayed When Working Mode Switch is Operated...1692
E-28 Engine or Hydraulic Pump Setting Does Not Change When Working Mode is Changed...1692
E-29 Travel Speed Monitor Does Not Change When Travel Speed Switch is Operated...1692
E-32 Travel Speed Does Not Change When Travel Speed is Shifted...1693
E-31 Alarm Buzzer Does Not Stop Sounding...1694
E-32 When Starting Switch is Turned OFF, Service Meter is Not Displayed...1694
E-33 Machine Monitor Service Mode Cannot be Selected...1695
E-34 Any of Work Equipment, Swing and Travel Does Not Work...1697
E-35 Any of Work Equipment, Swing and Travel Can Not be Locked...1699
E-36 Machine Can Not Swing While Swing Brake Cancel Switch is Canceled...1701
E-37 Swing Brake Does Not Operate While Swing Brake Cancel Switch is set to NORMAL position...1703
E-38 One-Touch Power Maximizing Function Does Not Work Or Pilot Monitor is Not Displayed...1705
E-39 One-Touch Power Maximizing Function Cannot be Released...1708
E-40 Travel Alarm Does Not Sound When Machine Travels...1709
E-41 Travel Alarm Does Not Stop Sounding When Machine Stops...1711
E-42 Horn Does Not Sound...1713
E-43 Horn Does Not Stop Sounding...1715
E-44 Wiper Monitor Does Not Light Up or Go Out When Wiper Switch is Operated...1716
E-45 Wiper Does Not Operate When Wiper Switch is Operated...1717
E-46 Window Washer Does Not Operate When Window Washer Switch is Operated...1719
E-47 Boom LOWER Indication is Not Displayed Properly With Monitoring Function...1719
E-48 Arm DUMP Indication is Not Displayed Properly With Monitoring Function...1719
E-49 Arm IN Indication is Not Displayed Properly With Monitoring Function...1719
E-50 BooM RAISE Indication is Not Displayed Properly With Monitoring Function...1720
E-51 Bucket CURL Indication is Not Displayed Properly With Monitoring Function...1720
E-52 Bucket DUMP Indication is Not Displayed Properly With Monitoring Function...1720
E-53 Swing Indication is Not Displayed Properly With Monitoring Function...1720
E-54 Travel Indication is Not Displayed Properly With Monitoring Function...1721
E-55 Attachment is Not Displayed Properly With Monitoring Function...1722
E-56 Attachment Hydraulic Circuit Cannot be Changed...1725
E-57 KOMTRAX System Does Not Work Properly...1727
E-58 Machine Push-up Function is Not Canceled...1729
HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...1733
Information Mentioned in Troubleshooting Table (H Mode)...1733
Failure Mode and Cause Table...1735
H-1 All of Work Equipment, Swing and Travel Operation Lacks Speed or Power...1744
H-2 Engine Speed Lowers Significantly or Engine Stalls...1749
H-3 Any of Work Equipment, Swing and Travel Does Not Work...1752
H-4 Unusual Sound is Heard from Around Hydraulic Pump...1752
H-5 Fine Control Performance or Response is Poor...1753
H-6 Boom Operation Lacks Speed or Power...1755
H-7 Arm Operation Lacks Speed or Power...1760
H-8 Bucket Operation Lacks Speed or Power...1765
H-9 Work Equipment Does Not Move in Single Operation...1769
H-10 Hydraulic Drift of Boom is Large...1770
H-11 Hydraulic Drift of Arm is Large...1771
H-12 Hydraulic Drift of Bucket is Large...1773
H-13 Time Lag of Work Equipment is Large...1775
H-14 When Part of Work Equipment is Relieved Singly, Other Parts of Work Equipment Move...1777
H-15 One-Touch Power Maximizing Function Does Not Work...1778
H-16 Machine Push Up Function Does Not Work...1779
H-17 In Combined Operation of Work Equipment, Equipment Having Heavier Load Moves Slower...1780
H-18 In Combined Operations of Swing and Boom RAISE, Boom Rising Speed is Low...1781
H-19 In Combined Operations of Swing and Travel, Travel Speed Drops Largely...1781
H-20 Machine Does Not Travel Straight...1782
H-21 Travel Speed is Too Low...1785
H-22 Machine is hard to Steer or Travel Power is Low...1787
H-23 Travel Speed Does Not Change, or Travel Speed is Too Low or High...1791
H-24 One of Tracks Dose Not Run...1793
H-25 Upper Structure Does Not Swing to the Right or Left...1795
H-26 Upper Structure Swing Only to the Right or Left...1796
H-27 Swing Acceleration is Poor or Swing Speed is Low (Either Right and Left)...1797
H-28 Swing Aceleration is Poor or Swing Speed is Low in Only One Direction...1799
H-29 Upper Structure Overruns Excessively When it Stops Swinging (Both Right and Left)...1800
H-30 Upper Structure Overruns Excessively When it Stops Swinging (Either Right or Left)...1801
H-31 Shock is Large When Upper Structure Stops Swinging...1802
H-32 Large Unusual Noise is Heard When Upper Structure Stops Swinging...1803
H-33 When Swing Holding Brake is Applied, Hydraulic Drift of Swing is Large...1804
H-34 When Swing Holding Brake is Released, Hydraulic Drift Of Swing is Large...1805
H-35 When additional attachment is installed, attachment circuit is not switched...1806
H-36 Oil Flow in Attachment Circuit Cannot be Controlled...1807
ENGINE (S-MODE)...1809
Information Mentioned in Troubleshooting Table (S-Mode)...1809
S-1 When Starting Switch is Turned to START Position, Engine Does Not Crank...1811
S-2 When Engine Cranks, Exhaust Smoke Does Not Come Out...1812
S-3 Fuel is Being Injected But Engine Does Not Start (Incomplete Combustion: Engine Cranks but Does Not Start)...1813
S-4 Startability is Poor...1815
S-5 Engine Does Not Pick Up Smoothly...1817
S-6 Engine Stops During Operation...1819
S-7 Engine Runs Rough or is Unstable...1821
S-8 Engine Lacks Power...1823
S-9 Exhaust Smoke is Black (KDPF Clogs Up Early)...1825
S-10 Engine Oil Consumption is Excessive...1827
S-11 Oil Becomes Contaminated Early...1828
S-12 Fuel Consumption is Excessive...1829
S-13 Oil is in Coolant (or Coolant Spurts or Coolant Level Goes Down)...1830
S-14 Oil Pressure Drops...1831
S-15 Fuel is Contaminated in Engine Oil...1833
S-16 Coolant Mixes in Engine Oil (Oil Becomes Cloudy White)...1834
S-17 Coolant Temperature Rises Too High (Overheating)...1835
S-18 Unusual Noise is Heard...1836
S-19 Vibration is Excessive...1837
S-20 Air Cannot be Bled from Fuel Circuit...1838
S-21 Automatic Regeneration is Operated Frequently...1839
S-22 Active Regeneration is Operated for Long...1840
S-23 White Smoke Comes Out in the Process of Active Regeneration...1841
50 DISASSEMBLY AND ASSEMBLY...1842
HOW TO READ THIS SECTION...1847
Removal and Installation of Assemblies...1847
Special Tools...1847
Removal...1847
Installation...1847
Disassembly and Assembly of Assemblies...1848
Special Tools...1848
Disassembly...1848
Assembly...1849
Coating Materials List...1850
SPECIAL TOOLS LIST...1855
Sketches of Special Tools...1859
CONNECTOR REPAIR PROCEDURES...1862
Stripping Insulation...1862
Wire Inspection...1862
Contact Terminal Removal (HD30 Type)...1863
Crimping Contact Terminal (HD30 Type)...1864
Insertion of Contact Terminal (HD30 Type)...1865
Contact Terminal Removal (DT Type)...1866
Crimping Contact Terminal (DT Type)...1867
Insertion of Contact Terminal (DT Type)...1868
ENGINE AND COOLING SYSTEM...1869
Supply Pump Assembly...1869
Removal...1869
Installation...1875
Fuel Injector Assembly...1883
Removal...1883
Installation...1892
Cylinder Head Assembly...1905
Removal...1905
Installation...1919
Radiator Assembly...1937
Removal...1937
Installation...1940
Hydraulic Oil Cooler Assembly...1941
Removal...1941
Installation...1945
Aftercooler Assembly...1947
Removal...1947
Installation...1948
Engine and Main Pump Assembly...1949
Removal...1949
Installation...1963
Engine Front Oil Seal...1967
Removal...1967
Installation...1971
Engine Rear Oil Seal...1975
Removal...1975
Installation...1977
Fuel Tank Assembly...1985
Removal...1985
Installation...1988
Engine Hood Assembly...1989
Removal...1989
Installation...1991
KDPF Assembly...1993
Removal...1993
Installation...1999
Disassembly...2003
Assembly...2009
KCCV Assembly...2015
Removal...2015
Installation...2016
Air Cleaner Assembly...2017
Removal...2017
Installation...2020
Air Conditioner Compressor Assembly...2021
Removal...2021
Installation...2022
Air Conditioner Condenser Assembly...2023
Removal...2023
Installation...2024
POWER TRAIN...2025
Travel Motor and Final Drive Assembly...2025
Removal...2025
Installation...2026
Final Drive (PC360LC-10)...2027
Disassembly...2027
Assembly...2032
Final Drive (PC390LC-10)...2039
Removal...2039
Installation...2039
Disassembly...2040
Assembly...2045
Swing Motor and Swing Machinery Assembly (PC360LC-10)...2053
Removal...2053
Installation...2054
Swing Motor and Swing Machinery (PC390LC-10)...2055
Removal...2055
Installation...2056
Swing Machinery (PC360LC-10)...2057
Disassembly...2057
Assembly...2061
Swing Machinery (PC390LC-10)...2067
Disassembly...2067
Assembly...2071
Swing Circle Assembly (PC360LC-10)...2077
Removal...2077
Installation...2077
Swing Circle Assembly (PC390LC-10)...2078
Removal...2078
Installation...2078
UNDERCARRIAGE AND FRAME...2079
Track Shoe Assembly...2079
Separation...2079
Installation...2081
Sprocket...2084
Removal...2084
Installation...2084
Idler and Idler Cushion Assembly...2085
Removal...2085
Installation...2085
Idler...2086
Disassembly...2086
Assembly...2087
Idler Cushion (PC360LC-10)...2091
Disassembly...2092
Assembly...2093
Idler Cushion (PC390LC-10)...2095
Disassembly...2096
Assembly...2097
Track Roller...2099
Disassembly...2099
Assembly...2101
Carrier Roller...2103
Disassembly...2103
Assembly...2105
Revolving Frame Assembly...2109
Removal...2109
Installation...2111
Counterweight Assembly...2113
Removal...2113
Installation...2116
HYDRAULIC SYSTEM...2117
Center Swivel Joint Assembly...2117
Removal...2117
Installation...2119
Disassembly...2121
Disassembly...2121
Assembly...2122
Hydraulic Tank Assembly...2123
Removal...2123
Installation...2126
Main Pump Assembly...2127
Removal...2127
Installation...2131
Control Valve Assembly...2133
Removal...2133
Installation...2140
Disassembly...2141
Replacing Procedures of Pressure Compensation Valve Seal...2142
Assembly...2143
Work Equipment PPC Valve...2147
Disassembly...2147
Assembly...2148
Travel PPC Valve...2149
Disassembly...2149
Assembly...2150
WORK EQUIPMENT...2151
Bucket Assembly...2151
Removal...2151
Installation...2152
Arm Assembly...2153
Removal...2153
Installation...2154
Work Equipment Assembly...2155
Removal...2155
Installation...2157
Work Equipment Cylinder...2159
Disassembly...2159
Assembly...2163
CAB AND ITS ATTACHMENTS...2169
Operator's Cab Assembly...2169
Removal...2169
Installation...2176
Operator Cab Glass (Fixed Glass)...2177
Removal...2178
Installation...2179
Front Window Assembly...2189
Removal...2189
Installation...2192
Floor Frame Assembly...2197
Removal...2197
Installation...2204
Air Conditioner Unit Assembly...2207
Removal...2207
Installation...2212
Operator's Seat...2213
Removal...2213
Installation...2215
Seat Belt...2217
Removal...2217
Installation...2218
Front Wiper Assembly...2219
Removal...2219
Installation...2225
ELECTRIC SYSTEM...2231
Engine Controller Assembly...2231
Removal...2231
Installation...2233
Pump Controller Assembly...2235
Removal...2235
Installation...2237
Machine Monitor Assembly...2239
Removal...2239
Installation...2242
Pump Swash Plate Sensor...2243
Removal...2243
Installation...2243
Mass Air Flow and Temperature Sensor...2245
Removal...2245
Installation...2246
KOMTRAX Terminal Assembly...2247
Removal...2247
Installation...2248
60 MAINTENANCE STANDARD...2250
ENGINE AND COOLING SYSTEM...2253
Engine Mounts...2253
Cooling System...2255
POWER TRAIN...2257
Swing Circle...2257
Swing Machinery...2259
Final Drive...2261
PC360LC-10...2261
PC390LC-10...2263
Sprocket...2265
PC360LC-10...2265
PC390LC-10...2267
UNDERCARRIAGE AND FRAME...2269
Track Frame and Idler Cushion...2269
Idler...2271
PC360LC-10...2271
PC390LC-10...2273
Track Roller...2275
PC360LC-10...2275
PC390LC-10...2277
Carrier Roller...2279
PC360LC-10...2279
PC390LC-10...2280
Track Shoe...2281
PC360LC-10...2281
PC390LC-10...2285
Triple Grouser Shoe...2287
PC360LC-10...2287
PC390LC-10...2288
HYDRAULIC SYSTEM...2289
Hydraulic Tank...2289
Main Pump...2290
Control Valve...2291
General View...2291
Sectional View (1/5)...2293
Sectional View (2/5)...2295
Sectional View (3/5)...2297
Sectional View (4/5)...2299
Sectional View (5/5)...2301
Swing Motor...2303
Travel Motor...2307
PPC Valve...2311
Work Equipment and Swing PPC Valve...2311
Travel PPC Valve...2314
1st-Line Attachment PPC Valve (with EPC Valve)...2317
EPC Valve...2319
2nd-Line Attachment PPC Valve...2321
Solenoid Valve...2323
Attachment Circuit Selector Valve...2325
Center Swivel Joint...2327
WORK EQUIPMENT...2328
Dimensions of Components...2328
Dimensions of Arm...2333
Boom Cylinder...2341
Arm Cylinder...2342
Bucket Cylinder...2343
80 AIR CONDITIONER...2344
AIR CONDITIONER...2346
Precautions for Refrigerant...2346
Air Conditioner Component...2347
Structure and Function of Refrigeration System...2350
Overview of Refrigeration System...2351
Air Conditioner Unit...2353
Function...2354
Functions of Major Components...2355
Dual Pressure Switch...2359
Air Conditioner Controller...2359
Air Conditioner Compressor...2360
Air Conditioner Condenser...2361
Receiver Drier...2362
Sunlight Sensor...2363
Outside Air Temperature Sensor...2363
Procedure for Testing and Troubleshooting...2365
Basic Inspection and Troubleshooting Sequence...2365
Air Conditioner Circuit Diagram and Arrangement of Connector Pins...2367
System Diagram...2368
Air Conditioner Controller Input and Output Signals...2369
Parts and Connectors Layout...2371
Layout of Air Conditioner Related Parts and Connectors...2372
Testing Air Leakage (Duct)...2374
Testing with Self-Diagnosis Function...2377
How to Enter Air Conditioner “Electrical Systems” Screen in Service Mode of the Machine Monitor...2378
Testing Vent (Mode) Changeover...2380
Testing FRESH/RECIRC Air Changeover...2382
Testing Sunlight Sensor...2383
Testing (Dual) Pressure Switch for Refrigerant...2384
Testing Relay...2385
Troubleshooting Chart 1...2386
Troubleshooting Chart 2...2387
Information Mentioned in Troubleshooting Table...2390
Information in Troubleshooting Table...2390
Failure Code List Related to Air Conditioner...2391
879AKA - A/C Inner Sensor Open Circuit...2392
879AKB - A/C Inner Sensor Short Circuit...2392
879BKA - A/C Outer Sensor Open Circuit...2393
879BKB - A/C Outer Sensor Short Circuit...2395
879CKA - Ventilating Sensor Open Circuit...2397
879CKB - Ventilating Sensor Short Circuit...2398
879DKZ - Sunlight Sensor Open or Short Circuit...2399
879EMC - Ventilation Damper Abnormality...2401
879FMC - Air Mix Damper Abnormality...2402
879GKX - Refrigerant Abnormality...2403
A-1 Troubleshooting for Power Supply System (The Air Conditioner Does Not Operate)...2405
A-2 Troubleshooting of Compressor System (Air is Not Cooled)...2407
A-3 Troubleshooting of Blower Motor System (Air Does Not Come Out or Air Flow is Normal)...2411
A-4 Troubleshooting for FRESH/RECIRC Air Changeover...2413
Troubleshooting with Gauge Pressure...2415
[Measurement Condition for Pressure]...2415
Testing Refrigerant Pressure...2418
Check...2419
Precautions for Disconnecting and Connecting Refrigerant Piping...2421
Disconnection...2421
Connection...2421
Tightening Torque for Joint Portion of Refrigerant Piping...2422
Handling of Compressor Oil...2423
Oil Level Control of Compressor...2423
Refilling of Compressor Oil...2423
90 DIAGRAMS AND SCHEMATICS...2426
HYDRAULIC SYSTEM...2428
Hydraulic Circuit Symbols...2428
Hydraulic Circuit Diagram...2432
ELECTRICAL SYSTEM...2433
Electrical Symbols...2433
Air Conditioner Electrical Diagram...2443
Electrical Circuit Diagram (1/6)...2437
Electrical Circuit Diagram (2/6)...2438
Electrical Circuit Diagram (3/6)...2439
Electrical Circuit Diagram (4/6)...2440
Electrical Circuit Diagram (5/6)...2441
Electrical Circuit Diagram (6/6)...2442
CEBM025205 - Hydraulic Excavator PC360LC-10, PC390LC-10 Shop Manual...2444
00 - FOREWORD...2445
CONTENTS...2445
SAFETY...2462
Safety Notice...2462
Important Safety Notice...2462
General Precautions...2462
Preparations For Work...2464
Precautions During Work...2464
GENERAL...2467
HOW TO READ THE SHOP MANUAL...2469
Volumes...2469
Distribution And Updating...2469
Filing Method...2469
Revised Edition Mark...2469
