Komatsu Hydraulic Excavator PC360-10, PC360LC-10 Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Komatsu Hydraulic Excavator PC360-10, PC360LC-10, with all the technical information to maintain, diagnose, repair, and service like professional mechanics.
Komatsu Hydraulic Excavator PC360-10, PC360LC-10 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: 3,208 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
GEN00110-02 - Hydraulic Excavator PC360LC-10 Field Assembly Instruction.pdf
OMEH3607M1 - Hydraulic Excavator PC360-7 Operation & Maintenance Manual.pdf
SEN05619-03 - Hydraulic Excavator PC360LC-10 Shop Manual.pdf
SMEH3607M0 - Hydraulic Excavator PC360-7 Shop Manual.pdf
TEN00521-03 - Hydraulic Excavator PC360LC-10 Operation & Maintenance Manual.pdf
MAIN SECTIONS
GEN00110-02 - Hydraulic Excavator PC360LC-10 Field Assembly Instruction....2
COVER....2
FOREWORD....3
CONTENTS....5
Specifications....7
Precautions for field assembly....8
Disposal of removed parts....9
Assembling procedures, applicable equipment and schedule....10
Flow of field assembly....11
Kit layout diagram....12
Transportation....13
Tool list for field assembly....15
Tightening torque....16
Coating materials....21
Selection of wire ropes used for assembly....25
Selection of nylon slings used for assembly....26
A. ASSEMBLY OF CHASSIS....27
A-1 Installation of handrail....28
A-2 Installation of mirror....30
B. ASSEMBLING OF WORK EQUIPMENT....33
B-1 Installation of arm assembly....34
B-2 Releasing remaining pressure in hydraulic circuit....36
B-3 Installation of bucket cylinder hoses between boom and bucket cylinder....37
B-4 Installation of bucket....38
B-5 Greasing after completion of work equipment....41
B-6 Bleeding air from work equipment circuit....42
C. INCREASING AND DECREASING OF TRACK FRAME GAUGE, ASSEMBLING OF COUNTERWEIGHT....43
C-1 Adjustment of track tension....44
C-2 Sticking sheet to counterweight....47
C-3 Installation of camera....48
C-4 Installation of counterweight....54
M. PROCEDURE FOR INSPECTION AND MAINTENANCE AFTER COMPLETION OF ASSEMBLY....57
M-1 Replacement of return filter (Standard filter to flushing filter)....58
M-2 Flushing of hydraulic circuit....59
M-3 Replacement of return filter (Standard filter to flushing filter)....61
M-4 Check of oil/coolant level at each part....63
M-5 Inspection of oil level in hydraulic tank and refill....65
M-6 Parts to be touched up after field assembly....67
M-7 Error code....68
Mounting bolt torque check sheet....69
Field assembly inspection report (Backhoe)....71
OMEH3607M1 - Hydraulic Excavator PC360-7 Operation & Maintenance Manual....97
COVER....97
LIST OF REVISED PAGES....98
FOREWORD....99
FOREWORD....100
SAFETY INFORMATION....101
INTRODUCTION....103
PRODUCT INFORMATION....104
CONTENTS....106
SAFETY....111
SAFETY INFORMATION....112
POSITION FOR ATTACHING SAFETY LABELS....114
SAFETY INFORMATION....120
SAFETY MACHINE OPERATION....129
SAFETY MAINTENANCE INFORMATION....142
OPERATION....151
GENERAL VIEW....152
EXPLANATION OF COMPONENTS....154
MACHINE OPERATIONS AND CONTROLS....218
TRANSPORTATION....268
COLD WEATHER OPERATION....278
LONG TERM STORAGE....283
TROUBLESHOOTING....285
MAINTENANCE....298
MAINTENANCE INFORMATION....299
LUBRICANTS,COOLANT AND FILTERS....302
WEAR PARTS LIST....306
USE OF FUEL,COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE....307
TIGHTENING TORQUE SPECIFICATIONS....311
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS....312
MAINTENANCE SCHEDULE....313
MAINTENANCE PROCEDURE....316
WHEN REQUIRED....317
CHECK BEFORE STARTING....343
EVERY 50 HOURS MAINTENANCE....344
EVERY 250 HOURS MAINTENANCE....345
EVERY 500 HOURS MAINTENANCE....350
EVERY 1000 HOURS MAINTENANCE....358
EVERY 2000 HOURS MAINTENANCE....362
EVERY 4000 HOURS MAINTENANCE....364
EVERY 5000 HOURS MAINTENANCE....365
