Komatsu Hydraulic Excavators PC360LC-10, PC390LC-10, PC360LCi-11, PC390LCi-11 Repair Service Manual
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.
PRODUCT DETAILS:
Total Pages: 8,075 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
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
MAIN SECTIONS
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 Operators 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