Revisions...2469
Symbols...2469
HOISTING INSTRUCTIONS...2470
Hoisting...2470
Making Signs...2470
Precautions...2470
Precautions for Sling Work...2470
Precautions for Using Mobile Crane...2471
Precautions for Using Overhead Hoist Crane...2471
Selecting Wire Ropes...2473
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS...2474
Points to Remember When Handling Electric Equipment...2474
Points to Remember When Handling Hydraulic Equipment...2485
PUSH PULL COUPLER...2487
Type 1...2487
Disconnection...2487
Connection...2487
Type 2...2488
Disconnection...2488
Connection...2488
Type 3...2489
Disconnection...2489
Connection...2489
EXPLANATION OF MAINTENANCE STANDARD TERMS...2490
HANDLING OF FUEL SYSTEM DEVICES...2491
HANDLING OF INTAKE SYSTEM PARTS...2492
STANDARD TIGHTENING TORQUE...2493
Bolts And Nuts...2493
Tightening Torque Of Hose Nuts...2494
Tightening Torque Of Split Flange Bolts...2494
Tightening Torque For Flared Nuts...2494
Tightening Torques for Split Flanged Bolts...2495
Tightening Torques For O-ring Boss Piping Joints...2495
Table Of Tightening Torques For O-ring Boss Plugs...2495
Tightening Torque For Hoses (Taper Seal Type And Face Seal Type)...2496
Tightening Torque For Face Seal Joints...2496
For 102, 107, and 114 Engine Series (Bolts and Nuts)...2496
For 102, 107, and 114 Engine Series (Eye Joints)...2497
For 102, 107, and 114 Engine Series (Taper Screws)...2497
ELECTRIC WIRE CODE...2498
Classification By Thickness...2498
Classification By Color And Code...2498
How To Read Electric Wire Code...2499
PRECAUTIONS FOR OPERATIONS...2502
Precautions when Carrying Out Removal Work...2502
Precautions when Carrying Out Installation Work...2503
Precautions when Completing the Operation...2504
CONVERSION TABLES...2505
Method Of Using The Conversion Table...2505
COATING MATERIALS...2511
LIST OF ABBREVIATIONS...2513
List of Abbreviations Used in the Shop Manual...2513
List of Abbreviations Used in the Circuit Diagrams...2517
01 - GENERAL...2518
SPECIFICATION DIMENSION DRAWINGS...2519
Dimensions...2519
Working Ranges...2520
SPECIFICATIONS...2521
Engine...2521
Undercarriage...2521
Hydraulic System...2522
WEIGHT TABLE...2525
FUEL, COOLANT AND LUBRICANTS...2527
Lubrication Chart...2529
ENGINE AND COOLING SYSTEM...2534
Engine Related Parts...2534
KVGT...2536
Operation...2537
EGR System Piping Drawing...2542
Function...2543
EGR System Circuit Diagram...2544
Operation...2544
EGR Valve...2545
Operation...2546
EGR Cooler...2547
Operation...2547
KCCV Layout Drawing...2548
Operation...2549
KCCV Ventilator...2550
Function...2550
Operation...2551
CDR Valve...2551
KDPF...2552
Function...2553
Types of Regeneration...2554
Cooling System...2557
POWER TRAIN...2559
Power Train...2559
Swing Circle...2561
Swing Machinery...2563
Specifications...2564
Final Drive...2565
PC360LC-10...2565
PC390LC-10...2567
UNDERCARRIAGE AND FRAME...2569
Track Frame and Idler Cushion...2569
HYDRAULIC SYSTEM...2571
Hydraulic Component Layout...2571
Valve Control...2573
Hydraulic Tank...2575
Oil Filler Cap...2577
CLSS...2578
Structure of CLSS...2578
Basic principle...2579
Main Pump...2582
Operation...2586
LS Valve...2588
PC Valve...2594
LS(PC)-EPC Valve...2601
Control Valve...2604
Functions and Operation by Valve...2616
Hydraulic Circuit Diagram and Name of Valves...2616
Unload Valve...2620
Introduction of LS Pressure...2621
LS By-Pass Plug...2622
Pressure Compensation Valve...2623
Shuttle Valve In Pressure Compensation Valve...2626
Boom Regeneration Circuit...2628
Arm Regeneration Circuit...2630
Merge-Divider Valve...2632
LS Selector Valve...2635
Self-Pressure Reducing Valve...2636
Travel Junction Valve...2640
Travel PPC Shuttle Valve...2644
Boom Hydraulic Drift Prevention Valve...2646
Arm Hydraulic Drift Prevention Valve (If Equipped)...2649
Suction Safety Valve for Drift Prevention Valve...2652
Arm Quick Return Valve...2654
Variable Back Pressure Valve...2656
Main Relief Valve...2658
Suction 2-Stage Safety Valve...2660
Swing Motor...2662
Swing Holding Brake...2664
Relief Valve...2666
Swing 2-Stage Relief Valve...2668
Swing Motor Reverse Prevention Valve...2669
Travel Motor - Type KMV180ADT-2 (PC360LC-10)...2672
Operation of Travel Motor...2675
Operation of Parking Brake...2677
Brake Valve...2678
Counterbalance Valve...2679
Suction Safety Valve...2681
Travel Motor - Type KMV200ADT-2 (PC390LC-10)...2684
Operation of Travel Motor...2687
Parking Brake...2690
Brake Valve...2692
Safety Valve...2694
PPC Valve...2698
Work Equipment and Swing PPC Valve...2698
Travel PPC Valve...2704
1st-Line Attachment PPC Valve (with EPC Valve) (If Equipped)...2708
EPC Valve (If Equipped)...2710
2nd-Line Attachment PPC Valve (If Equipped)...2714
Solenoid Valve...2716
Attachment Circuit Selector Valve (If Equipped)...2720
Center Swivel Joint...2722
Accumulator...2724
PPC Accumulator...2724
WORK EQUIPMENT...2726
Work Equipment...2726
Work Equipment Shim...2727
Bucket Play Adjustment Shim...2727
CAB AND ITS ATTACHMENTS...2728
Cab Mount and Cab Tipping Stopper...2728
ROPS Cab...2730
ELECTRICAL SYSTEM...2732
Electrical Control System...2732
Machine Control System Diagram...2732
Engine Control Function...2734
Engine and Pump Combined Control Function...2736
Pump and Valve Control Function...2742
One-Touch Power Maximizing Function...2744
Machine Push-Up Function...2746
Auto-Deceleration Function...2748
Engine Automatic Warm-Up Function...2750
Overheat Prevention Function...2752
Turbocharger Protection Function...2753
Swing Control Function...2754
Quick Warm-Up Function...2756
Swing 2-Stage Relief Function...2756
Travel Control Function...2758
PPC Lock Function...2760
Attachment Flow Control Function...2762
System Component Part...2764
Engine Controller...2764
Pump Controller...2768
Fuel Control Dial...2772
Resister for PC-EPC valve...2773
CAN Terminating Resistor...2774
Engine Oil Pressure Switch...2775
PPC Oil Pressure Switch...2776
MACHINE MONITOR SYSTEM...2778
Machine Monitor...2780
Input and Output Signals...2781
Display...2784
Gauges...2786
Caution Monitor...2788
Pilot Monitor...2792
Switches...2794
Guidance ICON and Function Switch...2796
Operator Mode Function...2800
Service Mode Function...2802
KOMTRAX SYSTEM...2804
KOMTRAX terminal...2805
Input and Output Signals...2806
SENSORS...2808
Ambient Pressure Sensor...2808
Charge (Boost) Pressure and Temperature Sensor...2809
Coolant Temperature Sensor...2810
Ne (Crankshaft) Speed Sensor...2810
Bkup (Camshaft) Speed Sensor...2811
Common Rail Pressure Sensor...2811
Exhaust Manifold Pressure Sensor...2812
EGR Orifice Temperature Sensor...2812
EGR Valve Lift Sensor...2813
Turbo Speed Sensor...2814
KVGT Position Sensor...2815
Mass Air Flow and Temperature Sensor...2816
KDPF Differential Pressure and Outlet Pressure Sensor...2816
KDOC Inlet Temperature Sensor...2817
KDOC Outlet Temperature Sensor...2817
KDPF Outlet Temperature Sensor...2818
Crankcase Pressure Sensor...2818
Engine Oil Level Sensor...2819
Fuel Level Sensor...2820
Coolant Level Sensor...2821
Hydraulic Oil Temperature Sensor...2821
Front Pump Oil Pressure Sensor...2822
Rear Pump Oil Pressure Sensor...2823
PPC Oil Pressure Sensor...2824
Air Cleaner Clogging Sensor...2825
Front Pump Swash Plate Sensor...2826
Rear Pump Swash Plate Sensor...2828
Water-In-Fuel Sensor...2830
10 - STRUCTURE AND FUNCTION...2530
20 - STANDARD VALUE TABLES...2832
STANDARD SERVICE VALUE TABLES...2833
Standard Value Table for Engine Related Parts...2833
Standard Value Table for Chassis Related Parts...2835
Engine Speed...2835
Travel of Control Valve Spool...2835
Travel of Control Lever...2836
Operating Effort of Control Lever and Pedal...2836
Hydraulic Pressure...2837
Swing...2838
Travel...2839
Work Equipment...2841
Performance in Combined Operation...2843
Pump Swash Plate Sensor...2843
Main Pump...2843
Posture of Machine for Measuring Performance and Measurement Procedure...2845
Control Valve: Spool Stroke...2845
Swing 1: Overrun When Stopping Swing, Time Taken to Start Swing, Time Taken to Swing...2845
Swing 2: Hydraulic Drift of Swing...2845
Travel 1: Travel Speed, Idle Running (Without Load)...2845
Travel 2: Travel Speed (Actual Run), Travel Deviation...2846
Travel 3: Travel Deviation...2846
Travel 4: Hydraulic Drift of Travel...2846
Work Equipment 1: Hydraulic Drift of Work Equipment...2846
Work Equipment 2: Boom Speed...2847
Work Equipment 3: Arm Speed...2847
Work Equipment 4: Bucket Speed...2847
Work Equipment 5: Boom Time Lag...2847
Work Equipment 6: Arm Time Lag...2848
Work Equipment 7: Bucket Time Lag...2848
30 - TESTING AND ADJUSTING...2850
GENERAL INFORMATION...2854
Tools for Testing, Adjusting, and Troubleshooting...2854
Sketch of Tools for Testing and Adjusting...2861
ENGINE AND COOLING SYSTEM...2864
Checking Engine Speed...2864
Measuring Boost Pressure...2866
Measuring Exhaust Gas Color...2870
Measuring and Adjusting Valve Clearance...2872
Testing...2872
Adjustment...2875
Measuring Compression Pressure...2878
Measuring Blow-By Pressure...2888
Measuring Engine Oil Pressure...2890
Measuring EGR Valve and KVGT Oil Pressure...2894
Measuring Fuel Pressure...2896
Testing Low-Pressure Circuit (Main Fuel Filter Inlet Side)...2898
Testing Low-Pressure Circuit (Pressure Difference)...2899
Testing Return Circuit...2900
Testing the Negative Pressure Circuit (At Fuel Supply Connector)...2902
Testing the Negative Pressure Circuit (At Supply Pump)...2903
Testing Fuel Feed Pump Outlet Pressure (At Supply Pump)...2904
Measuring Fuel Delivery, Return and Leakage...2905
Testing Supply Pump Delivery...2906
Testing Supply Pump Return Rate...2908
Testing Leakage from Pressure Limiter...2910
Measuring Return Rate from Injector...2911
Testing Delivery of Fuel Feed Pump...2912
Bleeding Air from Fuel System...2913
Bleeding Air...2913
Checking Fuel Circuit for Leakage...2914
Handling Cylinder Cut-Out Mode Operation...2915
Handling No-Injection Cranking Operation...2915
Checking and Adjusting Air Conditioner Compressor Belt Tension...2916
Checking...2916
Adjusting...2916
Replacing Fan Belt...2917
Replacing Alternator Belt...2918
POWER TRAIN...2920
Testing Swing Circle Bearing Clearance...2920
Testing...2920
UNDERCARRIAGE AND FRAME...2922
Testing and Adjusting Track Shoe Tension...2922
Testing...2922
Adjusting...2922
HYDRAULIC SYSTEM...2924
Releasing Remaining Pressure from Hydraulic Circuit...2924
Measuring and Adjusting of Oil Pressure in Work Equipment, Swing, and Travel Circuits...2926
Measuring Method by Using Machine Monitor...2926
Measuring Method by Using Oil Pressure Gauge...2928
Combination of Pump, Actuator, and Valve...2930
Measuring Unload Pressure...2930
Measuring Work Equipment Relief Pressure...2930
Measuring Swing Relief Pressure...2931
Measuring Travel Relief Pressure...2931
Work After Finishing Measurement...2931
Adjusting...2932
Adjusting Work Equipment and Travel Relief Pressure...2932
Adjusting Boom LOWER Relief Pressure (On the Side Where High Pressure is Set)...2933
Adjusting Boom LOWER Relief Pressure (On the Side Where Low Pressure is Set)...2934
Adjusting Swing Relief Pressure...2935
Measuring Oil Pressure in Control Circuit...2936
Measuring with Machine Monitor...2936
Measuring with Oil Pressure Gauge...2940
Measuring and Adjusting Oil Pressure in Pump PC Control Circuit...2942
Testing...2943
Measuring PC Valve Output Pressure (Servo Piston Inlet Pressure) With Machine Monitor...2943
Measuring PC-EPC Valve Output Pressure With the Machine Monitor...2946
Measuring PC Valve Output Pressure (Servo Piston Inlet Pressure) With Oil Pressure Gauge...2950
Measuring PC-EPC Valve Output Pressure With Oil Pressure Gauge...2954
Adjusting...2956
Measuring and Adjusting Oil Pressure in Pump LS Control Circuit...2957
Testing...2958
Measuring LS Valve Output Pressure (Servo Piston Inlet Pressure) With Machine Monitor...2958
Measuring LS Differential Pressure with the Machine Monitor...2962
Measuring LS-EPC Valve Output Pressure with the Machine Monitor...2966
Measuring LS Valve Output Pressure (Servo Piston Inlet Pressure) with Oil Pressure Gauge...2968
Measuring LS Differential Pressure with Oil Pressure Gauge...2972
Measuring LS-EPC Valve Output Pressure with Oil Pressure Gauge...2976
Adjusting...2977
Measuring Solenoid Valve Output Pressure...2978
Testing...2979
Measuring with Machine Monitor...2979
Measuring with Oil Pressure Gauge...2980
Operating Condition...2982
Measuring PPC Valve Output Pressure...2984
Testing...2984
Measuring with Machine Monitor...2984
Measuring with Oil Pressure Gauge...2985
Adjusting Play of Work Equipment and Swing PPC Valves...2987
Adjusting...2987
Testing Pump Swash Plate Sensor...2988
Testing Output Voltage of Pump Swash Plate Sensor...2988
Isolating the Parts Causing Hydraulic Drift in Work Equipment...2990
Measuring Oil Leakage...2992
Bleeding Air From Hydraulic Circuit...2996
CAB AND ITS ATTACHMENTS...3000
Checking Cab Tipping Stopper...3000
Adjusting Mirrors...3002
ELECTRICAL SYSTEM...3006
Special Functions of Machine Monitor...3006
Upper Part of Machine Monitor (Display Portion)...3007
Upper Part of Machine Monitor (Switch Portion)...3007
Lower Part of Machine Monitor (Switch Portion)...3007
Ordinary Functions and Special Functions of Machine Monitor...3007
Operator Mode (Outline)...3010
Service Mode...3030
Angle Adjustment of Rear View Camera...3098
Handling Voltage Circuit of Engine Controller...3100
Handling Battery Disconnect Switch...3101
Testing Diodes...3102
PM CLINIC...3104
PM Clinic Service...3104
Check Items Related to Engine...3106
Check Items Related to Oil Pressure...3107
Check Sheet...3108
40 - TROUBLESHOOTING...3116
GENERAL INFORMATION ON TROUBLESHOOTING...3125
Points to Remember When Troubleshooting...3125
Sequence of Events in Troubleshooting...3127
Checks Before Troubleshooting...3129
Testing Procedure Before Troubleshooting...3131
Walk-Around Check...3131
Checking in Accordance with Checking Procedure...3133
Preparation Work for Troubleshooting of Electrical System...3156
Preparation Work...3156
Classification and Procedure for Troubleshooting...3161
Classification of Troubleshooting...3161
Procedure for Troubleshooting...3161
Symptom of Probable Failure and Troubleshooting No...3165
Information Mentioned in Troubleshooting Table...3169
Diagnostic Procedure for Wiring Harness Open Circuit of Pressure Sensor System...3171
Connector list...3174
Layout of connectors...3179
Connection Table for Connector Pin Numbers...3185
T-Branch Box and T-Branch Adapter Table...3220
Fuse List and Location...3224
Connection Table of Fuse Box...3224
Locations of Fusible Links...3225
Location of Fuse Box and Fuse Numbers...3225
Precautions for Cleaning and Replacing KDPF (KCSF, KDOC)...3226
FAILURE CODE (DISPLAY OF CODE)...3229
Failure Codes Table...3229
879AKA - A/C Inner Sensor Open Circuit...3236
879AKB - A/C Inner Sensor Short Circuit...3236
879BKA - A/C Outer Sensor Open Circuit...3236
879BKB - A/C Outer Sensor Short Circuit...3236
879CKA - Ventilating Sensor Open Circuit...3236
879CKB - Ventilating Sensor Short Circuit...3236
879DKZ - Sunlight Sensor Open or Short Circuit...3236
879EMC - Ventilation Damper Abnormality...3237
879FMC - Air Mix Damper Abnormality...3237
879GKX - Refrigerant Abnormality...3237
989L00 - Engine Controller Lock Caution 1...3238
989M00 - Engine Controller Lock Caution 2...3238
989N00 - Engine Controller Lock Caution 3...3239
A1U0N3 - KDPF Dry Request (HC Release) 1...3240
A1U0N4 - KDPF Dry Request (HC Release) 2...3242
AA10NX - Air Cleaner Clogging...3244
AB00KE - Charge Voltage Low...3246
B@BAZG - Engine Oil Pressure Low...3248
B@BAZK - Eng Oil Level Low...3250
B@BCNS - Engine Coolant Overheat...3252
B@BCZK - Radiator Coolant Level Low...3254
B@HANS - Hyd Oil Overheat...3256
CA115 - Eng Ne and Bkup Speed Sens Error...3257
CA122 - Chg Air Press Sensor High Error...3258
CA123 - Chg Air Press Sensor Low Error...3260
CA131 - Throttle Sensor High Error...3262
CA132 - Throttle Sensor Low Error...3264
CA144 - Coolant Temp Sens High Error...3266
CA145 - Coolant Temp Sens Low Error...3268
CA153 - Chg Air Temp Sensor High Error...3270