SPECIFICATIONS....366
ATTACHMENTS AND OPTIONS....370
GENERAL PRECAUTIONS....371
HANDLING BUCKET WITH HOOK....374
MACHINES READY FOR ATTACHMENTS....375
ATTACHMENT GUIDE....387
RECOMMENDED ATTACHMENT OPERATIONS....395
SEN05619-03 - Hydraulic Excavator PC360LC-10 Shop Manual....400
COVER....400
00 Index and foreword ....402
Index ....403
Foreword, safety and general information ....415
Important safety notice ....415
How to read the shop manual ....422
Explanation of terms for maintenance standard ....424
Handling equipment of fuel system devices ....426
Handling of intake system parts ....427
Handling of hydraulic equipment ....428
Method of disconnecting and connecting of push-pull type coupler ....430
Handling of electrical equipment ....433
How to read electric wire code ....441
Precautions when performing operation ....444
Practical use of KOMTRAX ....449
Standard tightening torque table ....450
List of abbreviation ....456
Conversion table ....461
01 Specification ....466
Table of contents ....467
Specifications ....468
Specification drawing ....468
Working range drawings ....469
Specifications ....470
Weight table ....473
Table of fuel, coolant and lubricants ....475
10 Structure and function ....476
Table of contents ....477
Engine and cooling system ....478
Engine related parts ....478
KVGT ....480
EGR system piping drawing ....487
EGR system circuit diagram ....489
EGR valve ....491
EGR cooler ....493
KCCV layout drawing ....494
KCCV ventilator ....497
KDPF ....499
Cooling system ....503
Power train ....505
Power train ....505
Swing circle ....506
Swing machinery ....507
Final drive ....509
Undercarriage and frame ....511
Track frame and idler cushion ....511
Hydraulic system ....513
Hydraulic component layout ....513
Valve control ....515
Hydraulic tank ....517
CLSS ....519
Main pump ....524
Control valve ....549
Swing motor ....605
Travel motor ....616
PPC valve ....631
Solenoid valve ....652
Attachment circuit selector valve ....656
Center swivel joint ....659
Accumulator ....661
Work equipment ....662
Work equipment ....662
Cab and its attachments ....665
Cab mount and cab tipping stopper ....665
ROPS cab ....666
Electrical system ....667
Electrical control system ....667
Machine monitor system ....715
KOMTRAX system ....734
Sensor ....737
20 Standard value tables ....758
Table of contents ....759
Standard service value table ....760
Standard value table for engine related parts ....760
Standard value table for machine ....762
30 Testing and adjusting ....776
Table of contents ....777
Related information on testing and adjusting ....778
Tools for testing and adjusting ....778
Sketch of tools for testing and adjusting ....782
Engine and cooling system ....784
Testing engine speed ....784
Testing boost pressure ....785
Testing exhaust gas color ....788
Testing and adjusting valve clearance ....790
Testing compression pressure ....794
Testing blowby pressure ....802
Testing engine oil pressure ....804
Testing EGR valve and KVGT oil pressures ....805
Testing fuel pressure ....806
Testing fuel discharge, return and leakage ....813
Bleeding air from fuel system ....819
Testing fuel circuit for leakage ....820
Handling cylinder cutout mode operation ....821
Handling no-injection cranking operation ....822
Checking and adjusting air conditioner compressor belt tension ....823
Replacing fan belt ....824
Replacing alternator belt ....825
Power train ....826
Testing swing circle bearing clearance ....826
Undercarriage and frame ....827
Testing and adjusting track tension ....827
Hydraulic system ....828
Releasing remaining pressure from hydraulic circuit ....828
Testing and adjusting oil pressure in work equipment, swing, and travel circuits ....829
Testing oil pressure of control circuit ....835
Testing and adjusting oil pressure in pump PC control circuit ....837