CA154 - Chg Air Temp Sensor Low Error...3272
CA187 - Sensor 2 Supply Volt Low Error...3274
CA221 - Ambient Press Sensor High Error...3276
CA222 - Ambient Press Sensor Low Error...3278
CA227 - Sensor 2 Supply Volt High Error...3280
CA234 - Eng Overspeed...3281
CA238 - Ne Speed Sensor Supply Volt Error...3282
CA239 - Ne Speed Sens Supply Volt High Error...3284
CA271 - IMV/PCV1 Short Error...3286
CA272 - IMV/PCV1 Open Error...3288
CA281 - Pump Press Balance Error...3290
CA295 - Ambient Press Sens In Range Error...3291
CA322 - Inj #1 (L#1) Open/Short Error...3292
CA323 - Inj #5 (L#5) Open/Short Error...3294
CA324 - Inj #3 (L#3) Open/Short Error...3296
CA325 - Inj #6 (L#6) Open/Short Error...3298
CA331 - Inj #2 (L#2) Open/Short Error...3300
CA332 - Inj #4 (L#4) Open/Short Error...3302
CA343 - ECM Critical Internal Failure...3304
CA351 - Injectors Drive Circuit Error...3305
CA352 - Sensor 1 Supply Volt Low Error...3306
CA356 - Mass Air Flow Sensor High Error...3308
CA357 - Mass Air Flow Sensor Low Error...3310
CA386 - Sensor 1 Supply Volt High Error...3313
CA428 - Water in Fuel Sensor High Error...3314
CA429 - Water in Fuel Sensor Low Error...3316
CA435 - Eng Oil Press Sw Error...3318
CA441 - Battery Voltage Low Error...3320
CA442 - Battery Voltage High Error...3322
CA449 - Rail Press Very High Error...3323
CA451 - Rail Press Sensor High Error...3326
CA452 - Rail Press Sensor Low Error...3328
CA488 - Chg Air Temp High Torque Derate...3330
CA515 - Rail Press Sens Sup Volt High Error...3332
CA516 - Rail Press Sens Sup Volt Low Error...3334
CA553 - Rail Press High Error 1...3336
CA555 - Crankcase Press High Error 1...3337
CA556 - Crankcase Press High Error 2...3338
CA559 - Rail Press Low Error 1...3339
CA595 - Turbo Speed High Error 2...3343
CA687 - Turbo Speed Low Error...3344
CA689 - Eng Ne Speed Sensor Error...3346
CA691 - Intake Air Temp Sens High Error...3350
CA692 - Intake Air Temp Sens Low Error...3352
CA697 - ECM Int Temp Sensor High Error...3354
CA698 - ECM Int Temp Sensor Low Error...3355
CA731 - Eng Bkup Speed Sens Phase Error...3356
CA778 - Eng Bkup Speed Sensor Error...3358
CA1117 - Persistent Data Lost Error...3362
CA1664 - KDOC Malfunction...3364
CA1691 - Regeneration Ineffective...3366
CA1695 - Sensor 5 Supply Volt High Error...3370
CA1696 - Sensor 5 Supply Volt Low Error...3372
CA1843 - Crankcase Press Sens High Error...3374
CA1844 - Crankcase Press Sens Low Error...3376
CA1879 - KDPF Differential P Sensor High Error...3378
CA1881 - KDPF Differential P Sensor Low Error...3380
CA1883 - KDPF Differential P Sens In Range Error...3382
CA1921 - KDPF Soot Load High Error 1...3386
CA1922 - KDPF Soot Load High Error 2...3388
CA1942 - Crankcase Press Sens In Range Error...3392
CA1993 - KDPF Differential Pressure Low Error...3393
CA2185 - Throt Sensor Sup Volt High Error...3394
CA2186 - Throt Sensor Sup Volt Low Error...3396
CA2249 - Rail Press Very Low Error...3398
CA2265 - Fuel Feed Pump Open Error...3400
CA2266 - Fuel Feed Pump Short Error...3402
CA2271 - EGR Valve Pos Sens High Error...3404
CA2272 - EGR Valve Pos Sens Low Error...3408
CA2288 - Turbo Speed High Error 1...3411
CA2311 - IMV Solenoid Error...3412
CA2349 - EGR Valve Solenoid Open Error...3413
CA2353 - EGR Valve Solenoid Short Error...3415
CA2357 - EGR Valve Servo Error...3417
CA2373 - Exhaust Manifold Press Sens High error...3418
CA2374 - Exhaust Manifold Press Sens Low Error...3420
CA2375 - EGR Orifice Temp Sens High Error...3422
CA2376 - EGR Orifice Temp Sens Low Error...3424
CA2381 - KVGT Pos Sens High Error...3426
CA2382 - KVGT Pos Sens Low Error...3428
CA2383 - KVGT Solenoid Open Error...3432
CA2386 - KVGT Solenoid Short Error...3434
CA2387 - KVGT Valve Servo Error...3436
CA2554 - Exh Manifold Press Sens In Range Error...3437
CA2555 - Grid Htr Relay Open Circuit Error...3438
CA2556 - Grid Htr Relay Volt High Error...3440
CA2637 - KDOC Blocked...3442
CA2639 - Manual Stationary Regeneration Request...3444
CA2961 - EGR Orifice Temp High Error 1...3446
CA2973 - Chg Air Press Sensor In Range Error...3447
CA3133 - KDPF Outlet Press Sens High Error...3448
CA3134 - KDPF Outlet Press Sens Low Error...3450
CA3135 - KDPF Outlet Press Sens In Range Error...3452
CA3251 - KDOC Inlet Temp High Error...3456
CA3253 - KDOC Temp Error - Non Regeneration...3460
CA3254 - KDOC Outlet Temp High Error 1...3462
CA3255 - KDPF Temp Error - Non Regeneration...3465
CA3256 - KDPF Outlet Temp High Error 1...3466
CA3311 - KDOC Outlet Temp High Error 2...3467
CA3312 - KDPF Outlet Temp High Error 2...3468
CA3313 - KDOC Inlet Temp Sensor Low Error...3472
CA3314 - KDOC Inlet Temp Sens High Error...3476
CA3315 - KDOC Inlet Temp Sens In Range Error...3480
CA3316 - KDOC Outlet Temp Sens Low Error...3484
CA3317 - KDOC Outlet Temp Sens High Error...3488
CA3318 - KDOC Outlet Temp Sens In Range Error...3492
CA3319 - KDPF Outlet Temp Sens High Error...3496
CA3321 - KDPF Outlet Temp Sens Low Error...3500
CA3322 - KDPF Outlet Temp Sens In Range Error...3504
CA3419 - Mass Air Flow (MAF) Sensor Sup Volt High Error...3508
CA3421 - Mass Air Flow (MAF) Sensor Sup Volt Low Error...3510
CA3741 - Rail Press Valve Trip Error...3512
D110KB - Battery Relay Output Voltage...3514
D19JKZ - Personal Code Relay Abnormality...3516
D811MC - KOMTRAX Error...3519
D862KA - GPS Antenna Open Circuit...3519
D8AQKR - CAN2 Discon (KOMTRAX)...3520
DA20MC - Pump Controller...3521
DA22KK - Pump Solenoid Power Low Error...3522
DA25KP - 5 V Sensor 1 Power Abnormality...3525
DA29KQ - Model Selection Abnormality...3528
DA2QKR - CAN2 Discon (Pump Con)...3530
DA2RKR - CAN1 Discon (Pump Con)...3533
DAF0MB - Monitor Memory Error...3534
DAF0MC - Monitor Error...3535
DAF8KB - Camera Power Supply Short Circuit...3536
DAF9KQ - Model Selection Abnormality...3538
DAFGMC - GPS Module Error...3539
DAFQKR - CAN2 Discon...3540
DAZ9KQ - A/C Model Selection Abnormality...3541
DAZQKR - CAN2 Discon (AC)...3542
DB2QKR - CAN2 Discon (Engine Con)...3546
DB2RKR - CAN1 Discon (Engine Con)...3552
DGH2KB - Hyd Oil Sensor Short Circuit...3558
DHA4KA - Air Cleaner Clog Sensor Open Circuit...3560
DHPAMA - F Pump Press Sensor Abnormality...3561
DHPBMA - R Pump Press Sensor Abnormality...3564
DHS3MA - Arm In PPC Press Sensor Abnormality...3568
DHS4MA - Bucket Curl PPC Press Sensor Abnormality...3572
DHS8MA - Boom Raise PPC Press Sensor Abnormality...3576
DHS9MA - Boom Lower PPC Press Sensor Abnormality...3580
DHSAMA - Swing RH PPC Press Sensor Abnormality...3584
DHSBMA - Swing LH PPC Press Sensor Abnormality...3588
DHSCMA - Arm Out PPC Press Sensor Abnormality...3592
DHSDMA - Bucket Dump PPC Press Sensor Abnormality...3596
DHSFMA - Travel Fwd LH PPC Press Sensor Abnormality...3600
DHSGMA - Travel Fwd RH PPC Press Sensor Abnormality...3604
DHSHMA - Travel Rev LH PPC Press Sensor Abnormality...3608
DHSJMA - Travel Rev RH PPC Press Sensor Abnormality...3612
DKR0MA - F Pump Swash Plate Sensor Abnormality...3616
DKR1MA - R Pump Swash Plate Sensor Abnormality...3620
DV20KB - Travel Alarm Short Circuit...3624
DW43KA - Travel Speed Sol Open Circuit...3626
DW43KB - Travel Speed Sol Short Circuit...3628
DW45KA - Swing Brake Sol Open Circuit...3630
DW45KB - Swing Brake Sol Short Circuit...3634
DW91KA - Travel Junction Sol Open Circuit...3638
DW91KB - Travel Junction Sol Short Circuit...3640
DWA2KA - Attachment Sol Open Circuit...3642
DWA2KB - Attachment Sol Short Circuit...3644
DWK0KA - 2-Stage Relief Sol Open Circuit...3646
DWK0KB - 2-Stage Relief Sol Short Circuit...3648
DWK2KA - Variable Back Press Sol Open Circuit...3650
DWK2KB - Variable Back Press Sol Short Circuit...3652
DWK8KA - Swing Press C/O Sol Open Circuit...3654
DWK8KB - Swing Press C/O Sol Short Circuit...3656
DXA8KA - PC-EPC (F) Sol Open Circuit...3658
DXA8KB - PC-EPC (F) Sol Short Circuit...3660
DXA9KA - PC-EPC (R) Sol Open Circuit...3662
DXA9KB - PC-EPC (R) Sol Short Circuit...3666
DXE0KA - LS-EPC Sol Open Circuit...3668
DXE0KB - LS-EPC Sol Short Circuit...3670
DXE4KA - Attachment Flow EPC Open Circuit...3672
DXE4KB - Attachment Flow EPC Short Circuit...3674
DXE5KA - Merge-divide Main Sol Open Circuit...3676
DXE5KB - Merge-divide Main Sol Short Circuit...3678
DXE6KA - Merge-divide LS Sol Open Circuit...3680
DXE6KB - Merge-divide LS Sol Short Circuit...3682
DY20KA - Wiper Working Abnormality...3684
DY20MA - Wiper Parking Abnormality...3688
DY2CKB - Washer Drive Short Circuit...3690
DY2DKB - Wiper Drive (Fwd) Short Circuit...3692
DY2EKB - Wiper Drive (Rev) Short Circuit...3694
ELECTRICAL SYSTEM (E-MODE)...3696
E-1 Engine Does Not Start (Engine Does Not Rotate)...3696
E-2 Manual Pre-Heating System Does Not Work...3704
E-3 Automatic Pre-Heating System Does Not Work...3708
E-4 Pre-Heating Monitor Does Not Light Up When Pre-Heater is Operated...3710
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing...3712
E-6 When Starting Switch is Turned to ON Position (Before Starting Engine), Engine Oil Level Monitor Lights Up in Yellow...3715
E-7 When Starting Switch is Turned to ON Position (Before Starting Engine), Radiator Coolant Level Monitor Lights Up in Yellow...3715
E-8 Coolant Temperature Monitor Lights Up in White While Engine is Running...3716
E-9 Hydraulic Oil Temperature Monitor Lights Up in White While Engine is Running...3716
E-10 Charge Level Monitor Lights Up While Engine is Running...3717
E-11 Fuel Level Monitor Lights Up in Red While Engine is Running...3717
E-12 Air Cleaner Clogging Monitor Lights Up in Yellow While Engine is Running...3717
E-13 Engine Coolant Temperature Monitor Lights Up in Red While Engine is Running...3718
E-14 Hydraulic Oil Temperature Monitor Lights Up in Red While Engine is Running...3718
E-15 Engine Oil Pressure Monitor Lights Up in Red While Engine is Running...3719
E-16 Fuel Gauge Display Does Not Move from Minimum or Maximum...3720
E-17 Display of Fuel Gauge Differs from Actual Fuel Level...3722
E-18 Coolant Temperature Gauge Indicate Either Min or Max and Does Not Move...3723
E-20 Hydraulic Oil Temperature Gauge Indicate Either Min or Max and Does Not Move...3726
E-21 Hydraulic Oil Temperature Gauge Differs from Actual oil Temperature...3728
E-22 Machine Monitor Does Not Display Partially...3729
E-23 Function Switch Does Not Work...3729
E-24 Automatic Pre-Heating System Does Not Work (In Cold Weather)...3730
E-25 Auto-Deceleration Monitor Does Not Light Up or Does Not Go Out When Auto-Deceleration Switch is Operated...3731
E-26 Auto-Deceleration is Not Actuated or Canceled When Lever is Operated...3732
E-27 Working Mode Selector Screen Selection Screen is Not Displayed When Working Mode Switch is Operated...3733
E-28 Engine or Hydraulic Pump Setting Does Not Change When Working Mode is Changed...3733
E-29 Travel Speed Monitor Does Not Change When Travel Speed Switch is Operated...3733
E-32 Travel Speed Does Not Change When Travel Speed is Shifted...3734
E-31 Alarm Buzzer Does Not Stop Sounding...3735
E-32 When Starting Switch is Turned OFF, Service Meter is Not Displayed...3735
E-33 Machine Monitor Service Mode Cannot be Selected...3736
E-34 Any of Work Equipment, Swing and Travel Does Not Work...3738
E-35 Any of Work Equipment, Swing and Travel Can Not be Locked...3740
E-36 Machine Can Not Swing While Swing Brake Cancel Switch is Canceled...3742
E-37 Swing Brake Does Not Operate While Swing Brake Cancel Switch is set to NORMAL position...3744
E-38 One-Touch Power Maximizing Function Does Not Work Or Pilot Monitor is Not Displayed...3746
E-39 One-Touch Power Maximizing Function Cannot be Released...3749
E-40 Travel Alarm Does Not Sound When Machine Travels...3750
E-41 Travel Alarm Does Not Stop Sounding When Machine Stops...3752
E-42 Horn Does Not Sound...3754
E-43 Horn Does Not Stop Sounding...3756
E-44 Wiper Monitor Does Not Light Up or Go Out When Wiper Switch is Operated...3757
E-45 Wiper Does Not Operate When Wiper Switch is Operated...3758
E-46 Window Washer Does Not Operate When Window Washer Switch is Operated...3760
E-47 Boom LOWER Indication is Not Displayed Properly With Monitoring Function...3760
E-48 Arm DUMP Indication is Not Displayed Properly With Monitoring Function...3760
E-49 Arm IN Indication is Not Displayed Properly With Monitoring Function...3760
E-50 Boom RAISE Indication is Not Displayed Properly With Monitoring Function...3761
E-51 Bucket CURL Indication is Not Displayed Properly With Monitoring Function...3761
E-52 Bucket DUMP Indication is Not Displayed Properly With Monitoring Function...3761
E-53 Swing Indication is Not Displayed Properly With Monitoring Function...3761
E-54 Travel Indication is Not Displayed Properly With Monitoring Function...3762
E-55 Attachment is Not Displayed Properly With Monitoring Function...3763
E-56 Attachment Hydraulic Circuit Cannot be Changed...3766
E-57 KOMTRAX System Does Not Work Properly...3768
E-58 Machine Push-up Function is Not Canceled...3770
HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...3774
Information Mentioned in Troubleshooting Table (H Mode)...3774
Failure Mode and Cause Table...3776
H-1 All of Work Equipment, Swing and Travel Operation Lacks Speed or Power...3785
H-2 Engine Speed Lowers Significantly or Engine Stalls...3790
H-3 Any of Work Equipment, Swing and Travel Does Not Work...3793
H-4 Unusual Sound is Heard from Around Hydraulic Pump...3793
H-5 Fine Control Performance or Response is Poor...3794
H-6 Boom Operation Lacks Speed or Power...3796
H-7 Arm Operation Lacks Speed or Power...3801
H-8 Bucket Operation Lacks Speed or Power...3806
H-9 Work Equipment Does Not Move in Single Operation...3810
H-10 Hydraulic Drift of Boom is Large...3811
H-11 Hydraulic Drift of Arm is Large...3812
H-12 Hydraulic Drift of Bucket is Large...3814
H-13 Time Lag of Work Equipment is Large...3816
H-14 When Part of Work Equipment is Relieved Singly, Other Parts of Work Equipment Move...3818
H-15 One-Touch Power Maximizing Function Does Not Work...3819
H-16 Machine Push Up Function Does Not Work...3820
H-17 In Combined Operation of Work Equipment, Equipment Having Heavier Load Moves Slower...3821
H-18 In Combined Operations of Swing and Boom RAISE, Boom Rising Speed is Low...3822
H-19 In Combined Operations of Swing and Travel, Travel Speed Drops Largely...3822
H-20 Machine Does Not Travel Straight...3823
H-21 Travel Speed is Too Low...3826
H-22 Machine is hard to Steer or Travel Power is Low...3828
H-23 Travel Speed Does Not Change, or Travel Speed is Too Low or High...3832
H-24 One of Tracks Dose Not Run...3834
H-25 Upper Structure Does Not Swing to the Right or Left...3836
H-26 Upper Structure Swing Only to the Right or Left...3837
H-27 Swing Acceleration is Poor or Swing Speed is Low (Either Right and Left)...3838
H-28 Swing Acceleration is Poor or Swing Speed is Low in Only One Direction...3840
H-29 Upper Structure Overruns Excessively When it Stops Swinging (Both Right and Left)...3841
H-30 Upper Structure Overruns Excessively When it Stops Swinging (Either Right or Left)...3842
H-31 Shock is Large When Upper Structure Stops Swinging...3843
H-32 Large Unusual Noise is Heard When Upper Structure Stops Swinging...3844
H-33 When Swing Holding Brake is Applied, Hydraulic Drift of Swing is Large...3845
H-34 When Swing Holding Brake is Released, Hydraulic Drift Of Swing is Large...3846
H-35 When additional attachment is installed, attachment circuit is not switched...3847
H-36 Oil Flow in Attachment Circuit Cannot be Controlled...3848
ENGINE (S-MODE)...3850
Information Mentioned in Troubleshooting Table (S-Mode)...3850
S-1 When Starting Switch is Turned to START Position, Engine Does Not Crank...3852
S-2 When Engine Cranks, Exhaust Smoke Does Not Come Out...3853
S-3 Fuel is Being Injected But Engine Does Not Start (Incomplete Combustion: Engine Cranks but Does Not Start)...3854
S-4 Startability is Poor...3856
S-5 Engine Does Not Pick Up Smoothly...3858
S-6 Engine Stops During Operation...3860
S-7 Engine Runs Rough or is Unstable...3862
S-8 Engine Lacks Power...3864
S-9 Exhaust Smoke is Black (KDPF Clogs Up Early)...3866
S-10 Engine Oil Consumption is Excessive...3868
S-11 Oil Becomes Contaminated Early...3869