Testing and adjusting oil pressure in pump LS control circuit ....842
Testing outlet pressure of solenoid valve ....851
Testing PPC valve output pressure ....855
Adjusting play of work equipment and swing PPC valves ....857
Testing pump swash plate sensor ....858
Isolating the parts causing hydraulic drift in work equipment ....859
Testing oil leakage ....861
Bleeding air from hydraulic circuit ....863
Cab and its attachments ....866
Checking cab tipping stopper ....866
Adjusting mirrors ....867
Electrical system ....870
Special functions of machine monitor ....870
Adjusting rearview camera angle ....936
Handling voltage circuit of engine controller ....938
Handling battery disconnect switch ....939
Testing diodes ....940
Pm clinic ....941
Pm clinic service ....941
40 Troubleshooting ....950
Table of contents ....951
Related information on troubleshooting ....958
Troubleshooting points ....958
Sequence of events in troubleshooting ....960
Checks before troubleshooting ....962
Inspection procedure before troubleshooting ....964
Preparation work for troubleshooting of electrical system ....983
Classification and procedure for troubleshooting ....990
Symptom and troubleshooting numbers ....993
Information in troubleshooting table ....996
Troubleshooting method for open circuit in wiring harness of pressure sensor system ....998
Connector list and layout ....1000
Connector contact identification ....1011
T-branch box and T-branch adapter table ....1049
Fuse location table ....1054
Preparation of dummy temperature sensor (for KDOC and KDPF temperature sensors) ....1056
Preparation of short circuit electrical connector (for failure codes [CA1883] and [CA3135]) ....1057
Precautions for KDPF (KCSF and KDOC) Cleaning and Replacement ....1058
Failure codes table ....1061
Troubleshooting by failure code (Display of code) ....1070
Failure code [879AKA] A/C Inner Sensor Open Circuit ....1070
Failure code [879AKB] A/C Inner Sensor Short Circuit ....1071
Failure code [879BKA] A/C Outer Sensor Open Circuit ....1072
Failure code [879BKB] A/C Outer Sensor Short Circuit ....1073
Failure code [879CKA] Ventilating Sensor Open Circuit ....1074
Failure code [879CKB] Ventilating Sensor Short Circuit ....1075
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit ....1076
Failure code [879EMC] Ventilation Damper Abnormality ....1077
Failure code [879FMC] Air Mix Damper Abnormality ....1078
Failure code [879GKX] Refrigerant Abnormality ....1079
Failure code [989L00] Engine Controller Lock Caution 1 ....1080
Failure code [989M00] Engine Controller Lock Caution 2 ....1081
Failure code [989N00] Engine Controller Lock Caution 3 ....1082
Failure code [A1U0N3] HC Desorb Request 1 ....1083
Failure code [A1U0N4] HC Desorb Request 2 ....1085
Failure code [AA10NX] Air Cleaner Clogging ....1087
Failure code [AB00KE] Charge Voltage Low ....1089
Failure code [B@BAZG] Eng Oil Press Low ....1091
Failure code [B@BAZK] Eng Oil Level Low ....1092
Failure code [B@BCNS] Eng Water Overheat ....1093
Failure code [B@BCZK] Eng Water Level Low ....1094
Failure code [B@HANS] Hyd Oil Overheat ....1096
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ....1097
Failure code [CA122] Chg Air Press Sensor High Error ....1098
Failure code [CA123] Chg Air Press Sensor Low Error ....1100
Failure code [CA131] Throttle Sensor High Error ....1102
Failure code [CA132] Throttle Sensor Low Error ....1104
Failure code [CA144] Coolant Temp Sens High Error ....1106
Failure code [CA145] Coolant Temp Sens Low Error ....1108
Failure code [CA153] Chg Air Temp Sensor High Error ....1110
Failure code [CA154] Chg Air Temp Sensor Low Error ....1112
Failure code [CA187] Sensor 2 Supply Volt Low Error ....1114
Failure code [CA221] Ambient Press Sensor High Error ....1116
Failure code [CA222] Ambient Press Sensor Low Error ....1118
Failure code [CA227] Sensor 2 Supply Volt High Error ....1120
Failure code [CA234] Eng Overspeed ....1121
Failure code [CA238] Ne Speed Sensor Supply Volt Error ....1122
Failure code [CA239] Ne Speed Sens Supply Volt High Error ....1123
Failure code [CA271] IMV/PCV1 Short Error ....1124
Failure code [CA272] IMV/PCV1 Open Error ....1126
Failure code [CA281] Pump Press Balance Error ....1128
Failure code [CA295] Ambient Pressure Sensor In Range Error ....1129
Failure code [CA322] Inj #1(L#1) Open/Short Error ....1130
Failure code [CA323] Inj #5(L#5) Open/Short Error ....1132
Failure code [CA324] Inj #3(L#3) Open/Short Error ....1134
Failure code [CA325] Inj #6(L#6) Open/Short Error ....1136
Failure code [CA331] Inj #2(L#2) Open/Short Error ....1138
Failure code [CA332] Inj #4(L#4) Open/Short Error ....1140
Failure code [CA343] ECM Critical Internal Failure ....1142
Failure code [CA351] Injectors Drive Circuit Error ....1143
Failure code [CA352] Sensor 1 Supply Volt Low Error ....1144
Failure code [CA356] Mass Air Flow Sensor High Error ....1146
Failure code [CA357] Mass Air Flow Sensor Low Error ....1148
Failure code [CA386] Sensor 1 Supply Volt High Error ....1150
Failure code [CA428] Water in Fuel Sensor High Error ....1151
Failure code [CA429] Water in Fuel Sensor Low Error ....1153
Failure code [CA435] Eng Oil Press Sw Error ....1155
Failure code [CA441] Battery Voltage Low Error ....1156
Failure code [CA442] Battery Voltage High Error ....1158
Failure code [CA449] Rail Press Very High Error ....1159
Failure code [CA451] Rail Press Sensor High Error ....1161
Failure code [CA452] Rail Press Sensor Low Error ....1163
Failure code [CA488] Chg Air Temp High Torque Derate ....1165
Failure code [CA515] Rail Press Sens Sup Volt High Error ....1166
Failure code [CA516] Rail Press Sens Sup Volt Low Error ....1168
Failure code [CA553] Rail Press High Error ....1170
Failure code [CA555] Crankcase Press High Error 2 ....1171
Failure code [CA556] Crankcase Press High Error 2 ....1172
Failure code [CA559] Rail Pump Press Low Error ....1173
Failure code [CA595] Turbo Speed High Error 2 ....1177
Failure code [CA687] Turbo Speed Low Error ....1178
Failure code [CA689] Eng Ne Speed Sensor Error ....1180
Failure code [CA691] Intake Air Temp Sens High Error ....1184
Failure code [CA692] Intake Air Temp Sens Low Error ....1186
Failure code [CA697] ECM Internal Temp Sensor High Error ....1188
Failure code [CA698] ECM Int Temp Sensor Low Error ....1189
Failure code [CA731] Eng Bkup Speed Sens Phase Error ....1190
Failure code [CA778] Eng Bkup Speed Sensor Error ....1192
Failure code [CA1117] Persistent Data Lost Error ....1197
Failure code [CA1664] KDOC Malfunction ....1198
Failure code [CA1691] Regeneration Ineffective ....1200
Failure code [CA1695] Sens 5 Supply Volt High Error ....1203
Failure code [CA1696] Sens 5 Supply Volt Low Error ....1204
Failure code [CA1843] Crankcase Press Sens High Error ....1206
Failure code [CA1844] Crankcase Press Sens Low Error ....1208
Failure code [CA1879] KDPF Delta P Sensor High Error ....1210
Failure code [CA1881] KDPF Delta P Sensor Low Error ....1212
Failure code [CA1883] KDPF Delta P Sens In Range Error ....1214
Failure code [CA1921] KDPF Soot Load High Error 1 ....1217
Failure code [CA1922] KDPF Soot Load High Error 2 ....1220
Failure code [CA1942] Crankcase Press Sens In Range Error ....1225
Failure code [CA1993] KDPF Delta Pressure Low Error ....1226
Failure code [CA2185] Throt Sens Sup Volt High Error ....1229
Failure code [CA2186] Throt Sens Sup Volt Low Error ....1231
Failure code [CA2249] Rail Press Very Low Error ....1233
Failure code [CA2265] Fuel Feed Pump Open Error ....1234
Failure code [CA2266] Fuel Feed Pump Short Error ....1236
Failure code [CA2271] EGR Valve Pos Sens High Error ....1238