S-12 Fuel Consumption is Excessive...3870
S-13 Oil is in Coolant (or Coolant Spurts or Coolant Level Goes Down)...3871
S-14 Oil Pressure Drops...3872
S-15 Fuel is Contaminated in Engine Oil...3874
S-16 Coolant Mixes in Engine Oil (Becomes Cloudy White)...3875
S-17 Coolant Temperature Rises Too High (Overheating)...3876
S-18 Unusual Noise is Heard...3877
S-19 Vibration is Excessive...3878
S-20 Air Cannot be Bled from Fuel Circuit...3879
S-21 Automatic Regeneration is Operated Frequently...3880
S-22 Active Regeneration is Operated for Long...3881
S-23 White Smoke Comes Out in the Process of Active Regeneration...3882
50 - DISASSEMBLY AND ASSEMBLY...3883
HOW TO READ THIS SECTION...3888
Removal and Installation of Assemblies...3888
Special Tools...3888
Removal...3888
Installation...3888
Disassembly and Assembly of Assemblies...3889
Special Tools...3889
Disassembly...3889
Assembly...3890
Coating Materials List...3891
SPECIAL TOOLS LIST...3896
Sketches of Special Tools...3900
CONNECTOR REPAIR PROCEDURES...3903
Stripping Insulation...3903
Wire Inspection...3903
Contact Terminal Removal (HD30 Type)...3904
Crimping Contact Terminal (HD30 Type)...3905
Insertion of Contact Terminal (HD30 Type)...3906
Contact Terminal Removal (DT Type)...3907
Crimping Contact Terminal (DT Type)...3908
Insertion of Contact Terminal (DT Type)...3909
ENGINE AND COOLING SYSTEM...3910
Supply Pump Assembly...3910
Removal...3910
Installation...3916
Fuel Injector Assembly...3924
Removal...3924
Installation...3933
Cylinder Head Assembly...3946
Removal...3946
Installation...3960
Radiator Assembly...3978
Removal...3978
Installation...3981
Hydraulic Oil Cooler Assembly...3982
Removal...3982
Installation...3986
Aftercooler Assembly...3988
Removal...3988
Installation...3989
Engine and Main Pump Assembly...3990
Removal...3990
Installation...4004
Engine Front Oil Seal...4008
Removal...4008
Installation...4012
Engine Rear Oil Seal...4016
Removal...4016
Installation...4018
Fuel Tank Assembly...4026
Removal...4026
Installation...4029
Engine Hood Assembly...4030
Removal...4030
Installation...4032
KDPF Assembly...4034
Removal...4034
Installation...4040
Disassembly...4044
Assembly...4050
KCCV Assembly...4056
Removal...4056
Installation...4057
Air Cleaner Assembly...4058
Removal...4058
Installation...4061
Air Conditioner Compressor Assembly...4062
Removal...4062
Installation...4063
Air Conditioner Condenser Assembly...4064
Removal...4064
Installation...4065
POWER TRAIN...4066
Travel Motor and Final Drive Assembly...4066
Removal...4066
Installation...4067
Final Drive (PC360LC-10)...4068
Disassembly...4068
Assembly...4073
Final Drive (PC390LC-10)...4080
Removal...4080
Installation...4080
Disassembly...4081
Assembly...4086
Swing Motor and Swing Machinery Assembly (PC360LC-10)...4094
Removal...4094
Installation...4095
Swing Motor and Swing Machinery (PC390LC-10)...4096
Removal...4096
Installation...4097
Swing Machinery (PC360LC-10)...4098
Disassembly...4098
Assembly...4102
Swing Machinery (PC390LC-10)...4108
Disassembly...4108
Assembly...4112
Swing Circle Assembly (PC360LC-10)...4118
Removal...4118
Installation...4118
Swing Circle Assembly (PC390LC-10)...4119
Removal...4119
Installation...4119
UNDERCARRIAGE AND FRAME...4120
Track Shoe Assembly...4120
Separation...4120
Installation...4122
Sprocket...4125
Removal...4125
Installation...4125
Idler and Idler Cushion Assembly...4126
Removal...4126
Installation...4126
Idler...4127
Disassembly...4127
Assembly...4128
Idler Cushion (PC360LC-10)...4132
Disassembly...4133
Assembly...4134
Idler Cushion (PC390LC-10)...4136
Disassembly...4137
Assembly...4138
Track Roller...4140
Disassembly...4140
Assembly...4142
Carrier Roller...4144
Disassembly...4144
Assembly...4146
Revolving Frame Assembly...4150
Removal...4150
Installation...4152
Counterweight Assembly...4154
Removal...4154
Installation...4157
HYDRAULIC SYSTEM...4158
Center Swivel Joint Assembly...4158
Removal...4158
Installation...4160
Disassembly...4162
Disassembly...4162
Assembly...4163
Hydraulic Tank Assembly...4164
Removal...4164
Installation...4167
Main Pump Assembly...4168
Removal...4168
Installation...4172
Control Valve Assembly...4174
Removal...4174
Installation...4181
Disassembly...4182
Replacing Procedures of Pressure Compensation Valve Seal...4183
Assembly...4184
Work Equipment PPC Valve...4188
Disassembly...4188
Assembly...4189
Travel PPC Valve...4190
Disassembly...4190
Assembly...4191
WORK EQUIPMENT...4192
Bucket Assembly...4192
Removal...4192
Installation...4193
Arm Assembly...4194
Removal...4194
Installation...4195
Work Equipment Assembly...4196
Removal...4196
Installation...4198
Work Equipment Cylinder...4200
Disassembly...4200
Assembly...4204
CAB AND ITS ATTACHMENTS...4210
Operator's Cab Assembly...4210
Removal...4210
Installation...4217
Operator Cab Glass (Fixed Glass)...4218
Removal...4219
Installation...4220
Front Window Assembly...4230
Removal...4230
Installation...4233
Floor Frame Assembly...4238
Removal...4238
Installation...4245
Air Conditioner Unit Assembly...4248
Removal...4248
Installation...4253
Operator's Seat...4254
Removal...4254
Installation...4256
Seat Belt...4258
Removal...4258
Installation...4259
Front Wiper Assembly...4260
Removal...4260
Installation...4266
ELECTRIC SYSTEM...4272
Engine Controller Assembly...4272
Removal...4272
Installation...4274
Pump Controller Assembly...4276
Removal...4276
Installation...4278
Machine Monitor Assembly...4280
Removal...4280
Installation...4283
Pump Swash Plate Sensor...4284
Removal...4284
Installation...4284
Mass Air Flow and Temperature Sensor...4286
Removal...4286
Installation...4287
KOMTRAX Terminal Assembly...4288
Removal...4288
Installation...4289
60 - MAINTENANCE STANDARD...4291
ENGINE AND COOLING SYSTEM...4294
Engine Mounts...4294
Cooling System...4296
POWER TRAIN...4298
Swing Circle...4298
Swing Machinery...4300
Final Drive...4302
PC360LC-10...4302
PC390LC-10...4304
Sprocket...4306
PC360LC-10...4306
PC390LC-10...4308
UNDERCARRIAGE AND FRAME...4310
Track Frame and Idler Cushion...4310
Idler...4312
PC360LC-10...4312
PC390LC-10...4314
Track Roller...4316
PC360LC-10...4316
PC390LC-10...4318
Carrier Roller...4320
PC360LC-10...4320
PC390LC-10...4321
Track Shoe...4322
PC360LC-10...4322
PC390LC-10...4326
Triple Grouser Shoe...4328
PC360LC-10...4328
PC390LC-10...4329
HYDRAULIC SYSTEM...4330
Hydraulic Tank...4330
Main Pump...4331
Control Valve...4332
General View...4332
Sectional View (1/5)...4334
Sectional View (2/5)...4336
Sectional View (3/5)...4338
Sectional View (4/5)...4340
Sectional View (5/5)...4342
Swing Motor...4344
Travel Motor...4348
PPC Valve...4352
Work Equipment and Swing PPC Valve...4352
Travel PPC Valve...4355
1st-Line Attachment PPC Valve (with EPC Valve)...4358
EPC Valve...4360
2nd-Line Attachment PPC Valve...4362
Solenoid Valve...4364
Attachment Circuit Selector Valve...4366
Center Swivel Joint...4368
WORK EQUIPMENT...4369
Dimensions of Components...4369
Dimensions of Arm...4374
Boom Cylinder...4382
Arm Cylinder...4383
Bucket Cylinder...4384
80 - AIR CONDITIONER...4385
AIR CONDITIONER...4387
Precautions for Refrigerant...4387
Air Conditioner Component...4388
Structure and Function of Refrigeration System...4391
Overview of Refrigeration System...4392
Air Conditioner Unit...4394
Function...4395
Functions of Major Components...4396
Dual Pressure Switch...4400
Air Conditioner Controller...4400
Air Conditioner Compressor...4401
Air Conditioner Condenser...4402
Receiver Drier...4403
Sunlight Sensor...4404
Outside Air Temperature Sensor...4404
Procedure for Testing and Troubleshooting...4406
Basic Inspection and Troubleshooting Sequence...4406
Air Conditioner Circuit Diagram and Arrangement of Connector Pins...4408
System Diagram...4409
Air Conditioner Controller Input and Output Signals...4410
Parts and Connectors Layout...4412
Layout of Air Conditioner Related Parts and Connectors...4413
Testing Air Leakage (Duct)...4415
Testing with Self-Diagnosis Function...4418
How to Enter Air Conditioner “Electrical Systems” Screen in Service Mode of the Machine Monitor...4419
Testing Vent (Mode) Changeover...4421
Testing FRESH/RECIRC Air Changeover...4423
Testing Sunlight Sensor...4424
Testing (Dual) Pressure Switch for Refrigerant...4425
Testing Relay...4426
Troubleshooting Chart 1...4427
Troubleshooting Chart 2...4428
Information Mentioned in Troubleshooting Table...4431
Information in Troubleshooting Table...4431
Failure Code List Related to Air Conditioner...4432
879AKA - A/C Inner Sensor Open Circuit...4433
879AKB - A/C Inner Sensor Short Circuit...4433
879BKA - A/C Outer Sensor Open Circuit...4434
879BKB - A/C Outer Sensor Short Circuit...4436
879CKA - Ventilating Sensor Open Circuit...4438
879CKB - Ventilating Sensor Short Circuit...4439
879DKZ - Sunlight Sensor Open or Short Circuit...4440
879EMC - Ventilation Damper Abnormality...4442
879FMC - Air Mix Damper Abnormality...4443
879GKX - Refrigerant Abnormality...4444
A-1 Troubleshooting for Power Supply System (The Air Conditioner Does Not Operate)...4446
A-2 Troubleshooting of Compressor System (Air is Not Cooled)...4448
A-3 Troubleshooting of Blower Motor System (Air Does Not Come Out or Air Flow is Normal)...4452
A-4 Troubleshooting for FRESH/RECIRC Air Changeover...4454
Troubleshooting with Gauge Pressure...4456
[Measurement Condition for Pressure]...4456
Testing Refrigerant Pressure...4459
Check...4460
Precautions for Disconnecting and Connecting Refrigerant Piping...4462
Disconnection...4462
Connection...4462
Tightening Torque for Joint Portion of Refrigerant Piping...4463
Handling of Compressor Oil...4464
Oil Level Control of Compressor...4464
Refilling of Compressor Oil...4464
90 - DIAGRAMS AND SCHEMATICS...4467
HYDRAULIC SYSTEM...4469
Hydraulic Circuit Diagram...4473
ELECTRICAL SYSTEM...4474
Electrical Circuit Diagram (1/6)...4478
Electrical Circuit Diagram (2/6)...4479
Electrical Circuit Diagram (3/6)...4480
Electrical Circuit Diagram (4/6)...4481
Electrical Circuit Diagram (5/6)...4482
Electrical Circuit Diagram (6/6)...4483
Air Conditioner Electrical Diagram...4484
CEBM031702 - Hydraulic Excavator PC360LCi -11, PC390LCi -11 Shop Manual...4485
SHOP MANUAL, PC360LCi-11, PC390LCi-11...0
00 INDEX AND FOREWORD...4487
INDEX...4488
ABBREVIATION LIST...4508
FOREWORD, SAFETY, BASIC INFORMATION...4514
HOW TO READ THE SHOP MANUAL...4514
SAFETY NOTICE FOR OPERATION...4516
PRECAUTIONS TO PREVENT FIRE...4524
ACTIONS IF FIRE OCCURS...4526
PRECAUTIONS FOR DISPOSING OF WASTE MATERIALS...4527
ACTIONS TAKEN TO MEET EXHAUST GAS REGULATIONS...4528
PRECAUTIONS FOR DEF...4529
GENERAL CHARACTER AND PRECAUTIONS FOR HANDLING...4529
PRECAUTIONS FOR ADDING...4529
PRECAUTIONS FOR STORING...4529
PRECAUTIONS FOR FIRE HAZARD AND LEAKAGE...4529
THE OTHER PRECAUTIONS...4529
STORE AdBlue/DEF...4530
PRECAUTIONS FOR HANDLING HYDRAULIC EQUIPMENT...4531
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF PIPINGS...4534
PRECAUTIONS FOR HANDLING ELECTRICAL EQUIPMENT...4541
PRECAUTIONS FOR HANDLING FUEL SYSTEM EQUIPMENT...4543
PRECAUTIONS FOR HANDLING INTAKE SYSTEM EQUIPMENT...4544
PRACTICAL USE OF KOMTRAX...4545
DISCONNECT AND CONNECT PUSH-PULL TYPE COUPLER...4546
METHOD FOR DISCONNECTING AND CONNECTING TYPE 1 PUSH-PULL TYPE COUPLER...4546
METHOD FOR DISCONNECTING AND CONNECTING TYPE 2 PUSH-PULL TYPE COUPLER...4547
METHOD FOR DISCONNECTING AND CONNECTING TYPE 3 PUSH-PULL TYPE COUPLER...4548
PRECAUTIONS FOR DISCONNECTION AND CONNECTION OF CONNECTORS...4550
METHOD FOR DISCONNECTING AND CONNECTING DEUTSCH CONNECTOR...4554
METHOD FOR DISCONNECTING AND CONNECTING SLIDE LOCK TYPE CONNECTOR...4555
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PULL...4557
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH LOCK TO PUSH...4558
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH HOUSING TO ROTATE...4560
HOW TO READ ELECTRICAL WIRE CODE...4561
EXPLANATION OF TERMS FOR MAINTENANCE STANDARD...4565
STANDARD TIGHTENING TORQUE TABLE...4568
CONVERSION TABLE...4575
01 SPECIFICATIONS...4581
CONTENTS...4582
ABBREVIATION LIST...4583
SPECIFICATIONS...4589
SPECIFICATION DRAWING...4589
SPECIFICATION DRAWING: PC360LCI-11/PC390LCI-11...4589
WORKING RANGE DRAWINGS...4591
WORKING RANGE: PC360LCI-11/PC390LCI-11...4591
SPECIFICATIONS...4592
SPECIFICATIONS: PC360LCI-11/PC390LCI-11...4592
WEIGHT TABLE...4595
WEIGHT TABLE: PC360LCI-11/PC390LCI-11...4595
TABLE OF FUEL, COOLANT, AND LUBRICANTS...4597
10 STRUCTURE AND FUNCTION...4599
CONTENTS...4600
ABBREVIATION LIST...4604
UREA SCR SYSTEM...4610
LAYOUT DRAWING OF UREA SCR SYSTEM...4610
UREA SCR SYSTEM DIAGRAM...4614
FUNCTION OF UREA SCR SYSTEM...4615
FUNCTION OF AdBlue/DEF SYSTEM...4615
INDUCEMENT STRATEGY...4617
COMPONENT PARTS OF UREA SCR SYSTEM...4631
AdBlue/DEF MIXING TUBE...4631
SCR ASSEMBLY...4631
AdBlue/DEF TANK...4634
AdBlue/DEF PUMP...4636
AdBlue/DEF INJECTOR...4637
AdBlue/DEF HOSE...4638
AdBlue/DEF TANK HEATING VALVE...4639
BOOT-UP SYSTEM...4640
LAYOUT DRAWING OF BOOT-UP SYSTEM...4640
SYSTEM OPERATING LAMP SYSTEM...4642
SYSTEM OPERATING LAMP SYSTEM DIAGRAM...4642
FUNCTION OF SYSTEM OPERATING LAMP SYSTEM...4642
BATTERY DISCONNECT SWITCH...4644
FUNCTION OF BATTERY DISCONNECT SWITCH...4644
ENGINE SYSTEM...4645
LAYOUT DRAWING OF ENGINE SYSTEM...4645
SPECIFICATIONS OF ENGINE SYSTEM...4646
FUNCTION OF ENGINE SYSTEM...4646
ENGINE CONTROL SYSTEM...4647
ENGINE CONTROL SYSTEM DIAGRAM...4647
FUNCTION OF ENGINE CONTROL SYSTEM...4648
AUTO-DECELERATION SYSTEM...4650
AUTO-DECELERATION SYSTEM DIAGRAM...4650
FUNCTION OF AUTO-DECELERATION SYSTEM...4650
OPERATION OF AUTO-DECELERATION SYSTEM...4651
ENGINE AUTOMATIC WARM-UP SYSTEM...4652
ENGINE AUTOMATIC WARM-UP SYSTEM DIAGRAM...4652
FUNCTION OF ENGINE AUTOMATIC WARM-UP SYSTEM...4653
OVERHEAT PREVENTION SYSTEM...4654
OVERHEAT PREVENTION SYSTEM DIAGRAM...4654
FUNCTION OF OVERHEAT PREVENTION SYSTEM...4655
TURBOCHARGER PROTECTION SYSTEM...4656
TURBOCHARGER PROTECTION SYSTEM DIAGRAM...4656
FUNCTION OF TURBOCHARGER PROTECTION SYSTEM...4657
AUTOMATIC IDLE STOP SYSTEM...4658
AUTOMATIC IDLE STOP SYSTEM DIAGRAM...4658
FUNCTION OF AUTOMATIC IDLE STOP SYSTEM...4658
COMPONENT PARTS OF ENGINE SYSTEM...4661
VGT...4661
EGR SYSTEM...4664
EGR VALVE...4666
EGR COOLER...4668
KCCV SYSTEM...4669
KCCV VENTILATOR...4671
KDPF...4672
COOLING SYSTEM...4677
LAYOUT DRAWING OF COOLING SYSTEM...4677
SPECIFICATIONS OF COOLING SYSTEM...4678
CONTROL SYSTEM...4679
LAYOUT DRAWING OF CONTROL SYSTEM...4679
MACHINE MONITOR SYSTEM...4682
MACHINE MONITOR SYSTEM DIAGRAM...4682
FUNCTION OF MACHINE MONITOR SYSTEM...4682
KomVision SYSTEM...4684
LAYOUT DRAWING OF KOMVISION SYSTEM...4684
KomVision SYSTEM DIAGRAM...4685
FUNCTION OF KomVision SYSTEM...4686
KOMTRAX SYSTEM...4688
KOMTRAX SYSTEM DIAGRAM...4688
FUNCTION OF KOMTRAX SYSTEM...4688
COMPONENT PARTS OF CONTROL SYSTEM...4689
MACHINE MONITOR...4689
KomVision CONTROLLER...4703
KomVision CAMERA...4707
KOMTRAX TERMINAL...4707
PUMP CONTROLLER...4709
RESISTOR FOR PC-EPC VALVE...4713
CAN TERMINATING RESISTOR...4714
ENGINE CONTROLLER...4715
FUEL CONTROL DIAL...4721
HYDRAULIC SYSTEM...4723
LAYOUT DRAWING OF HYDRAULIC SYSTEM...4723
CLSS...4726
STRUCTURE OF CLSS...4726
OPERATION OF UNLOAD VALVE AND LS PRESSURE...4728
PUMP SWASH PLATE ANGLE (OIL FLOW) CONTROL...4729
PRESSURE COMPENSATION CONTROL...4742
ENGINE AND PUMP COMBINED CONTROL SYSTEM...4745
ENGINE AND PUMP COMBINED CONTROL SYSTEM DIAGRAM...4745
FUNCTION OF ENGINE AND PUMP COMBINED CONTROL SYSTEM...4746
PUMP AND VALVE CONTROL SYSTEM...4751
PUMP AND VALVE CONTROL SYSTEM DIAGRAM...4751
FUNCTION OF PUMP AND VALVE CONTROL SYSTEM...4752
COMPONENT PARTS OF HYDRAULIC SYSTEM...4754
HYDRAULIC TANK...4754
MAIN PUMP...4757
CONTROL VALVE...4783
WORK EQUIPMENT SYSTEM...4843
LAYOUT DRAWING OF WORK EQUIPMENT SYSTEM...4843
STRUCTURE OF VALVE CONTROL...4848
ONE-TOUCH POWER MAXIMIZING SYSTEM...4850
ONE-TOUCH POWER MAXIMIZING SYSTEM DIAGRAM...4850
FUNCTION OF ONE-TOUCH POWER MAXIMIZING SYSTEM...4851
MACHINE PUSH-UP SYSTEM...4852
MACHINE PUSH-UP SYSTEM DIAGRAM...4852
FUNCTION OF MACHINE PUSH-UP SYSTEM...4853
PPC LOCK SYSTEM...4854
PPC LOCK SYSTEM DIAGRAM...4854
FUNCTION OF PPC LOCK SYSTEM...4854
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM...4855
WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM DIAGRAM...4855
FUNCTION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM...4855
OPERATION OF WORK EQUIPMENT AND TRAVEL AUTOMATIC LOCK SYSTEM...4856
OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT...4857
OIL FLOW ADJUSTER SYSTEM DIAGRAM FOR ATTACHMENT...4857
FUNCTION OF OIL FLOW ADJUSTER SYSTEM FOR ATTACHMENT...4858
COMPONENT PARTS OF WORK EQUIPMENT SYSTEM...4859
WORK EQUIPMENT AND SWING PPC VALVE...4859
1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)...4864
2ND-LINE ATTACHMENT PPC VALVE...4868
SOLENOID VALVE...4870
ATTACHMENT CIRCUIT SELECTOR VALVE...4873
PILOT CIRCUIT ACCUMULATOR...4875
ICT SYSTEM...4877
LAYOUT DRAWING OF ICT SYSTEM...4877
ICT CONTROL SYSTEM DIAGRAM...4879
BUCKET EDGE POSITION DETECTION SYSTEM...4880
BUCKET EDGE POSITION DETECTION SYSTEM DIAGRAM...4880
FUNCTION OF BUCKET EDGE POSITION DETECTION SYSTEM...4880
OPERATION OF BUCKET EDGE POSITION DETECTION SYSTEM...4880
THE INTELLIGENT MACHINE CONTROL SYSTEM...4882
FUNCTION OF THE INTELLIGENT MACHINE CONTROL SYSTEM...4882
AUTO GRADE ASSIST CONTROL...4882
AUTO STOP CONTROL...4889
CUSHION SYSTEM FOR ARM IN END...4897
CUSHION SYSTEM FOR ARM IN END DIAGRAM...4897
FUNCTION OF CUSHION SYSTEM FOR ARM IN END...4897
OPERATION OF CUSHION SYSTEM FOR ARM IN END...4897
CUSHION SYSTEM FOR BOOM RAISE END...4899
CUSHION SYSTEM FOR BOOM RAISE END DIAGRAM...4899
FUNCTION OF CUSHION SYSTEM FOR BOOM RAISE END...4899
OPERATION OF CUSHION SYSTEM FOR BOOM RAISE END...4899
BOOM SECONDARY DRIVE SWITCH...4901
CONTROL FUNCTION WHEN BOOM SECONDARY DRIVE SWITCH IS TURNED TO ON POSITION...4901
COMPONENT PARTS OF ICT SYSTEM...4902
ICT SENSOR CONTROLLER...4902
WORK EQUIPMENT CONTROLLER...4906
CONTROL BOX...4910
GNSS RECEIVER...4913
GNSS ANTENNA...4916
IMU SENSOR...4917
INTELLIGENT MACHINE CONTROL EPC VALVE...4919
STROKE SENSOR FOR BOOM CYLINDER...4922
STROKE SENSOR FOR ARM CYLINDER...4923
STROKE AND RESET SENSOR FOR BUCKET CYLINDER...4924
RESET SENSOR FOR BOOM CYLINDER...4926
RESET SENSOR FOR ARM CYLINDER...4927
BOOM SPOOL STROKE SENSOR...4928
ARM SPOOL STROKE SENSOR...4930
SWING SYSTEM...4932
LAYOUT DRAWING OF SWING SYSTEM...4932
SWING CONTROL SYSTEM DIAGRAM...4935
FUNCTION OF SWING CONTROL SYSTEM...4935
COMPONENT PARTS OF SWING SYSTEM...4939
SWING MOTOR...4939
SWING MACHINERY...4950
SWING CIRCLE...4951
TRAVEL SYSTEM...4953
LAYOUT DRAWING OF TRAVEL SYSTEM...4953
TRAVEL CONTROL SYSTEM DIAGRAM...4957
FUNCTION OF TRAVEL CONTROL SYSTEM...4957
COMPONENT PARTS OF TRAVEL SYSTEM...4959
TRAVEL MOTOR...4959
FINAL DRIVE...4971
TRAVEL PPC VALVE...4972
CENTER SWIVEL JOINT...4977
UNDERCARRIAGE AND FRAME...4979
LAYOUT DRAWING OF UNDERCARRIAGE...4979
SPECIFICATIONS OF UNDERCARRIAGE...4979
WORK EQUIPMENT...4981
STRUCTURE OF WORK EQUIPMENT...4981
FUNCTION OF WORK EQUIPMENT...4982
WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM...4983
FUNCTION OF WORK EQUIPMENT CLEARANCE ADJUSTMENT SHIM...4983
BUCKET CLEARANCE ADJUSTMENT SHIM...4984
FUNCTION OF BUCKET CLEARANCE ADJUSTMENT SHIM...4984
CAB AND ITS ATTACHMENTS...4985
ROPS CAB...4985
STRUCTURE OF ROPS CAB...4985
FUNCTION OF ROPS CAB...4985
CAB MOUNT...4986
STRUCTURE OF CAB MOUNT...4986
FUNCTION OF CAB MOUNT...4986
CAB TIPPING STOPPER...4987
STRUCTURE OF CAB TIPPING STOPPER...4987
FUNCTION OF CAB TIPPING STOPPER...4987
20 STANDARD VALUE TABLE...4989
CONTENTS...4990
ABBREVIATION LIST...4991
STANDARD VALUE TABLE FOR ENGINE...4997
STANDARD VALUE TABLE FOR ENGINE: PC360LCI-11/PC390LCI-11...4997
STANDARD VALUE TABLE FOR MACHINE...5002
STANDARD VALUE TABLE FOR MACHINE: PC360LCI-11/PC390LCI-11...5002
MACHINE POSTURE AND PROCEDURE FOR MEASURING PERFORMANCE...5026
STANDARD VALUE TABLE FOR ELECTRICAL...5030
STANDARD VALUE TABLE FOR ELECTRICAL...5030
30 TESTING AND ADJUSTING...5039
CONTENTS...5040
ABBREVIATION LIST...5044
RELATED INFORMATION ON TESTING AND ADJUSTING...5050
TOOLS FOR TESTING AND ADJUSTING...5050
SKETCH OF TOOLS FOR TESTING AND ADJUSTING...5060
ENGINE AND COOLING SYSTEM...5062
TEST ENGINE SPEED...5062
METHOD FOR TESTING ENGINE SPEED...5062
TEST BOOST PRESSURE...5066
METHOD FOR TESTING BOOST PRESSURE ON MACHINE MONITOR...5066
METHOD FOR TESTING BOOST PRESSURE...5067
TEST EXHAUST GAS COLOR...5068
METHOD FOR TESTING EXHAUST GAS COLOR BY HANDY SMOKE CHECKER...5068
METHOD FOR TESTING EXHAUST GAS COLOR BY SMOKE METER...5069
TEST AND ADJUST VALVE CLEARANCE...5070
METHOD FOR TESTING VALVE CLEARANCE...5070
METHOD FOR ADJUSTING VALVE CLEARANCE...5072
TEST COMPRESSION PRESSURE...5073
METHOD FOR TESTING COMPRESSION PRESSURE...5073
TEST BLOWBY PRESSURE...5076
METHOD FOR TESTING BLOWBY PRESSURE...5076
TEST ENGINE OIL PRESSURE...5078
METHOD FOR TESTING ENGINE OIL PRESSURE...5078
TEST EGR VALVE AND VGT OIL PRESSURE...5080
METHOD FOR TESTING EGR VALVE AND VGT OIL PRESSURE...5080
TEST FUEL PRESSURE...5082
METHOD FOR TESTING FUEL PRESSURE...5083
TEST FUEL DISCHARGE, RETURN AND LEAKAGE...5089
METHOD FOR TESTING FUEL DISCHARGE, RETURN AND LEAKAGE...5090
BLEED AIR FROM FUEL SYSTEM...5096
METHOD FOR BLEEDING AIR FROM FUEL SYSTEM...5096
TEST FUEL CIRCUIT FOR LEAKAGE...5097
METHOD FOR TESTING FUEL CIRCUIT FOR LEAKAGE...5097
HANDLE CYLINDER CUT-OUT MODE OPERATION...5099
HANDLE NO-INJECTION CRANKING OPERATION...5100
TEST AND ADJUST AIR CONDITIONER COMPRESSOR BELT TENSION...5101
METHOD FOR TESTING AIR CONDITIONER COMPRESSOR BELT TENSION...5101
METHOD FOR ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION...5101
WRITE ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER...5102
METHOD FOR WRITING ASH IN SOOT ACCUMULATION CORRECTION TO ENGINE CONTROLLER...5102
TEST SCR RELATED FUNCTIONS...5103
TEST AdBlue/DEF PUMP RAISED PRESSURE...5106
TEST INJECTION AMOUNT FROM AdBlue/DEF INJECTOR...5109
TEST AdBlue/DEF LINE HEATER RELAY 1...5113
TEST AdBlue/DEF LINE HEATER RELAY 2...5115
TEST AdBlue/DEF PUMP HEATER RELAY...5118
TEST AdBlue/DEF TANK HEATER VALVE...5121
TEST DENITRATION EFFICIENCY OF SCR...5124
CLEAN AdBlue/DEF TANK...5128
METHOD FOR CLEANING AdBlue/DEF TANK...5128
POWER TRAIN...5132
TEST SWING CIRCLE BEARING CLEARANCE...5132
METHOD FOR TESTING SWING CIRCLE BEARING CLEARANCE...5132
UNDERCARRIAGE AND FRAME...5133
TEST AND ADJUST TRACK TENSION...5133
METHOD FOR TESTING TRACK TENSION...5133
METHOD FOR ADJUSTING TRACK TENSION...5133
HYDRAULIC SYSTEM...5135
RELEASE REMAINING PRESSURE FROM HYDRAULIC SYSTEM...5135
METHOD FOR RELEASING REMAINING PRESSURE FROM HYDRAULIC TANK...5135
METHOD FOR RELEASING REMAINING PRESSURE IN HYDRAULIC CYLINDER CIRCUIT...5135
METHOD FOR RELEASING REMAINING PRESSURE FROM SWING MOTOR CIRCUIT...5139
METHOD FOR RELEASING REMAINING PRESSURE FROM TRAVEL MOTOR CIRCUIT...5139
TEST AND ADJUST OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS...5140
METHOD FOR TESTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS...5141
METHOD FOR ADJUSTING OIL PRESSURE IN WORK EQUIPMENT, SWING, AND TRAVEL CIRCUITS...5149
TEST OIL PRESSURE OF CONTROL CIRCUIT...5153
METHOD FOR TESTING OIL PRESSURE OF CONTROL CIRCUIT...5153
TEST AND ADJUST OIL PRESSURE IN PUMP PC CONTROL CIRCUIT...5155
TEST PC VALVE OUTPUT PRESSURE (SERVO PISTON INLET PRESSURE)...5155
TEST PC-EPC VALVE OUTPUT PRESSURE...5156
METHOD FOR ADJUSTING OIL PRESSURE IN PUMP PC CONTROL CIRCUIT...5157
TEST AND ADJUST OIL PRESSURE IN PUMP LS CONTROL CIRCUIT...5158
METHOD FOR TESTING OIL PRESSURE WITH SENSOR ADAPTER (SPECIAL TOOL)...5158
METHOD FOR TESTING LS DIFFERENTIAL PRESSURE...5159
METHOD FOR TESTING LS VALVE OUTPUT PRESSURE (SERVO PISTON INLET PRESSURE)...5161
METHOD FOR TESTING LS-EPC VALVE OUTPUT PRESSURE...5161
METHOD FOR ADJUSTING LS VALVE...5162
TEST OUTLET PRESSURE OF SOLENOID VALVE...5163
METHOD FOR TESTING OUTLET PRESSURE OF SOLENOID VALVE...5163
OPERATING CONDITION OF SOLENOID VALVE...5164
TEST PPC VALVE OUTPUT PRESSURE...5166
METHOD FOR TESTING PPC VALVE OUTPUT PRESSURE...5166
ADJUST WORK EQUIPMENT AND SWING PPC VALVES...5168
METHOD FOR ADJUSTING PLAY OF WORK EQUIPMENT AND SWING PPC VALVES...5168
TEST PUMP SWASH PLATE SENSOR...5169
METHOD FOR TESTING PUMP SWASH PLATE SENSOR...5169
TEST THE PARTS CAUSING HYDRAULIC DRIFT IN WORK EQUIPMENT...5170
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF BOOM CYLINDER AND BUCKET CYLINDER...5170
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF ARM CYLINDER...5170
METHOD FOR TESTING THE PARTS CAUSING HYDRAULIC DRIFT OF PPC VALVE...5171
TEST OIL LEAKAGE...5172
METHOD FOR TESTING OIL LEAKAGE FROM BOOM CYLINDER...5172
METHOD FOR TESTING OIL LEAKAGE FROM ARM CYLINDER...5172
METHOD FOR TESTING OIL LEAKAGE FROM BUCKET CYLINDER...5173
METHOD FOR TESTING OIL LEAKAGE FROM SWING MOTOR...5173
METHOD FOR TESTING OIL LEAKAGE FROM TRAVEL MOTOR...5173
BLEED AIR FROM HYDRAULIC CIRCUIT...5175
METHOD FOR BLEEDING AIR FROM HYDRAULIC CIRCUIT...5177
CAB AND ITS ATTACHMENTS...5180
TEST CAB TIPPING STOPPER...5180
METHOD FOR TESTING CAB TIPPING STOPPER...5180
METHOD FOR ADJUSTING MIRRORS...5181
PROCEDURE FOR ADJUSTING MACHINE LEFT FRONT MIRROR (A)...5181
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE LEFT FRONT MIRROR (A)...5182
PROCEDURE FOR ADJUSTING MACHINE RIGHT FRONT MIRROR (B)...5183
PROCEDURE FOR ADJUSTING REGULAR POSITION OF MACHINE RIGHT FRONT MIRROR (B)...5184
PROCEDURE FOR ADJUSTING MACHINE RIGHT SIDE MIRROR (C)...5185
ELECTRICAL SYSTEM...5187
SET AND OPERATE MACHINE MONITOR...5187
OPERATOR MODE...5190
DISPLAY FUNCTION OF TECHNICIAN IDENTIFICATION STATUS SCREEN...5191
DISPLAY FUNCTION OF OPERATOR IDENTIFICATION INPUT SCREEN...5191
CHECKING FUNCTION BY LCD (LIQUID CRYSTAL DISPLAY)...5192
CHECKING FUNCTION OF SERVICE METER...5192
METHOD FOR SETTING USAGE LIMITATION AND CHANGING PASSWORD...5192
SERVICE MODE...5195
METHOD FOR OPERATING SERVICE MODE...5195
METHOD FOR CHECKING PRE-DEFINED MONITORING INFORMATION...5197
METHOD FOR CHECKING SELF-DEFINE MONITORING INFORMATION...5204
ABNORMALITY RECORD MENU...5217
METHOD FOR CONFIRMING MAINTENANCE RECORD...5222
METHOD FOR OPERATING MAINTENANCE MODE SETTING...5223
METHOD FOR OPERATING PHONE NUMBER ENTRY SETTING...5227
DEFAULT MENU...5228
DIAGNOSTIC TESTS MENU...5235
ADJUSTMENT MENU...5244
METHOD FOR PERFORMING NO-INJECTION CRANKING...5261
KOMTRAX SETTINGS MENU...5262
METHOD FOR DISPLAYING SERVICE MESSAGE...5264
METHOD FOR STARTING UP KOMTRAX TERMINAL...5266
ADJUST REARVIEW CAMERA ANGLE...5271
METHOD FOR ADJUSTING REAR VIEW CAMERA ANGLE...5271
HANDLE VOLTAGE CIRCUIT OF ENGINE CONTROLLER...5274
HANDLE BATTERY DISCONNECT SWITCH...5275
TEST DIODES...5276
METHOD FOR TESTING DIODE USING DIGITAL TESTER...5276
METHOD FOR TESTING DIODE USING ANALOG TESTER...5276
ICT SYSTEM...5277
SET AND OPERATE CONTROL BOX...5277
METHOD FOR SETTING THE STARTING SWITCH INTERLOCK FUNCTION OF THE CONTROL BOX...5279
METHOD FOR SELECTING EXCAVATOR MODEL AND IN THE CONTROL BOX...5282
CALIBRATE INTELLIGENT MACHINE CONTROL...5286
PPC Pressure Sensor Calibration...5288
Control Map Calibration...5369
METHOD FOR TESTING THE INTELLIGENT MACHINE CONTROL SYSTEM...5518
CALIBRATE IMU SENSOR FOR YAW ANGLE...5524
IMU SENSOR CALIBRATION...5531
ACTION TO BE TAKEN IF AN ERROR OCCURS DURING CALIBRATION OF IMU SENSOR...5543
WORK EQUIPMENT CYLINDER CALIBRATION...5543
ACTION TO BE TAKEN IF AN ERROR OCCURS DURING CALIBRATION OF WORK EQUIPMENT CYLINDER...5556
GENERAL CALIBRATION OF BUCKET BLADE EDGE POSITION, BOOM DIMENSIONS, ARM DIMENSIONS, BUCKET LINK DIMENSIONS, AND GNSS ANTENNA POSITION WITH TOTAL STATION...5558
CALIBRATION OF BOOM DIMENSIONS AND ARM DIMENSIONS WITH TOTAL STATION...5610
CALIBRATION OF BUCKET LINK DIMENSIONS WITH TOTAL STATION...5630
CALIBRATION OF GNSS ANTENNA WITH TOTAL STATION...5666
INPUT RANGE OF THE MEASURED VALUES IN CALIBRATION WITH TOTAL STATION...5690
VERIFY THE INPUT VALUES IN CALIBRATION WITH TOTAL STATION...5692
ACTION TO BE TAKEN IF AN ERROR OCCURS DURING CALIBRATION WITH TOTAL STATION...5692
CALIBRATION OF GNSS ANTENNA WITHOUT TOTAL STATION...5693
CALIBRATION OF BUCKET BLADE EDGE POSITION WITHOUT TOTAL STATION...5698
INPUT RANGE OF THE MEASURED VALUES IN CALIBRATION WITHOUT TOTAL STATION...5708
ACTION TO BE TAKEN IF AN ERROR OCCURS DURING CALIBRATION WITHOUT TOTAL STATION...5708
Pm CLINIC...5710
Pm CLINIC SERVICE...5710
Pm CLINIC CHECK SHEET: PC360LCI-11/PC390LCI-11...5711
40 TROUBLESHOOTING...5725
CONTENTS...5726
ABBREVIATION LIST...5739
RELATED INFORMATION ON TROUBLESHOOTING...5745
GENERAL TROUBLESHOOTING POINTS...5745
TROUBLESHOOTING POINTS FOR UREA SCR SYSTEM...5746
SEQUENCE OF EVENTS IN TROUBLESHOOTING...5758
CHECKS BEFORE TROUBLESHOOTING...5760
INSPECTION PROCEDURE BEFORE TROUBLESHOOTING...5762
WALK-AROUND CHECK...5762
TESTING IN ACCORDANCE WITH TESTING PROCEDURE...5764
CHECK FUEL LEVEL AND TYPE...5764
CHECK IMPURE INGREDIENT IN FUEL...5764
CHECK FUEL PREFILTER...5765
WATER SEPARATOR - CHECK / DRAIN WATER AND SEDIMENT...5765
METHOD FOR REPLACING FUEL PREFILTER CARTRIDGE...5766
CHECK MAIN FILTER...5767
CHECK ENGINE OIL LEVEL (OIL AMOUNT IN OIL PAN)...5769
CHECK COOLANT LEVEL (RESERVOIR TANK)...5770
CHECK CLOGGING OF AIR CLEANER...5771
OUTER ELEMENT - CLEAN...5771
ELEMENTS - REPLACE...5773
CHECK HYDRAULIC OIL LEVEL...5774
CHECK HYDRAULIC OIL STRAINER...5775
CHECK HYDRAULIC FILTER...5776
CHECK OIL LEVEL IN SWING MACHINERY CASE...5777
CHECK OIL LEVEL IN DAMPER CASE...5777
CHECK OIL LEVEL IN FINAL DRIVE CASE...5778
BLEED AIR FROM FUEL SYSTEM...5778
BLEED AIR FROM HYDRAULIC SYSTEM...5778
ELECTRICAL EQUIPMENT - CHECK METHOD...5778
PREPARATION FOR TROUBLESHOOTING OF ELECTRICAL SYSTEM...5784
PREPARATION FOR TROUBLESHOOTING OF MACHINE MONITOR...5784
PREPARATION FOR TROUBLESHOOTING OF ENGINE CONTROLLER...5784
PREPARATION FOR TROUBLESHOOTING OF ICT SENSOR CONTROLLER...5785
PREPARATION FOR TROUBLESHOOTING OF KOMTRAX TERMINAL...5786
PREPARATION FOR TROUBLESHOOTING OF KomVision CONTROLLER...5786
PREPARATION FOR TROUBLESHOOTING OF CONTROL BOX...5786
PREPARATION FOR TROUBLESHOOTING OF GNSS RECIVER...5786
METHOD FOR DISCONNECTING AND CONNECTING CONNECTOR WITH SPECIAL LOCK...5787
PROCEDURE FOR TESTING AND TROUBLESHOOTING...5791
SYMPTOMS OF FAILURE AND TROUBLESHOOTING NUMBERS...5794
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...5799
TROUBLESHOOTING METHOD FOR OPEN CIRCUIT IN WIRING HARNESS OF PRESSURE SENSOR SYSTEM...5801
CONNECTOR LIST AND LAYOUT...5804
CONNECTOR CONTACT IDENTIFICATION...5824
T-BRANCH BOX AND T-BRANCH ADAPTER TABLE...5864
FUSE LOCATION TABLE...5870
PRECAUTIONS FOR CLEANING AND REPLACING KDPF (KCSF and KDOC)...5873
PREPARATION OF SHORT CIRCUIT ELECTRICAL CONNECTOR (FOR FAILURE CODES [CA1883] AND [CA3135])...5877
FAILURE CODES TABLE...5879
TROUBLESHOOTING BY FAILURE CODE (DISPLAY OF CODE)...5900
FAILURE CODE [879AKA]...5900
FAILURE CODE [879AKB]...5901
FAILURE CODE [879BKA]...5902
FAILURE CODE [879BKB]...5904
FAILURE CODE [879CKA]...5906
FAILURE CODE [879CKB]...5907
FAILURE CODE [879DKZ]...5908
FAILURE CODE [879EMC]...5910
FAILURE CODE [879FMC]...5911
FAILURE CODE [879GKX]...5912
FAILURE CODE [989L00]...5914
FAILURE CODE [989M00]...5915
FAILURE CODE [989N00] Engine Controller Lock Caution3...5916
FAILURE CODE [A1U0N3]...5917
FAILURE CODE [A1U0N4]...5919
FAILURE CODE [A900FR]...5921
FAILURE CODE [A900N6]...5922
FAILURE CODE [A900NY]...5923
FAILURE CODE [AA10NX] Air Cleaner Clogging...5924
FAILURE CODE [AB00KE]...5926
FAILURE CODE [AQ10N3]...5929
FAILURE CODE [AS00N3] Manual Stationary Regeneration Request (SCR)...5931
FAILURE CODE [AS00R2]...5933
FAILURE CODE [AS00R3]...5934
FAILURE CODE [AS00R4]...5935
FAILURE CODE [AS00R5]...5936
FAILURE CODE [AS00R6]...5937
FAILURE CODE [AS00ZK] AdBlue/DEF Level Low Error 5...5938
FAILURE CODE [AS10KM]...5939
FAILURE CODE [AS10NR]...5940
FAILURE CODE [AS10NT]...5941
FAILURE CODE [B@BAZG]...5942
FAILURE CODE [B@BAZK]...5943
FAILURE CODE [B@BCNS]...5945
FAILURE CODE [B@BCQA]...5946
FAILURE CODE [B@BCZK]...5948
FAILURE CODE [B@HANS]...5950
FAILURE CODE [CA115]...5951
FAILURE CODE [CA122] Charge pressure sensor high error...5952
FAILURE CODE [CA123]...5954
en)...5956
en)...5958
FAILURE CODE [CA144]...5960
FAILURE CODE [CA145]...5962