Failure code [CA2272] EGR Valve Pos Sens Low Error ....1240
Failure code [CA2288] Turbo Speed High Error 1 ....1243
Failure code [CA2311] IMV Solenoid Error ....1244
Failure code [CA2349] EGR Valve Solenoid Open Error ....1245
Failure code [CA2353] EGR Valve Solenoid Short Error ....1247
Failure code [CA2357] EGR Valve Servo Error ....1249
Failure code [CA2373] Exhaust Manifold Press Sens High error ....1250
Failure code [CA2374] Exhaust Manifold Press Sens Low error ....1252
Failure code [CA2375] EGR Orifice Temp Sens High Error ....1254
Failure code [CA2376] EGR Orifice Temp Sens Low Error ....1256
Failure code [CA2381] KVGT Pos Sens High Error ....1258
Failure code [CA2382] KVGT Pos Sens Low Error ....1260
Failure code [CA2383] KVGT Solenoid Open Error ....1263
Failure code [CA2386] KVGT Solenoid Short Error ....1265
Failure code [CA2387] KVGT Servo Error ....1267
Failure code [CA2554] Exh Manifold Press Sens In Range Error ....1268
Failure code [CA2555] Grid Htr Relay Open Circuit Error ....1269
Failure code [CA2556] Grid Htr Relay Short Circuit Error ....1271
Failure code [CA2637] KDOC Face Plugging ....1273
Failure code [CA2639] Manual Stationary Regeneration Request ....1275
Failure code [CA2961] EGR Orifice Temp High Error 1 ....1278
Failure code [CA2973] Chg Air Press Sensor In Range Error ....1279
Failure code [CA3133] KDPF Outlet Press Sens High Error ....1280
Failure code [CA3134] KDPF Outlet Press Sens Low Error ....1282
Failure code [CA3135] KDPF Outlet Press Sens In Range Error ....1284
Failure code [CA3251] KDOC Inlet Temp High Error ....1288
Failure code [CA3253] KDOC Temp Error - Non Regeneration ....1291
Failure code [CA3254] KDOC Outlet Temp High Error 1 ....1294
Failure code [CA3255] KDPF Temp Error - Non Regeneration ....1297
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....1300
Failure code [CA3311] KDOC Outlet Temp High Error 2 ....1303
Failure code [CA3312] KDPF Outlet Temp High Error 2 ....1306
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ....1309
Failure code [CA3314] KDOC Inlet Temp Sens High Error ....1312
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error ....1316
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ....1320
Failure code [CA3317] KDOC Outlet Temp Sens High Error ....1323
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error ....1327
Failure code [CA3319] KDPF Outlet Temp Sens High Error ....1331
Failure code [CA3321] KDPF Outlet Temp Sens Low Error ....1335
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error ....1338
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ....1342
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ....1344
Failure code [CA3741] Rail Press Valve Trip Error ....1346
Failure code [D110KB] Battery Relay Drive S/C ....1347
Failure code [D19JKZ] Personal Code Relay Abnormality ....1349
Failure code [D811MC] KOMTRAX Error ....1352
Failure code [D862KA] GPS Antenna Open Circuit ....1353
Failure code [D8ALKA] System Operating Lamp Disconnection (KOMTRAX) ....1354
Failure code [D8ALKB] System Operating Lamp Short Circuit (KOMTRAX) ....1356
Failure code [D8AQKR] CAN2 Discon (KOMTRAX) ....1357
Failure code [DA20MC] Pump Controller Malfunction ....1358
Failure code [DA22KK] Pump Solenoid Power Low Error ....1359
Failure code [DA25KP] 5V Sensor1 Power Abnormality ....1361
Failure code [DA29KQ] Model Selection Abnormality ....1364
Failure code [DA2LKA] System Operating Lamp Disconnection (Pump Con) ....1366
Failure code [DA2LKB] System Operating Lamp Short Circuit (Pump Con) ....1368
Failure code [DA2QKR] CAN2 Discon ( Pump Con) ....1369
Failure code [DA2RKR] CAN1 Discon ( Pump Con) ....1372
Failure code [DAF0MB] Monitor ROM Abnormality ....1373
Failure code [DAF0MC] Monitor Error ....1374
Failure code [DAF8KB] Camera Power Supply Short Circuit ....1375