FAILURE CODE [CA153]...5964
FAILURE CODE [CA154] Charge temperature sensor low error...5967
FAILURE CODE [CA187] Sensor power supply 2 low error...5970
FAILURE CODE [CA221] Atmospheric pressure sensor high error...5972
FAILURE CODE [CA222] Atmospheric pressure sensor low error...5974
FAILURE CODE [CA227]...5976
FAILURE CODE [CA234] Eng overspeed...5977
FAILURE CODE [CA238] NE Speed Sensor Supply Voltage Error...5978
FAILURE CODE [CA239] NE Speed Sensor Supply Voltage High Error...5980
FAILURE CODE [CA249] Ambient Air Temp Sensor High Error...5982
FAILURE CODE [CA256] Ambient Air Temp Sensor Low Error...5984
FAILURE CODE [CA271]...5986
FAILURE CODE [CA272]...5988
FAILURE CODE [CA281]...5990
FAILURE CODE [CA322]...5991
FAILURE CODE [CA323]...5993
FAILURE CODE [CA324]...5995
FAILURE CODE [CA325]...5997
FAILURE CODE [CA331]...5999
FAILURE CODE [CA332]...6001
FAILURE CODE [CA343]...6003
en)...6004
FAILURE CODE [CA352] Sensor power supply 1 low error...6005
FAILURE CODE [CA356] Mass air flow sensor high error...6008
FAILURE CODE [CA357] Mass air flow sensor low error...6010
FAILURE CODE [CA386]...6012
FAILURE CODE [CA428]...6013
FAILURE CODE [CA429]...6015
FAILURE CODE [CA435]...6017
FAILURE CODE [CA441]...6019
FAILURE CODE [CA442]...6021
FAILURE CODE [CA449]...6022
FAILURE CODE [CA451]...6026
FAILURE CODE [CA452]...6029
FAILURE CODE [CA488] Charge Air Temperature High Torque Derate...6031
FAILURE CODE [CA515] Rail pressure sensor supply volt high error...6032
FAILURE CODE [CA516] Rail pressure sensor supply volt low error...6034
FAILURE CODE [CA553]...6036
FAILURE CODE [CA555]...6037
FAILURE CODE [CA556]...6038
FAILURE CODE [CA559]...6039
FAILURE CODE [CA595]...6043
FAILURE CODE [CA687] Turbo speed low error...6044
FAILURE CODE [CA689]...6046
FAILURE CODE [CA691] Intake air temperature sensor high error...6051
FAILURE CODE [CA692] Intake air temperature sensor low error...6053
FAILURE CODE [CA697] ECM internal temperature sensor high error...6055
FAILURE CODE [CA698] ECM internal temperature sensor low error...6056
FAILURE CODE [CA731]...6057
FAILURE CODE [CA778]...6059
en)...6064
FAILURE CODE [CA1664] KDOC Malfunction...6065
FAILURE CODE [CA1669]...6067
FAILURE CODE [CA1673]...6068
FAILURE CODE [CA1677] AdBlue/DEF Temperature Sensor Low Error...6069
FAILURE CODE [CA1678] AdBlue/DEF Temperature Sensor High Error...6070
FAILURE CODE [CA1682]...6071
FAILURE CODE[CA1683]AdBlue/DEF Tank Heating Valve Volt High Error...6073
FAILURE CODE [CA1684]...6075
FAILURE CODE [CA1686]...6077
FAILURE CODE [CA1691]...6078
FAILURE CODE [CA1694]...6081
FAILURE CODE [CA1695]...6084
FAILURE CODE [CA1696] Sensor 5 Supply Volt Low Error...6085
FAILURE CODE [CA1712] AdBlue/DEF Tank Thawing Error...6087
FAILURE CODE [CA1713] AdBlue/DEF Tank Heater Valve Open Stuck Error...6090
FAILURE CODE [CA1714] AdBlue/DEF Quality Sensor Out of Calibration Error...6092
FAILURE CODE [CA1715] AdBlue/DEF Quality Sensor Internal Circuit Error...6093
FAILURE CODE [CA1776] Sensor Supply Relay Volt High Error...6094
FAILURE CODE [CA1777] Sensor Supply Relay Voltage Low Error...6097
FAILURE CODE [CA1843] Crankcase pressure sensor high error...6100
FAILURE CODE [CA1844] Crankcase pressure sensor low error...6102
FAILURE CODE [CA1879] KDPF delta pressure sensor high error...6105
FAILURE CODE [CA1881] KDPF delta pressure sensor low error...6108
FAILURE CODE [CA1883] KDPF delta pressure sensor in range error...6110
FAILURE CODE [CA1885]...6113
FAILURE CODE [CA1887]...6115
en)...6117
en)...6120
FAILURE CODE [CA1942]...6125
FAILURE CODE [CA1993] KDPF delta pressure low error...6126
FAILURE CODE [CA2185]...6129
FAILURE CODE [CA2186]...6131
FAILURE CODE [CA2249]...6133
FAILURE CODE [CA2265] Fuel feed pump open error...6134
FAILURE CODE [CA2266] Fuel feed pump short error...6136
FAILURE CODE [CA2271] EGR valve lift sensor high error...6138
FAILURE CODE [CA2272]...6141
FAILURE CODE [CA2288]...6144
FAILURE CODE [CA2311]...6145
FAILURE CODE [CA2349] EGR valve solenoid open error...6146
FAILURE CODE [CA2353] EGR valve solenoid short error...6149
FAILURE CODE [CA2357] EGR valve servo error...6151
FAILURE CODE [CA2381] KVGT position sensor high error...6152
FAILURE CODE [CA2382]...6155
FAILURE CODE [CA2383]...6158
FAILURE CODE [CA2386] KVGT solenoid short error...6161
FAILURE CODE [CA2387] KVGT servo error...6163
FAILURE CODE [CA2555] Intake Air Heater Relay Open Circuit Error...6164
FAILURE CODE [CA2556] Intake Air Heater Relay Short Circuit Error...6167
FAILURE CODE [CA2637]...6170
FAILURE CODE [CA2639] Manual stationary regeneration request...6172
FAILURE CODE [CA2771] SCR Outlet NOx Sensor Datalink Timeout Error...6175
FAILURE CODE [CA2777]...6181
FAILURE CODE [CA2976]...6184
FAILURE CODE [CA3133] KDPF outlet pressure sensor high error...6186
FAILURE CODE [CA3134] KDPF outlet pressure sensor low error...6188
FAILURE CODE [CA3135] KDPF Outlet Press Sens In Range Error...6190
FAILURE CODE [CA3142] SCR Temp Sensor High Error...6193
FAILURE CODE [CA3143]...6194
FAILURE CODE [CA3144]...6195
FAILURE CODE [CA3146]...6197
FAILURE CODE [CA3147]...6198
FAILURE CODE [CA3148] SCR Outlet Temperature Sensor In Range Error...6199
FAILURE CODE [CA3151]...6201
FAILURE CODE [CA3165]...6207
FAILURE CODE [CA3229]...6209
FAILURE CODE [CA3231]...6211
FAILURE CODE [CA3232]...6213
FAILURE CODE [CA3235]...6217
FAILURE CODE [CA3239] AdBlue/DEF Line Heater 2 Voltage High Error...6219
FAILURE CODE [CA3241] AdBlue/DEF Line Heater 2 Voltage Low Error...6222
FAILURE CODE [CA3242]...6225
FAILURE CODE [CA3251]...6228
FAILURE CODE [CA3253]...6230
FAILURE CODE [CA3254]...6233
FAILURE CODE [CA3255]...6236
FAILURE CODE [CA3256]...6240
FAILURE CODE [CA3311]...6242
FAILURE CODE [CA3312]...6244
FAILURE CODE [CA3313] KDOC inlet temperature sensor low error...6247
FAILURE CODE [CA3314]...6248
FAILURE CODE [CA3315]...6249
FAILURE CODE [CA3316] KDOC outlet temperature sensor low error...6251
FAILURE CODE [CA3317]...6252
FAILURE CODE [CA3318]...6253
FAILURE CODE [CA3319]...6255
FAILURE CODE [CA3321] KDPF outlet temperature sensor low error...6256
FAILURE CODE [CA3322]...6258
FAILURE CODE [CA3419]...6260
FAILURE CODE [CA3421]...6262
FAILURE CODE [CA3497]...6264
FAILURE CODE [CA3498]...6265
FAILURE CODE [CA3543]...6266
FAILURE CODE [CA3545]...6272
FAILURE CODE [CA3547]...6274
FAILURE CODE [CA3558]...6275
FAILURE CODE [CA3559]...6277
FAILURE CODE [CA3562]...6279
FAILURE CODE [CA3563]...6281
FAILURE CODE [CA3567] AdBlue/DEF Injector Open Circuit Error or Short Circuit Error...6284
FAILURE CODE [CA3568] AdBlue/DEF Injector Malfunction...6287
FAILURE CODE [CA3571]...6291
FAILURE CODE [CA3572]...6293
FAILURE CODE [CA3574] AdBlue/DEF Pump Pressure Too Low Error...6295
FAILURE CODE [CA3575] AdBlue/DEF Pump Pressure Too High Error...6297
FAILURE CODE [CA3577]...6299
FAILURE CODE [CA3578]...6301
FAILURE CODE [CA3582]...6303
FAILURE CODE [CA3583]...6309
FAILURE CODE [CA3596]...6311
FAILURE CODE [CA3649]...6313
FAILURE CODE [CA3681]...6315
FAILURE CODE [CA3682]...6320
FAILURE CODE [CA3713]...6326
FAILURE CODE [CA3717] SCR Outlet Sensor Volt Mismatch Error...6329
FAILURE CODE [CA3718]...6330
FAILURE CODE [CA3725]...6331
FAILURE CODE [CA3741]...6334
FAILURE CODE [CA3748] Turbo out NOx Sensor Stuck In Range Error...6335
FAILURE CODE [CA3751]...6337
FAILURE CODE [CA3755] AdBlue/DEF Dosing Performance Degradation Error...6339
FAILURE CODE [CA3866]...6341
FAILURE CODE [CA3867]...6344
FAILURE CODE [CA3868]...6347
FAILURE CODE [CA3899] SCR NH3 Sensor Circuit Error...6351
FAILURE CODE [CA3911]...6353
FAILURE CODE [CA3912] SCR NH3 Sensor Heater Warmup Error...6357
FAILURE CODE [CA3932] SCR NH3 Sensor Heater Volt High Error...6359
FAILURE CODE [CA3933] SCR NH3 Sensor Heater Volt Low Error...6361
FAILURE CODE [CA3934]...6363
FAILURE CODE [CA3935] SCR NH3 Sensor Trim Resistance Error...6366
FAILURE CODE [CA3936] SCR NH3 Sensor Internal Circuit Error...6368
FAILURE CODE [CA4151]...6370
FAILURE CODE [CA4152]...6374
FAILURE CODE [CA4155]...6378
FAILURE CODE [CA4156]...6380
FAILURE CODE [CA4157]...6383
FAILURE CODE [CA4158]...6385
FAILURE CODE [CA4159]...6386
FAILURE CODE [CA4161]...6387
FAILURE CODE [CA4162]...6390
FAILURE CODE [CA4163]...6393
FAILURE CODE [CA4164]...6395
FAILURE CODE [CA4165]...6397
FAILURE CODE [CA4166]...6399
FAILURE CODE [CA4168]...6401
FAILURE CODE [CA4169]...6404
FAILURE CODE [CA4171]...6406
FAILURE CODE [CA4249]...6409
FAILURE CODE [CA4251]...6411
FAILURE CODE [CA4259]...6413
FAILURE CODE [CA4261]...6416
FAILURE CODE [CA4277]...6419
FAILURE CODE [CA4281]...6422
FAILURE CODE [CA4459]...6425
FAILURE CODE [CA4461]...6428
FAILURE CODE [CA4658] AdBlue/DEF Low Flow Error...6431
FAILURE CODE [CA4731] AdBlue/DEF Temp Sensor Out Of Calibration Error...6435
FAILURE CODE [CA4732] AdBlue/DEF Level Sensor Out Of Calibration Error...6436
FAILURE CODE [CA4739] AdBlue/DEF Level Sensor Internal Circuit Error...6437
FAILURE CODE [CA4768]...6438
FAILURE CODE [CA4769]...6440
FAILURE CODE [CA4842]...6443
FAILURE CODE [CA4952]...6446
FAILURE CODE [CA5115]...6448
FAILURE CODE [CA5179]...6451
FAILURE CODE [CA5181]...6453
FAILURE CODE [CA5383]...6455
FAILURE CODE [D110KB]...6457
FAILURE CODE [D19JKZ]...6459
FAILURE CODE [D811MC]...6461
FAILURE CODE [D862KA]...6462
FAILURE CODE [D8ALKA]...6463
FAILURE CODE [D8ALKB]...6465
FAILURE CODE [D8AQKR]...6467
FAILURE CODE [DA20MC]...6469
FAILURE CODE [DA22KK]...6470
FAILURE CODE [DA25KP]...6473
FAILURE CODE [DA29KQ]...6475
FAILURE CODE [DA2LKA]...6477
FAILURE CODE [DA2LKB]...6479
FAILURE CODE [DA2QKR]...6481
FAILURE CODE [DA2RKR]...6484
FAILURE CODE [DAF0MB]...6486
FAILURE CODE [DAF0MC]...6487
FAILURE CODE [DAF8KB] Short circuit in camera power supply...6488
FAILURE CODE [DAF9KQ]...6490
FAILURE CODE [DAFGMC]...6491
FAILURE CODE [DAFLKA]...6492
FAILURE CODE [DAFLKB]...6494
FAILURE CODE [DAFQKR]...6496
FAILURE CODE [DAZ9KQ]...6497
FAILURE CODE [DAZQKR]...6498
FAILURE CODE [DB2QKR]...6503
FAILURE CODE [DB2RKR]...6508
FAILURE CODE [DB90MC]...6513
FAILURE CODE [DB92KK]...6514
FAILURE CODE [DB95KP]...6516
FAILURE CODE [DB96KP]...6520
FAILURE CODE [DB99KQ]...6524
FAILURE CODE [DB9LKA]...6527
FAILURE CODE [DB9LKB]...6529
FAILURE CODE [DB9QKR]...6531
FAILURE CODE [DB9RKR]...6538
FAILURE CODE [DBP0KM]...6544
FAILURE CODE [DBP0KT]...6545
FAILURE CODE [DBPQKR]...6546
FAILURE CODE [DBR0MC]...6551
FAILURE CODE [DBR2KK]...6552
FAILURE CODE [DBR5KP]...6555
FAILURE CODE [DBR6KP]...6557
FAILURE CODE [DBR9KQ]...6559
FAILURE CODE [DBRLKA]...6562
FAILURE CODE [DBRLKB]...6564
FAILURE CODE [DBRQKR]...6566
FAILURE CODE [DBRRKR]...6573
FAILURE CODE [DBRSKB]...6579
FAILURE CODE [DBRTKB]...6581
FAILURE CODE [DBUSKR]...6583
FAILURE CODE [DD20MA]...6587
FAILURE CODE [DDNRKA]...6590
FAILURE CODE [DDNRKY]...6592
FAILURE CODE [DDNS00]...6594
FAILURE CODE [DGH2KB]...6596
FAILURE CODE [DHA4KA]...6598
FAILURE CODE [DHAAMA]...6600
FAILURE CODE [DHACMA]...6602
FAILURE CODE [DHPAMA]...6604
FAILURE CODE [DHPBMA]...6607
FAILURE CODE [DHS3MA]...6610
FAILURE CODE [DHS4MA]...6613
FAILURE CODE [DHS8MA]...6616
FAILURE CODE [DHS9MA]...6619
FAILURE CODE [DHSAMA]...6622
FAILURE CODE [DHSBMA]...6625
FAILURE CODE [DHSCMA]...6628
FAILURE CODE [DHSDMA]...6631
FAILURE CODE [DHSFMA]...6634
FAILURE CODE [DHSGMA]...6637
FAILURE CODE [DHSHMA]...6640
FAILURE CODE [DHSJMA]...6643
FAILURE CODE [DK80KM]...6646
FAILURE CODE [DK80KR]...6647
FAILURE CODE [DK80KT]...6653
FAILURE CODE [DKG1KM]...6654
FAILURE CODE [DKG1L8]...6655
FAILURE CODE [DKR0MA]...6656
FAILURE CODE [DKR1MA]...6659
FAILURE CODE [DKT0KM]...6662
FAILURE CODE [DKT0L8]...6663
FAILURE CODE [DKT1KA]...6664
FAILURE CODE [DKT1KB]...6666
FAILURE CODE [DKT2KA]...6668
FAILURE CODE [DKT2KB]...6670
FAILURE CODE [DKT4KM]...6672
FAILURE CODE [DKT4L8]...6673
FAILURE CODE [DKT5KA]...6674
FAILURE CODE [DKT5KB]...6676
FAILURE CODE [DKT6KA]...6678
FAILURE CODE [DKT6KB]...6680
FAILURE CODE [DKT8KA]...6682
FAILURE CODE [DKT8KB]...6684
FAILURE CODE [DKT9KA]...6686
FAILURE CODE [DKT9KB]...6688
FAILURE CODE [DKTAKA]...6690
FAILURE CODE [DKTAKB]...6692
FAILURE CODE [DKTAMB]...6694
FAILURE CODE [DKTBKX]...6695
FAILURE CODE [DKTBMC]...6697
FAILURE CODE [DKTEMB]...6698
FAILURE CODE [DKTFKX]...6700
FAILURE CODE [DKTFMC]...6702
FAILURE CODE [DKTJMB]...6703
FAILURE CODE [DKU1MA]...6705
FAILURE CODE [DKU2MA]...6706
FAILURE CODE [DKUGKA]...6707
FAILURE CODE [DKUGKB]...6709
FAILURE CODE [DKUGKY]...6711
FAILURE CODE [DKUHKA]...6713
FAILURE CODE [DKUHKB]...6715
FAILURE CODE [DKUHKY]...6717
FAILURE CODE [DKULKA]...6719
FAILURE CODE [DKULKB]...6721
FAILURE CODE [DKULKY]...6723
FAILURE CODE [DKV0KA]...6724
FAILURE CODE [DKV0KY]...6726
FAILURE CODE [DKV1KA]...6728
FAILURE CODE [DKV1KY]...6730
FAILURE CODE [DKV2KA]...6732
FAILURE CODE [DKV2KY]...6734
FAILURE CODE [DKV3KA]...6736
FAILURE CODE [DKV3KY]...6738
FAILURE CODE [DKV4MA]...6740
FAILURE CODE [DKV5MA]...6743
FAILURE CODE [DKV6MA]...6746
FAILURE CODE [DKV7MA]...6749
FAILURE CODE [DKV8MA]...6752
FAILURE CODE [DKV9MA]...6755
FAILURE CODE [DKVAMA]...6758
FAILURE CODE [DKVBKA]...6760
FAILURE CODE [DKVBKB]...6762
FAILURE CODE [DKVBKY]...6764
FAILURE CODE [DKVCKA]...6766
FAILURE CODE [DKVCKB]...6768
FAILURE CODE [DKVCKY]...6770
FAILURE CODE [DKVDKA]...6772
FAILURE CODE [DKVDKB]...6774
FAILURE CODE [DKVDKY]...6776
FAILURE CODE [DKVDMA]...6778
FAILURE CODE [DR10KA]...6779
FAILURE CODE [DR21KX]...6782
FAILURE CODE [DR31KX]...6784
FAILURE CODE [DUMBKA]...6786
FAILURE CODE [DUMBKB]...6788
FAILURE CODE [DV20KB]...6790
FAILURE CODE [DW43KA]...6792
FAILURE CODE [DW43KB]...6794
FAILURE CODE [DW43KY]...6796
FAILURE CODE [DW45KA]...6798
FAILURE CODE [DW45KB]...6801
FAILURE CODE [DW45KY]...6804
FAILURE CODE [DW4CKY]...6806
FAILURE CODE [DW4FKA]...6807
FAILURE CODE [DW4FKB]...6810
FAILURE CODE [DW4FKY]...6812
FAILURE CODE [DW4GKA]...6814
FAILURE CODE [DW4GKB]...6817
FAILURE CODE [DW4GKY]...6819
FAILURE CODE [DW4SKA]...6821
FAILURE CODE [DW4SKB]...6823
FAILURE CODE [DW4SKY]...6825
FAILURE CODE [DW91KA]...6827
FAILURE CODE [DW91KB]...6829
FAILURE CODE [DW91KY]...6831
FAILURE CODE [DWA2KA]...6833
FAILURE CODE [DWA2KB]...6835
FAILURE CODE [DWA2KY]...6837
FAILURE CODE [DWK0KA]...6839
FAILURE CODE [DWK0KB]...6841
FAILURE CODE [DWK0KY]...6843
FAILURE CODE [DWK2KA]...6845
FAILURE CODE [DWK2KB]...6847
FAILURE CODE [DWK2KY]...6849
FAILURE CODE [DWK8KA]...6851
FAILURE CODE [DWK8KB]...6853
FAILURE CODE [DWK8KY]...6855
FAILURE CODE [DXA8KA]...6857
FAILURE CODE [DXA8KB]...6860
FAILURE CODE [DXA9KA]...6862
FAILURE CODE [DXA9KB]...6865
FAILURE CODE [DXE0KA]...6867
FAILURE CODE [DXE0KB]...6869
FAILURE CODE [DXE4KA]...6871
FAILURE CODE [DXE4KB]...6873
FAILURE CODE [DXE4KY]...6875
FAILURE CODE [DXE5KA]...6876
FAILURE CODE [DXE5KB]...6878
FAILURE CODE [DXE6KA]...6880
FAILURE CODE [DXE6KB]...6882
FAILURE CODE [DXE7KA]...6884
FAILURE CODE [DXE7KB]...6886
FAILURE CODE [DXE7KY]...6888
FAILURE CODE [DXE8KA]...6890
FAILURE CODE [DXE8KB]...6892
FAILURE CODE [DXE8KY]...6894
FAILURE CODE [DXE9KA]...6896
FAILURE CODE [DXE9KB]...6898
FAILURE CODE [DXE9KY]...6900
FAILURE CODE [DXEAKA]...6902
FAILURE CODE [DXEAKB]...6904
FAILURE CODE [DXEAKY]...6906
FAILURE CODE [DY20KA]...6908
FAILURE CODE [DY20MA]...6911
FAILURE CODE [DY2CKB]...6913
FAILURE CODE [DY2DKB]...6916
FAILURE CODE [DY2EKB]...6918
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)...6920
E-1 ENGINE DOES NOT START (ENGINE DOES NOT CRANK)...6920
E-2 MANUAL PREHEATING SYSTEM DOES NOT WORK...6926
E-3 AUTOMATIC PREHEATING SYSTEM DOES NOT WORK...6929
E-4 WHILE PREHEATING IS WORKING, PREHEATING MONITOR DOES NOT LIGHT UP...6931
E-5 WHEN STARTING SWITCH IS TURNED TO ON POSITION, MACHINE MONITOR DISPLAYS NOTHING...6933
E-6 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), ENGINE OIL LEVEL MONITOR LIGHTS UP IN YELLOW...6936
E-7 WHILE STARTING SWITCH IS TURNED TO ON POSITION (WITH ENGINE STOPPED), RADIATOR COOLANT LEVEL MONITOR LIGHTS UP IN YELLOW...6937
E-8 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING...6938
E-9 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN WHITE WHILE ENGINE IS RUNNING...6939
E-10 AIR CLEANER CLOGGING MONITOR LIGHTS UP IN YELLOW WHILE ENGINE IS RUNNING...6940
E-11 CHARGE LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...6941
E-12 FUEL LEVEL MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...6942
E-13 WATER SEPARATOR MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...6943
E-14 ENGINE COOLANT TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...6944
E-15 ENGINE OIL PRESSURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...6945
E-16 HYDRAULIC OIL TEMPERATURE MONITOR LIGHTS UP IN RED WHILE ENGINE IS RUNNING...6946
E-17 FUEL GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM...6947
E-18 DISPLAY OF FUEL GAUGE DIFFERS FROM ACTUAL FUEL LEVEL...6949
E-19 ENGINE COOLANT TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM...6950
E-20 DISPLAY OF ENGINE COOLANT TEMPERATURE GAUGE DIFFERS FROM ACTUAL COOLANT TEMPERATURE...6951
E-21 HYDRAULIC OIL TEMPERATURE GAUGE DISPLAY DOES NOT MOVE FROM MINIMUM OR MAXIMUM...6952
E-22 DISPLAY OF HYDRAULIC OIL TEMPERATURE GAUGE DIFFERS FROM ACTUAL OIL TEMPERATURE...6954
E-23 SOME AREAS OF MACHINE MONITOR SCREEN ARE NOT DISPLAYED...6955
E-24 FUNCTION SWITCH DOES NOT OPERATE...6956
E-25 AUTOMATIC WARM-UP SYSTEM DOES NOT WORK (IN COLD WEATHER)...6957
E-26 WHEN AUTO-DECELERATOR SWITCH IS OPERATED, AUTO-DECELERATOR MONITOR DOES NOT LIGHT UP OR DOES NOT GO OFF...6958
E-27 AUTO-DECELERATOR IS NOT OPERATED OR CANCELED WITH LEVER...6959
E-28 WHEN WORKING MODE SWITCH IS OPERATED, WORKING MODE SELECTION SCREEN IS NOT DISPLAYED...6960
E-29 WHEN WORKING MODE IS CHANGED, SETTING OF ENGINE AND HYDRAULIC PUMP IS NOT CHANGED...6961
E-30 WHEN TRAVEL SPEED SWITCH IS OPERATED, TRAVEL SPEED MONITOR DOES NOT CHANGE...6962
E-31 WHEN TRAVEL SPEED SELECTION IS CHANGED, ACTUAL TRAVEL SPEED DOES NOT CHANGE...6963
E-32 ALARM BUZZER CANNOT BE CANCELED...6965
E-33 SERVICE METER IS NOT DISPLAYED, WHILE STARTING SWITCH IS IN OFF POSITION...6966
E-34 SERVICE MODE CANNOT BE SELECTED...6967
E-35 ALL OF WORK EQUIPMENTS, SWING, AND TRAVEL MECHANISM DO NOT MOVE...6968
E-36 ALL OF WORK EQUIPMENT, SWING, AND TRAVEL MECHANISM DO NOT LOCK...6970
E-37 WHEN SWING BRAKE CANCEL SWITCH IS SET TO CANCEL POSITION, MACHINE CANNOT SWING...6971
E-38 WHEN SWING BRAKE CANCEL SWITCH IS SET TO NORMAL POSITION, SWING HOLDING BRAKE DOES NOT OPERATE...6974
E-39 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE PROPERLY, OR INDICATOR NOT DISPLAYED ON MONITOR...6976
E-40 ONE-TOUCH POWER MAXIMIZING FUNCTION IS NOT CANCELLED...6978
E-41 ALARM DOES NOT SOUND DURING TRAVEL...6979
E-42 ALARM DOES NOT STOP SOUNDING WHILE MACHINE IS STOPPED...6981
E-43 HORN DOES NOT SOUND...6982
E-44 HORN DOES NOT STOP SOUNDING...6986
E-45 WHEN WIPER SWITCH IS OPERATED, WIPER MONITOR DOES NOT LIGHT UP OR GO OFF...6988
E-46 WHEN WIPER SWITCH IS OPERATED, WINDSHIELD WIPER DOES NOT OPERATE...6989
E-47 WHEN WINDOW WASHER SWITCH IS OPERATED, WINDOW WASHER DOES NOT OPERATE...6991
E-48 BOOM RAISE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...6992
E-49 BOOM LOWER INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...6993
E-50 ARM OUT INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...6994
E-51 ARM IN INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...6995
E-52 BUCKET DUMP INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...6996
E-53 BUCKET CURL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...6997
E-54 SWING INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...6998
E-55 TRAVEL INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...6999
E-56 SERVICE INDICATOR IS NOT DISPLAYED PROPERLY WITH MONITORING FUNCTION...7000
E-57 ATTACHMENT HYDRAULIC CIRCUIT CANNOT BE CHANGED...7002
E-58 KOMTRAX SYSTEM DOES NOT OPERATE NORMALLY...7003
E-59 MACHINE PUSH-UP FUNCTION CANNOT BE CANCELED...7004
E-60 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE...7006
E-61 CONTROL BOX SHUTS DOWN AFTER DISPLAYING THE MESSAGES [GPS receiver not connected !] AND [Slope sensor not connected !]...7007
E-62 CONTROL BOX DISPLAYS THE MESSAGE [GPS receiver not connected!]...7012
E-63 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for radio link...]...7016
E-64 CONTROL BOX DISPLAYS THE MESSAGE [Tilt Bucket Sensor Offline!]...7017
E-65 CONTROL BOX DISPLAYS THE MESSAGE [Waiting for satellites...]...7018
E-66 CONTROL BOX DISPLAYS THE MESSAGE [Komatsu controller not connected!]...7019
E-67 CONTROL BOX DISPLAYS THE MESSAGE [Sensors are invalid]...7022
E-68 CONTROL BOX DISPLAYS THE MESSAGE [Waiting to initialize...]...7025
E-69 CONTROL BOX DISPLAYS THE MESSAGE [Initializing...]...7026
E-70 CONTROL BOX DISPLAYS THE MESSAGE [No GPS Localization...]...7027
E-71 CONTROL BOX DISPLAYS THE MESSAGE [Low precisions...]...7028
E-72 CONTROL BOX DISPLAYS [Out of design area...]...7029
E-73 CONTROL BOX DISPLAYS THE MESSAGE [Avoidance Area Breach!]...7030
E-74 CONTROL BOX CAN NOT BE TURNED ON...7031
E-75 CONTROL BOX DOES NOT DISPLAY INTELLIGENT MACHINE CONTROL SCREEN...7032
E-76 CONTROL BOX DOES NOT DISPLAY HYDRAULIC EXCAVATOR IMAGE...7033
E-77 CONTROL BOX DOES NOT DISPLAY DESIGN SURFACE...7034
E-78 CONTROL BOX TOUCH PANEL DOES NOT RESPOND...7035
E-79 CONTROL BOX TOUCH PANEL IS INACCURATE...7036
E-80 WHEN CHECKING AND ADJUSTING THE BUCKET EDGE POSITION, THE VALUE IS DIFFERENT FROM ACTUAL MACHINE...7037
E-81 SEMI-AUTO MODE IS NOT DISPLAYED WHEN AUTO/MANUAL SWITCH IS PRESSED...7039
E-82 AUTO GRADE ASSIST CONTROL DOES NOT OPERATE WHILE SEMI-AUTO MODE IS DISPLAYED...7040
E-83 AUTO STOP CONTROL DOES NOT OPERATE WHILE SEMI-AUTO MODE IS DISPLAYED...7041
E-84 BLADE EDGE POSITION ON DESIGN SURFACE IS NOT ACCURATE WHEN AUTO GRADE ASSIST FUNCTION IS ON...7042
E-85 BLADE EDGE STOP POSITION IS NOT ACCURATE FOR DESIGN SURFACE WHEN AUTO STOP CONTROL FUNCTION IS ON...7044
E-86 FACING ANGLE COMPASS DOES NOT BECOME PERPENDICULAR TO TARGET...7046
E-87 NG OCCURS VERY OFTEN IN IMU CALIBRATION DIAGNOSIS...7047
E-88 CUSHION FOR BOOM RAISE END DOES NOT WORK OR IS WEAK...7048
E-89 CUSHION FOR ARM IN END DOES NOT WORK OR IS WEAK...7049
TROUBLESHOOTING FOR HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)...7052
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (H MODE)...7052
SYSTEM CHART OF HYDRAULIC AND MECHANICAL SYSTEMS...7053
FAILURE MODE AND CAUSE TABLE...7055
H-1 ALL WORK EQUIPMENT, SWING AND TRAVEL DO NOT WORK...7064
H-2 ALL WORK EQUIPMENT, SWING AND TRAVEL LACK SPEED AND POWER...7065
H-3 FINE CONTROL PERFORMANCE OR RESPONSE IS POOR...7068
H-4 UNUSUAL NOISE IS HEARD FROM AROUND HYDRAULIC PUMP...7069
H-5 ENGINE SPEED DROPS LARGELY OR ENGINE STOPS...7070
H-6 SPEED OR POWER OF BOOM IS LOW...7072
H-7 ARM SPEED OR POWER IS LOW...7078
H-8 BUCKET SPEED OR POWER IS LOW...7083
H-9 WORK EQUIPMENT DOES NOT MOVE IN SINGLE OPERATION...7086
H-10 HYDRAULIC DRIFT OF BOOM IS LARGE...7087
H-11 HYDRAULIC DRIFT OF ARM IS LARGE...7089
H-12 HYDRAULIC DRIFT OF BUCKET IS LARGE...7091
H-13 WHEN SINGLE WORK EQUIPMENT IS RELIEVED HYDRAULICALLY, OTHER WORK EQUIPMENT MOVES...7092
H-14 TIME LAG OF WORK EQUIPMENT IS LARGE...7093
H-15 ONE-TOUCH POWER MAXIMIZING FUNCTION DOES NOT OPERATE...7094
H-16 MACHINE PUSH-UP FUNCTION DOES NOT OPERATE...7095
H-17 ATTACHMENT CIRCUIT CANNOT BE CHANGED...7096
H-18 OIL FLOW IN ATTACHMENT CIRCUIT CANNOT BE CHANGED...7097
H-19 IN COMBINED OPERATION OF WORK EQUIPMENT, EQUIPMENT HAVING HEAVIER LOAD MOVES SLOWER...7098
H-20 IN COMBINED OPERATION OF SWING AND TRAVEL, TRAVEL SPEED DROPS LARGELY...7099
H-21 IN COMBINED OPERATION OF SWING AND BOOM RAISE, BOOM RISING SPEED IS LOW...7100
H-22 MACHINE DOES NOT TRAVEL STRAIGHT...7101
H-23 MACHINE IS NOT STEERED WELL OR STEERING POWER IS LOW...7103
H-24 TRAVEL SPEED IS LOW...7106
H-25 ONE OF TRACKS DOES NOT RUN...7108
H-26 TRAVEL SPEED DOES NOT CHANGE, OR TRAVEL SPEED IS TOO SLOW OR FAST...7110
H-27 UPPER STRUCTURE DOES NOT SWING BOTH TO THE RIGHT AND LEFT...7111
H-28 SWINGS ONLY IN ONE DIRECTION...7112
H-29 SWING ACCELERATION OR SWING SPEED IS LOW IN BOTH DIRECTIONS (RIGHT AND LEFT)...7113
H-30 SWING ACCELERATION PERFORMANCE IS POOR OR SWING SPEED IS SLOW IN ONLY ONE DIRECTION...7114
H-31 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (BOTH RIGHT AND LEFT)...7115
H-32 UPPER STRUCTURE OVERRUNS EXCESSIVELY WHEN IT STOPS SWINGING (ONLY ONE DIRECTION EITHER RIGHT OR LEFT)...7116
H-33 SHOCK IS LARGE WHEN UPPER STRUCTURE STOPS SWINGING...7117
H-34 LARGE UNUSUAL NOISE IS HEARD WHEN UPPER STRUCTURE STOPS SWINGING...7118
H-35 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS APPLIED)...7119
H-36 SWING DRIFT ON A SLOPE IS LARGE (WHILE SWING PARKING BRAKE IS RELEASED)...7120
TROUBLESHOOTING OF ENGINE (S-MODE)...7121
INFORMATION MENTIONED IN TROUBLESHOOTING TABLE (S MODE)...7121
S-1 ENGINE DOES NOT CRANK WHEN STARTING SWITCH IS TURNED TO START POSITION...7122
S-2 ENGINE CRANKS BUT NO EXHAUST GAS COMES OUT...7123
S-3 FUEL IS BEING INJECTED BUT ENGINE DOES NOT START (MISFIRING: ENGINE CRANKS BUT DOES NOT START)...7124
S-4 ENGINE STARTABILITY IS POOR...7126
S-5 ENGINE DOES NOT PICK UP SMOOTHLY...7128
S-6 ENGINE STOPS DURING OPERATION...7130
S-7 ENGINE RUNS ROUGH OR IS UNSTABLE...7132
S-8 ENGINE LACKS POWER...7133
S-9 KDPF GETS CLOGGED IN A SHORT TIME...7135
S-10 ENGINE OIL CONSUMPTION IS EXCESSIVE...7137
S-11 OIL BECOMES CONTAMINATED QUICKLY...7138
S-12 FUEL CONSUMPTION IS EXCESSIVE...7139
S-13 OIL IS IN COOLANT (OR COOLANT SPURTS BACK OR COOLANT LEVEL GOES DOWN)...7140
S-14 OIL PRESSURE DROPS...7141
S-15 FUEL MIXES INTO ENGINE OIL...7143
S-16 WATER MIXES INTO ENGINE OIL (MILKY)...7144
S-17 COOLANT TEMPERATURE RISES TOO HIGH (OVERHEATING)...7145
S-18 UNUSUAL NOISE IS HEARD...7146
S-19 VIBRATION IS EXCESSIVE...7147
S-20 AIR CANNOT BE BLED FROM FUEL CIRCUIT...7148
S-21 ACTIVE REGENERATION IS EXECUTED FREQUENTLY...7149
S-22 ACTIVE REGENERATION TAKES TIME...7151
S-23 WHITE SMOKE IS EXHAUSTED DURING ACTIVE REGENERATION...7152
S-24 AdBlue/DEF CONSUMPTION IS EXCESSIVE...7153
S-25 THERE IS UNUSUAL SMELL (IRRITATING ODOR)...7155
S-26 FOREIGN MATERIALS ENTER AdBlue/DEF (AdBlue/DEF INCREASES)...7156
50 DISASSEMBLY AND ASSEMBLY...7157
CONTENTS...7158
ABBREVIATION LIST...7164
RELATED INFORMATION ON DISASSEMBLY AND ASSEMBLY...7170
HOW TO READ THIS MANUAL...7170
COATING MATERIALS LIST...7172
SPECIAL TOOLS LIST...7176
SKETCHES OF SPECIAL TOOLS...7191
ENGINE AND COOLING SYSTEM...7199
REMOVE AND INSTALL SUPPLY PUMP ASSEMBLY...7199
METHOD FOR REMOVING SUPPLY PUMP ASSEMBLY...7199
METHOD FOR INSTALLING SUPPLY PUMP ASSEMBLY...7204
REMOVE AND INSTALL INJECTOR ASSEMBLY...7212
METHOD FOR REMOVING INJECTOR ASSEMBLY...7212
METHOD FOR INSTALLING INJECTOR ASSEMBLY...7219
REMOVE AND INSTALL CYLINDER HEAD ASSEMBLY...7231
METHOD FOR REMOVING CYLINDER HEAD ASSEMBLY...7232
METHOD FOR INSTALLING CYLINDER HEAD ASSEMBLY...7241
REMOVE AND INSTALL EGR VALVE ASSEMBLY...7259
METHOD FOR REMOVING EGR VALVE ASSEMBLY...7259
METHOD FOR INSTALLING EGR VALVE ASSEMBLY...7260
REMOVE AND INSTALL EGR COOLER ASSEMBLY...7262
METHOD FOR REMOVING EGR COOLER ASSEMBLY...7262
METHOD FOR INSTALLING EGR COOLER ASSEMBLY...7263
REMOVE AND INSTALL STARTER ASSEMBLY...7266
METHOD FOR REMOVING STARTER ASSEMBLY...7266
METHOD FOR INSTALLING STARTER ASSEMBLY...7267
REMOVE AND INSTALL ALTERNATOR BELT...7268
METHOD FOR REMOVING ALTERNATOR BELT...7268
METHOD FOR INSTALLING ALTERNATOR BELT...7271
REMOVE AND INSTALL RADIATOR ASSEMBLY...7274
METHOD FOR REMOVING RADIATOR ASSEMBLY...7274
METHOD FOR INSTALLING RADIATOR ASSEMBLY...7276
REMOVE AND INSTALL HYDRAULIC OIL COOLER ASSEMBLY...7278
METHOD FOR REMOVING HYDRAULIC OIL COOLER ASSEMBLY...7278
METHOD FOR INSTALLING HYDRAULIC OIL COOLER ASSEMBLY...7280
REMOVE AND INSTALL AFTERCOOLER ASSEMBLY...7283
METHOD FOR REMOVING AFTERCOOLER ASSEMBLY...7283
METHOD FOR INSTALLING AFTERCOOLER ASSEMBLY...7284
REMOVE AND INSTALL ENGINE AND MAIN PUMP ASSEMBLY...7286
METHOD FOR REMOVING ENGINE AND MAIN PUMP ASSEMBLY...7287
METHOD FOR INSTALLING ENGINE AND MAIN PUMP ASSEMBLY...7298
REMOVE AND INSTALL ENGINE FRONT OIL SEAL...7313
METHOD FOR REMOVING ENGINE FRONT OIL SEAL...7313
METHOD FOR INSTALLING ENGINE FRONT OIL SEAL...7317
REMOVE AND INSTALL ENGINE REAR OIL SEAL...7321
METHOD FOR REMOVING ENGINE REAR OIL SEAL...7322
METHOD FOR INSTALLING ENGINE REAR OIL SEAL...7323
REMOVE AND INSTALL ENGINE HOOD ASSEMBLY...7330
METHOD FOR REMOVING ENGINE HOOD ASSEMBLY...7330
METHOD FOR INSTALLING ENGINE HOOD ASSEMBLY...7331
REMOVE AND INSTALL FUEL TANK ASSEMBLY...7334
METHOD FOR REMOVING FUEL TANK ASSEMBLY...7334
METHOD FOR INSTALLING FUEL TANK ASSEMBLY...7339
REMOVE AND INSTALL AdBlue/DEF TANK ASSEMBLY...7343
METHOD FOR REMOVING AdBlue/DEF TANK ASSEMBLY...7343
METHOD FOR INSTALLING AdBlue/DEF TANK ASSEMBLY...7349
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...7355
REMOVE AND INSTALL AdBlue/DEF TANK SENSOR...7356
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...7356
METHOD FOR REMOVING AdBlue/DEF TANK SENSOR...7363
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR FLANGE ASSEMBLY...7363
METHOD FOR INSTALLING AdBlue/DEF TANK SENSOR...7368
REMOVE AND INSTALL AdBlue/DEF TANK STRAINER...7369
METHOD FOR REMOVING AdBlue/DEF TANK STRAINER...7369
METHOD FOR INSTALLING AdBlue/DEF TANK STRAINER...7369
REMOVE AND INSTALL KDPF ASSEMBLY...7370
METHOD FOR REMOVING KDPF ASSEMBLY...7370
METHOD FOR INSTALLING KDPF ASSEMBLY...7373
DISASSEMBLE AND ASSEMBLE OF KDPF ASSEMBLY...7377
METHOD FOR DISASSEMBLING KDPF ASSEMBLY...7378
METHOD FOR ASSEMBLING KDPF ASSEMBLY...7381
REMOVE AND INSTALL SCR ASSEMBLY...7386
METHOD FOR REMOVING SCR ASSEMBLY...7386
METHOD FOR INSTALLING SCR ASSEMBLY...7389
REMOVE AND INSTALL KDPF, SCR ASSEMBLY...7392
METHOD FOR REMOVING KDPF, SCR ASSEMBLY...7393
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY...7399
REMOVE AND INSTALL KDPF, SCR ASSEMBLY BRACKET...7406
METHOD FOR REMOVING KDPF, SCR ASSEMBLY BRACKET...7406
METHOD FOR INSTALLING KDPF, SCR ASSEMBLY BRACKET...7409
REMOVE AND INSTALL KCCV ASSEMBLY...7414
METHOD FOR REMOVING KCCV ASSEMBLY...7414
METHOD FOR INSTALLING KCCV ASSEMBLY...7415
REMOVE AND INSTALL AdBlue/DEF MIXING TUBE...7417
METHOD FOR REMOVING AdBlue/DEF MIXING TUBE...7417
METHOD FOR INSTALLING AdBlue/DEF MIXING TUBE...7421
REMOVE AND INSTALL AdBlue/DEF INJECTOR...7425
METHOD FOR REMOVING AdBlue/DEF INJECTOR...7425
METHOD FOR INSTALLING AdBlue/DEF INJECTOR...7428
REMOVE AND INSTALL AdBlue/DEF PUMP...7432
METHOD FOR REMOVING AdBlue/DEF PUMP...7432
METHOD FOR INSTALLING AdBlue/DEF PUMP...7435
REMOVE AND INSTALL AdBlue/DEF HOSE...7437
METHOD FOR REMOVING AdBlue/DEF HOSE...7438
METHOD FOR INSTALLING AdBlue/DEF HOSE...7444
REMOVE AND INSTALL AIR CLEANER ASSEMBLY...7452
METHOD FOR REMOVING AIR CLEANER ASSEMBLY...7452
METHOD FOR INSTALLING AIR CLEANER ASSEMBLY...7454
REMOVE AND INSTALL AIR CONDITIONER COMPRESSOR ASSEMBLY...7456
METHOD FOR REMOVING AIR CONDITIONER COMPRESSOR ASSEMBLY...7456
METHOD FOR INSTALLING AIR CONDITIONER COMPRESSOR ASSEMBLY...7457
REMOVE AND INSTALL AIR CONDITIONER CONDENSER ASSEMBLY...7459
METHOD FOR REMOVING AIR CONDITIONER CONDENSER ASSEMBLY...7459
METHOD FOR INSTALLING AIR CONDITIONER CONDENSER ASSEMBLY...7460
POWER TRAIN...7461
REMOVE AND INSTALL TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...7461
METHOD FOR REMOVING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...7461
METHOD FOR INSTALLING TRAVEL MOTOR AND FINAL DRIVE ASSEMBLY...7462
DISASSEMBLE AND ASSEMBLE FINAL DRIVE ASSEMBLY...7464
METHOD FOR DISASSEMBLING FINAL DRIVE ASSEMBLY...7465
METHOD FOR ASSEMBLING FINAL DRIVE ASSEMBLY...7469
REMOVE AND INSTALL SWING MOTOR AND SWING MACHINERY ASSEMBLY...7477
METHOD FOR REMOVING SWING MOTOR AND SWING MACHINERY ASSEMBLY...7477
METHOD FOR INSTALLING SWING MOTOR AND SWING MACHINERY ASSEMBLY...7478
DISASSEMBLE AND ASSEMBLE SWING MACHINERY ASSEMBLY...7480
METHOD FOR DISASSEMBLING SWING MACHINERY ASSEMBLY...7480
METHOD FOR ASSEMBLING SWING MACHINERY ASSEMBLY...7483
REMOVE AND INSTALL SWING CIRCLE ASSEMBLY...7490
METHOD FOR REMOVING SWING CIRCLE ASSEMBLY...7490
METHOD FOR INSTALLING SWING CIRCLE ASSEMBLY...7490
UNDERCARRIAGE AND FRAME...7492
SEPARATION AND CONNECTION OF TRACK ASSEMBLY...7492
METHOD FOR SEPARATING TRACK ASSEMBLY...7492
METHOD FOR INSTALLING TRACK ASSEMBLY...7494
REMOVE AND INSTALL SPROCKET...7497
METHOD FOR REMOVING SPROCKET...7497
METHOD FOR INSTALLING SPROCKET...7497
REMOVE AND INSTALL IDLER AND IDLER CUSHION ASSEMBLY...7499
METHOD FOR REMOVING IDLER AND IDLER CUSHION ASSEMBLY...7499
METHOD FOR INSTALLING IDLER AND IDLER CUSHION ASSEMBLY...7500
DISASSEMBLE AND ASSEMBLE IDLER ASSEMBLY...7501
METHOD FOR DISASSEMBLING IDLER ASSEMBLY...7501
METHOD FOR ASSEMBLING IDLER ASSEMBLY...7502
DISASSEMBLE AND ASSEMBLE OF IDLER CUSHION ASSEMBLY...7506
METHOD FOR DISASSEMBLING IDLER CUSHION ASSEMBLY...7506
METHOD FOR ASSEMBLING IDLER CUSHION ASSEMBLY...7507
DISASSEMBLE AND ASSEMBLE TRACK ROLLER ASSEMBLY...7509
METHOD FOR DISASSEMBLING TRACK ROLLER ASSEMBLY...7510
METHOD FOR ASSEMBLING TRACK ROLLER ASSEMBLY...7511
DISASSEMBLEAND ASSEMBLE CARRIER ROLLER ASSEMBLY...7513
METHOD FOR DISASSEMBLING CARRIER ROLLER ASSEMBLY...7513
METHOD FOR ASSEMBLING CARRIER ROLLER ASSEMBLY...7514
REMOVE AND INSTALL REVOLVING FRAME ASSEMBLY...7517
METHOD FOR REMOVING REVOLVING FRAME ASSEMBLY...7517
METHOD FOR INSTALLING REVOLVING FRAME ASSEMBLY...7520
REMOVE AND INSTALL COUNTERWEIGHT ASSEMBLY...7524
METHOD FOR REMOVING COUNTERWEIGHT ASSEMBLY...7524
METHOD FOR INSTALLING COUNTERWEIGHT ASSEMBLY...7525
HYDRAULIC SYSTEM...7528
REMOVE AND INSTALL CENTER SWIVEL JOINT ASSEMBLY...7528
METHOD FOR REMOVING CENTER SWIVEL JOINT ASSEMBLY...7528
METHOD FOR INSTALLING CENTER SWIVEL JOINT ASSEMBLY...7529
DISASSEMBLE AND ASSEMBLE CENTER SWIVEL JOINT ASSEMBLY...7532
METHOD FOR DISASSEMBLING CENTER SWIVEL JOINT ASSEMBLY...7533
METHOD FOR ASSEMBLING CENTER SWIVEL JOINT ASSEMBLY...7534
REMOVE AND INSTALL HYDRAULIC TANK ASSEMBLY...7535
METHOD FOR REMOVING HYDRAULIC TANK ASSEMBLY...7535
METHOD FOR INSTALLING HYDRAULIC TANK ASSEMBLY...7540
REMOVE AND INSTALL MAIN PUMP ASSEMBLY...7545
METHOD FOR REMOVING MAIN PUMP ASSEMBLY...7545
METHOD FOR INSTALLING MAIN PUMP ASSEMBLY...7548
REMOVE AND INSTALL JUNCTION BLOCK ASSEMBLY FOR INTELLIGENT MACHINE CONTROL...7551
METHOD FOR REMOVING JUNCTION BLOCK ASSEMBLY FOR INTELLIGENT MACHINE CONTROL...7551
METHOD FOR INSTALLING JUNCTION BLOCK ASSEMBLY FOR INTELLIGENT MACHINE CONTROL...7553
REMOVE AND INSTALL PRESSURE SENSOR FOR INTELLIGENT MACHINE CONTROL...7556
METHOD FOR REMOVING PRESSURE SENSOR FOR INTELLIGENT MACHINE CONTROL...7556
METHOD FOR INSTALLING PRESSURE SENSOR FOR INTELLIGENT MACHINE CONTROL...7558
REMOVE AND INSTALL BOOM SPOOL STROKE SENSOR...7562
METHOD FOR REMOVING BOOM SPOOL STROKE SENSOR...7562
METHOD FOR INSTALLING BOOM SPOOL STROKE SENSOR...7562
REMOVE AND INSTALL ARM SPOOL STROKE SENSOR...7564
METHOD FOR REMOVING ARM SPOOL STROKE SENSOR...7564
METHOD FOR INSTALLING ARM SPOOL STROKE SENSOR...7566
REMOVE AND INSTALL JUNCTION BLOCK BYPASS ADAPTER FOR INTELLIGENT MACHINE CONTROL...7568
METHOD FOR REMOVING JUNCTION BLOCK BYPASS ADAPTER FOR INTELLIGENT MACHINE CONTROL...7568
METHOD FOR REMOVING JUNCTION BLOCK BYPASS ADAPTER FOR INTELLIGENT MACHINE CONTROL...7570
REMOVE AND INSTALL CONTROL VALVE ASSEMBLY...7572
METHOD FOR REMOVING CONTROL VALVE ASSEMBLY...7572
METHOD FOR INSTALLING CONTROL VALVE ASSEMBLY...7578
DISASSEMBLE AND ASSEMBLE CONTROL VALVE ASSEMBLY...7584
METHOD FOR REPLACING PRESSURE COMPENSATION VALVE SEAL RING...7585
METHOD FOR ASSEMBLING CONTROL VALVE ASSEMBLY...7586
DISASSEMBLE AND ASSEMBLE WORK EQUIPMENT PPC VALVE ASSEMBLY...7591
METHOD FOR DISASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY...7591
METHOD FOR ASSEMBLING WORK EQUIPMENT PPC VALVE ASSEMBLY...7592
DISASSEMBLE AND ASSEMBLE TRAVEL PPC VALVE ASSEMBLY...7594
METHOD FOR DISASSEMBLING TRAVEL PPC VALVE ASSEMBLY...7594
METHOD FOR ASSEMBLING TRAVEL PPC VALVE ASSEMBLY...7595
WORK EQUIPMENT...7597
REMOVE AND INSTALL BUCKET ASSEMBLY...7597
METHOD FOR REMOVING BUCKET ASSEMBLY...7597
METHOD FOR INSTALLING BUCKET ASSEMBLY...7597
REMOVE AND INSTALL ARM ASSEMBLY...7599
METHOD FOR REMOVING ARM ASSEMBLY...7599
METHOD FOR INSTALLING ARM ASSEMBLY...7602
REMOVE AND INSTALL WORK EQUIPMENT ASSEMBLY...7605
METHOD FOR REMOVING WORK EQUIPMENT ASSEMBLY...7605
METHOD FOR INSTALLING WORK EQUIPMENT ASSEMBLY...7609
DISASSEMBLE AND ASSEMBLE STROKE SENSING BOOM CYLINDER ASSEMBLY...7614
METHOD FOR DISASSEMBLING STROKE SENSING BOOM CYLINDER ASSEMBLY...7615
METHOD FOR ASSEMBLING STROKE SENSING BOOM CYLINDER ASSEMBLY...7620
DISASSEMBLE AND ASSEMBLE STROKE SENSING ARM CYLINDER ASSEMBLY...7627
METHOD FOR DISASSEMBLING STROKE SENSING ARM CYLINDER ASSEMBLY...7628
METHOD FOR ASSEMBLING STROKE SENSING ARM CYLINDER ASSEMBLY...7633
DISASSEMBLE AND ASSEMBLE STROKE SENSING BUCKET CYLINDER ASSEMBLY...7642
METHOD FOR DISASSEMBLING STROKE SENSING BUCKET CYLINDER ASSEMBLY...7643
METHOD FOR ASSEMBLING STROKE SENSING BUCKET CYLINDER ASSEMBLY...7648
CAB AND ITS ATTACHMENTS...7659
REMOVE AND INSTALL OPERATOR'S CAB ASSEMBLY...7659
METHOD FOR REMOVING OPERATOR'S CAB ASSEMBLY...7659
METHOD FOR INSTALLING OPERATOR'S CAB ASSEMBLY...7669
REMOVE AND INSTALL OPERATOR CAB GLASS (ADHERED GLASS)...7678
METHOD FOR REMOVING OPERATOR CAB GLASS (ADHERED GLASS)...7680
METHOD FOR INSTALLING OPERATOR CAB GLASS (ADHERED GLASS)...7680
REMOVE AND INSTALL FRONT WINDOW ASSEMBLY...7690
METHOD FOR REMOVING FRONT WINDOW ASSEMBLY...7690
METHOD FOR INSTALLING FRONT WINDOW ASSEMBLY...7693
REMOVE AND INSTALL FLOOR FRAME ASSEMBLY...7699
METHOD FOR REMOVING FLOOR FRAME ASSEMBLY...7699
METHOD FOR INSTALLING FLOOR FRAME ASSEMBLY...7706
REMOVE AND INSTALL AIR CONDITIONER UNIT ASSEMBLY...7713
METHOD FOR REMOVING AIR CONDITIONER UNIT ASSEMBLY...7713
METHOD FOR INSTALLING AIR CONDITIONER UNIT ASSEMBLY...7720
REMOVE AND INSTALL OPERATOR'S SEAT...7728
METHOD FOR REMOVING OPERATOR'S SEAT...7728
METHOD FOR INSTALLING OPERATOR'S SEAT...7730
REMOVE AND INSTALL SEAT BELT...7734
METHOD FOR REMOVING SEAT BELT...7734
METHOD FOR INSTALLING SEAT BELT...7734
REMOVE AND INSTALL FRONT WIPER ASSEMBLY...7736
METHOD FOR REMOVING FRONT WIPER ASSEMBLY...7736
METHOD FOR INSTALLING FRONT WIPER ASSEMBLY...7742
ELECTRICAL SYSTEM...7750
REMOVE AND INSTALL ENGINE CONTROLLER ASSEMBLY...7750
METHOD FOR REMOVING ENGINE CONTROLLER ASSEMBLY...7750
METHOD FOR INSTALLING ENGINE CONTROLLER ASSEMBLY...7752
REMOVE AND INSTALL PUMP CONTROLLER ASSEMBLY...7756
METHOD FOR REMOVING PUMP CONTROLLER ASSEMBLY...7756
METHOD FOR INSTALLING PUMP CONTROLLER ASSEMBLY...7760
REMOVE AND INSTALL WORK EQUIPMENT CONTROLLER ASSEMBLY...7766
METHOD FOR REMOVING WORK EQUIPMENT CONTROLLER ASSEMBLY...7766
METHOD FOR INSTALLING WORK EQUIPMENT CONTROLLER ASSEMBLY...7767
REMOVE AND INSTALL KomVision CONTROLLER ASSEMBLY...7770
METHOD FOR REMOVING KomVision CONTROLLER ASSEMBLY...7770
METHOD FOR INSTALLING KomVision CONTROLLER...7771
REMOVE AND INSTALL MACHINE MONITOR ASSEMBLY...7772
METHOD FOR REMOVING MACHINE MONITOR ASSEMBLY...7772
METHOD FOR INSTALLING MACHINE MONITOR ASSEMBLY...7775
REMOVE AND INSTALL PUMP SWASH PLATE SENSOR...7779
METHOD FOR REMOVING PUMP SWASH PLATE SENSOR...7779
METHOD FOR INSTALLING PUMP SWASH PLATE SENSOR...7779
REMOVE AND INSTALL MASS AIR FLOW AND TEMPERATURE SENSOR...7781
METHOD FOR REMOVING MASS AIR FLOW AND TEMPERATURE SENSOR...7781
METHOD FOR INSTALLING MASS AIR FLOW AND TEMPERATURE SENSOR...7782
REMOVE AND INSTALL KCCV CRANKCASE PRESSURE SENSOR...7783
METHOD FOR REMOVING KCCV CRANKCASE PRESSURE SENSOR...7783
METHOD FOR INSTALLING KCCV CRANKCASE PRESSURE SENSOR...7784
REMOVE AND INSTALL SCR TEMPERATURE SENSOR...7785
METHOD FOR REMOVING SCR TEMPERATURE SENSOR...7785
METHOD FOR INSTALLING SCR TEMPERATURE SENSOR...7786
REMOVE AND INSTALL REARVIEW CAMERA...7788
METHOD FOR REMOVING REARVIEW CAMERA...7788
METHOD FOR INSTALLING REARVIEW CAMERA...7789
REMOVE AND INSTALL KomVision CAMERA...7791
METHOD FOR REMOVING KomVision CAMERA...7791
METHOD FOR INSTALLING KomVision CAMERA...7792
REMOVE AND INSTALL KOMTRAX TERMINAL ASSEMBLY...7794
METHOD FOR REMOVING KOMTRAX TERMINAL ASSEMBLY...7794
METHOD FOR INSTALLING KOMTRAX TERMINAL ASSEMBLY...7797
REMOVE AND INSTALL ICT SENSOR CONTROLLER ASSEMBLY...7801
METHOD FOR REMOVING ICT SENSOR CONTROLLER ASSEMBLY...7801
METHOD FOR INSTALLING ICT SENSOR CONTROLLER ASSEMBLY...7803
REMOVE AND INSTALL JUNCTION HARNESS OF CONTROL BOX...7807
METHOD FOR REMOVING JUNCTION HARNESS OF CONTROL BOX...7807
METHOD FOR INSTALLING JUNCTION HARNESS OF CONTROL BOX...7810
REMOVE AND INSTALL CONTROL BOX HARNESS...7813
METHOD FOR REMOVING CONTROL BOX HARNESS...7813
METHOD FOR INSTALLING CONTROL BOX HARNESS...7814
REMOVE AND INSTALL GNSS RECEIVER...7816
METHOD FOR REMOVING GNSS RECEIVER...7816
METHOD FOR INSTALLING GNSS RECEIVER...7817
REMOVE AND INSTALL NETWORK MODEM...7818
METHOD FOR REMOVING NETWORK MODEM...7818
METHOD FOR INSTALLING NETWORK MODEM...7818
REMOVE AND INSTALL GNSS RECEIVER ANTENNA...7819
METHOD FOR REMOVING GNSS RECEIVER ANTENNA...7819
METHOD FOR INSTALLING GNSS RECEIVER ANTENNA...7819
REMOVE AND INSTALL NETWORK MODEM ANTENNA...7821
METHOD FOR REMOVING NETWORK MODEM ANTENNA...7821
METHOD FOR INSTALLING NETWORK MODEM ANTENNA...7821
REMOVE AND INSTALL GNSS ANTENNA...7823
METHOD FOR REMOVING GNSS ANTENNA...7823
METHOD FOR INSTALLING GNSS ANTENNA...7824
REMOVE AND INSTALL IMU SENSOR...7825
METHOD FOR REMOVING IMU SENSOR...7825
METHOD FOR INSTALLING IMU SENSOR...7825
60 MAINTENANCE STANDARD...7829
CONTENTS...7830
ABBREVIATION LIST...7831
ENGINE AND COOLING SYSTEM...7837
MAINTENANCE STANDARD OF ENGINE MOUNT...7837
MAINTENANCE STANDARD OF COOLING SYSTEM...7839
POWER TRAIN...7841
MAINTENANCE STANDARD OF SWING CIRCLE...7841
MAINTENANCE STANDARD OF SWING MACHINERY...7842
MAINTENANCE STANDARD OF FINAL DRIVE...7844
MAINTENANCE STANDARD OF SPROCKET...7846
MAINTENANCE STANDARD OF SPROCKET TOOTH PROFILE FULL-SCALE DRAWING...7847
UNDERCARRIAGE AND FRAME...7849
MAINTENANCE STANDARD OF TRACK FRAME AND IDLER CUSHION...7849
MAINTENANCE STANDARD OF IDLER...7851
MAINTENANCE STANDARD OF TRACK ROLLER...7853
MAINTENANCE STANDARD OF CARRIER ROLLER...7855
MAINTENANCE STANDARD OF TRACK SHOE...7856
MAINTENANCE STANDARD OF TRIPLE SHOE...7859
HYDRAULIC SYSTEM...7860
MAINTENANCE STANDARD OF HYDRAULIC TANK...7860
MAINTENANCE STANDARD OF MAIN PUMP...7861
MAINTENANCE STANDARD OF SWING MOTOR...7863
MAINTENANCE STANDARD OF TRAVEL MOTOR...7866
MAINTENANCE STANDARD OF CONTROL VALVE...7869
MAINTENANCE STANDARD OF WORK EQUIPMENT AND SWING PPC VALVE...7881
MAINTENANCE STANDARD OF TRAVEL PPC VALVE...7884
MAINTENANCE STANDARD OF 1ST-LINE ATTACHMENT PPC VALVE (WITH EPC VALVE)...7887
MAINTENANCE STANDARD OF EPC VALVE OF 1ST-LINE ATTACHMENT PPC VALVE...7888
MAINTENANCE STANDARD OF 2ND-LINE ATTACHMENT PPC VALVE...7890
MAINTENANCE STANDARD OF SOLENOID VALVE...7892
MAINTENANCE STANDARD OF ATTACHMENT CIRCUIT SELECTOR VALVE...7893
MAINTENANCE STANDARD OF CENTER SWIVEL JOINT...7894
WORK EQUIPMENT...7895
MAINTENANCE STANDARD OF WORK EQUIPMENT LINKAGE...7895
DIMENSION OF ARM...7900
DIMENSIONS OF BUCKET...7902
MAINTENANCE STANDARD OF BOOM CYLINDER...7904
MAINTENANCE STANDARD OF STROKE SENSING BOOM CYLINDER...7905
MAINTENANCE STANDARD OF STROKE SENSING ARM CYLINDER...7907
MAINTENANCE STANDARD OF STROKE SENSING BUCKET CYLINDER...7909
MAINTENANCE STANDARD OF STROKE SENSOR FOR BOOM CYLINDER...7911
MAINTENANCE STANDARD OF STROKE SENSOR FOR ARM CYLINDER...7912
MAINTENANCE STANDARD OF STROKE AND RESET SENSOR FOR BUCKET CYLINDER...7913
80 APPENDIX...7915
CONTENTS...7916
ABBREVIATION LIST...7918
AIR CONDITIONER SYSTEM...7924
PRECAUTIONS FOR REFRIGERANT...7924
AIR CONDITIONER COMPONENT...7925
SPECIFICATIONS OF AIR CONDITIONER...7927
CONFIGURATION AND FUNCTION OF REFRIGERATION CYCLE...7928
OUTLINE OF REFRIGERATION CYCLE...7929
COMPONENT PARTS OF AIR CONDITIONER SYSTEM...7931
AIR CONDITIONER UNIT...7931
CONFIGURATION DIAGRAM OF AIR CONDITIONER UNIT...7931
FUNCTION OF AIR CONDITIONER UNIT...7933
COMPONENT PARTS OF AIR CONDITIONER UNIT...7935
FUNCTION OF EVAPORATOR AS AIR CONDITIONER UNIT COMPONENT...7936
FUNCTION OF HEATER CORE AS AIR CONDITIONER UNIT COMPONENT...7936
FUNCTION OF EVAPORATOR TEMPERATURE SENSOR AS AIR CONDITIONER UNIT COMPONENT...7936
FUNCTION OF SERVO MOTOR AS AIR CONDITIONER UNIT COMPONENT...7936
STRUCTURE OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...7937
FUNCTION OF EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...7937
OPERATE EXPANSION VALVE AS AIR CONDITIONER UNIT COMPONENT...7937
FUNCTION OF DUAL PRESSURE SWITCH...7938
AIR CONDITIONER CONTROLLER...7939
STRUCTURE OF AIR CONDITIONER CONTROLLER...7939
COMPRESSOR...7940
STRUCTURE OF COMPRESSOR...7940
SPECIFICATIONS OF COMPRESSOR...7940
FUNCTION OF COMPRESSOR...7940
CONDENSER...7941
STRUCTURE OF CONDENSER...7941
SPECIFICATIONS OF CONDENSER...7941
FUNCTION OF CONDENSER...7941
RECEIVER DRIER...7942
STRUCTURE OF RECEIVER DRIER...7942
SPECIFICATIONS OF RECEIVER DRIER...7942
FUNCTION OF RECEIVER DRIER...7942
SENSORS FOR AIR CONDITIONER SYSTEM...7943
STRUCTURE OF SUNLIGHT SENSOR...7943
FUNCTION OF SUNLIGHT SENSOR...7943
STRUCTURE OF AMBIENT TEMPERATURE SENSOR...7943
FUNCTION OF AMBIENT TEMPERATURE SENSOR...7943
EXPLANATION OF PROCEDURE FOR TESTING AND TROUBLESHOOTING OF AIR CONDITIONER...7945
CIRCUIT DIAGRAM AND ARRANGEMENT OF CONNECTOR PINS FOR AIR CONDITIONER...7947
AIR CONDITIONER SYSTEM DIAGRAM...7949
INPUT AND OUTPUT SIGNALS OF AIR CONDITIONER CONTROLLER...7950
FUNCTION OF AIR CONDITIONER CONTROLLER...7951
INSTALLATION LOCATIONS OF AIR CONDITIONER PARTS AND ARRANGEMENT OF CONNECTORS...7952
TESTING AIR LEAKAGE (DUCT)...7956
METHOD FOR TESTING AIR LEAKAGE (DUCT)...7956
TESTING AIR CONDITIONER USING SELF-DIAGNOSIS FUNCTION...7957
HOW TO OPEN THE ELECTRICAL SYSTEM ABNORMALITY RECORD SCREEN IN SERVICE MODE OF THE MACHINE MONITOR...7958
TEST VENT (MODE) CHANGEOVER...7959
METHOD FOR TESTING VENT (MODE) CHANGEOVER...7959
TESTING FRESH/RECIRC AIR CHANGEOVER...7960
METHOD FOR TESTING FRESH/RECIRC AIR CHANGEOVER...7960
TEST SUNLIGHT SENSOR...7961
METHOD FOR TESTING SUNLIGHT SENSOR...7961
TEST (DUAL) PRESSURE SWITCH FOR REFRIGERANT...7962
METHOD FOR TESTING (DUAL) PRESSURE SWITCH FOR REFRIGERANT...7962
TEST RELAYS...7963
METHOD FOR TESTING RELAYS...7963
AIR CONDITIONER TROUBLESHOOTING CHART 1...7964
AIR CONDITIONER TROUBLESHOOTING CHART 2...7965
INFORMATION DESCRIBED IN TROUBLESHOOTING TABLE...7968
FAILURE CODE [879AKA]...7970
FAILURE CODE [879AKB]...7971
FAILURE CODE [879BKA]...7972
FAILURE CODE [879BKB]...7974
FAILURE CODE [879CKA]...7976
FAILURE CODE [879CKB]...7977
FAILURE CODE [879DKZ]...7978
FAILURE CODE [879EMC]...7980
FAILURE CODE [879FMC]...7981
FAILURE CODE [879GKX]...7982
A-1 TROUBLESHOOTING FOR POWER SUPPLY SYSTEM (AIR CONDITIONER DOES NOT OPERATE)...7984
A-2 TROUBLESHOOTING FOR COMPRESSOR AND REFRIGERANT SYSTEM (AIR IS NOT COOLED)...7986
A-3 TROUBLESHOOTING FOR BLOWER MOTOR SYSTEM (NO AIR COMES OUT OR AIR FLOW IS ABNORMAL)...7989
A-4 TROUBLESHOOTING FOR FRESH/RECIRC AIR CHANGEOVER...7991
TROUBLESHOOTING USING GAUGE PRESSURE...7993
CONNECTION OF SERVICE TOOL...7996
METHOD FOR CONNECTING SERVICE TOOL...7996
PRECAUTIONS FOR DISCONNECTING AND CONNECTING HOSES AND TUBES IN AIR CONDITIONER PIPINGS...7998
HANDLE COMPRESSOR OIL...8000
90 CIRCUIT DIAGRAMS...8003
CONTENTS...8004
ABBREVIATION LIST...8005
HYDRAULIC CIRCUIT DIAGRAM...8011
SYMBOLS USED IN HYDRAULIC CIRCUIT DIAGRAM...8011
HYDRAULIC CIRCUIT DIAGRAM (1/3)...8015
HYDRAULIC CIRCUIT DIAGRAM (2/3)...8017
HYDRAULIC CIRCUIT DIAGRAM (3/3)...8019
ELECTRICAL CIRCUIT DIAGRAM...8021
SYMBOLS USED IN ELECTRICAL CIRCUIT DIAGRAM...8021
ELECTRICAL CIRCUIT DIAGRAM (1/14)...8025
ELECTRICAL CIRCUIT DIAGRAM (2/14)...8027
ELECTRICAL CIRCUIT DIAGRAM (3/14)...8029
ELECTRICAL CIRCUIT DIAGRAM (4/14)...8031
ELECTRICAL CIRCUIT DIAGRAM (5/14)...8033
ELECTRICAL CIRCUIT DIAGRAM (6/14)...8035
ELECTRICAL CIRCUIT DIAGRAM (7/14)...8037
ELECTRICAL CIRCUIT DIAGRAM (8/14)...8039
ELECTRICAL CIRCUIT DIAGRAM (9/14)...8041
ELECTRICAL CIRCUIT DIAGRAM (10/14)...8043
ELECTRICAL CIRCUIT DIAGRAM (11/14)...8045
ELECTRICAL CIRCUIT DIAGRAM (12/14)...8047
ELECTRICAL CIRCUIT DIAGRAM (13/14)...8049
ELECTRICAL CIRCUIT DIAGRAM (14/14)...8051
INDEX...8053
Komatsu Hydraulic Excavators PC360LC-10, PC390LC-10, PC360LCi-11, PC390LCi-11 Repair Service Manuals