Failure code [DAF9KQ] Model Selection Abnormality ....1377
Failure code [DAFGMC] GPS Module Error ....1378
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) ....1379
Failure code [DAFLKB] System Operating Lamp Short Circuit (Monitor) ....1381
Failure code [DAFQKR] CAN2 Discon (Monitor) ....1382
Failure code [DAZ9KQ] AC Model Selection Abnormality ....1383
Failure code [DAZQKR] CAN2 Discon (AC) ....1384
Failure code [DB2QKR] CAN2 Discon (Engine Con) ....1389
Failure code [DB2RKR] CAN1 Discon (Engine Con) ....1394
Failure code [DGH2KB] Hyd Oil Sensor Short Circuit ....1398
Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit ....1400
Failure code [DHPAMA] Pump Press Sensor Abnormality ....1402
Failure code [DHPBMA] R Pump Press Sensor Abnormality ....1405
Failure code [DHS3MA] Arm IN PPC Sen. Abnormality ....1408
Failure code [DHS4MA] Bucket CURL PPC Press Sensor Abnormality ....1410
Failure code [DHS8MA] Boom RAISE PPC Press Sensor Abnormality ....1413
Failure code [DHS9MA] Boom LOWER Press Sensor Abnormality ....1416
Failure code [DHSAMA] Swing RH PPC Press Sensor Abnomality ....1419
Failure code [DHSBMA] Swing LH PPC Press Sensor Abnomality ....1422
Failure code [DHSCMA] Arm OUT PPC Press Sensor Abnormality ....1425
Failure code [DHSDMA] Bucket Dump PPC Press Sensor Abnormality ....1428
Failure code [DHSFMA] Travel FW L PPC Press Sensor Abnormality ....1431
Failure code [DHSGMA] Travel FW R PPC Press Sensor Abnormality ....1434
Failure code [DHSHMA] Travel BW L PPC Press Sensor Abnormality ....1437
Failure code [DHSJMA] Travel BW R PPC Press Sensor Abnormality ....1440
Failure code [DKR0MA] F pump S/P sensor Abnormality ....1443
Failure code [DKR1MA] R pump S/P sensor Abnormality ....1445
Failure code [DR21KX] Camera 2 Picture Rev. Drive Abnormality ....1447
Failure code [DR31KX] Camera 3 Picture Rev. Drive Abnormality ....1449
Failure code [DV20KB] Travel Alarm Short Circuit ....1451
Failure code [DW43KA] Travel Speed Sol Open Circuit ....1453
Failure code [DW43KB] Travel Speed Sol Short Circuit ....1455
Failure code [DW45KA] swing holding brake Sol Open Circuit ....1457
Failure code [DW45KB] Swing Brake Sol Short Circuit ....1460
Failure code [DW91KA] Travel Junction Sol Open Circuit ....1463
Failure code [DW91KB] Travel Junction Sol Short Circuit ....1465
Failure code [DWA2KA] Attachment Sol Open Circuit ....1467
Failure code [DWA2KB] Attachment Sol Short Circuit ....1469
Failure code [DWK0KA] 2-stage Relief Sol Open Circuit ....1471
Failure code [DWK0KB] 2-stage Relief Sol Short Circuit ....1473
Failure code [DWK2KA] Variable Back Pressure Sol Open Circuit ....1475
Failure code [DWK2KB] Variable Back Pressure Sol Short Circuit ....1477
Failure code [DWK8KA] Swing C/O Solenoid Open Circuit ....1479
Failure code [DWK8KB] Swing C/O Solenoid Short Circuit ....1481
Failure code [DXA8KA] PC-EPC (F) Sol Open Circuit ....1483
Failure code [DXA8KB] PC-EPC (F) Sol Short Circuit ....1485
Failure code [DXA9KA] PC-EPC (R) Sol Open Circuit ....1487
Failure code [DXA9KB] PC-EPC (R) Sol Short Circuit ....1489
Failure code [DXE0KA] LS-EPC Sol Open Circuit ....1491
Failure code [DXE0KB] LS-EPC Sol Short Circuit ....1493
Failure code [DXE4KA] Service Current EPC Disc. ....1495
Failure code [DXE4KB] Service Current EPC S/C ....1496
Failure code [DXE5KA] Merge-divider Main Sol Open Circuit ....1497
Failure code [DXE5KB] Merge-divider Main Sol Short Circuit ....1499
Failure code [DXE6KA] Merge-divider LS Sol Open Circuit ....1501
Failure code [DXE6KB] Merge-divider LS Sol Short Circuit ....1503
Failure code [DY20KA] Wiper Working Abnormality ....1505
Failure code [DY20MA] Wiper Parking Abnormality ....1507
Failure code [DY2CKB] Washer Drive Short Circuit ....1509
Failure code [DY2DKB] Wiper Drive (For) Short ....1511
Failure code [DY2EKB] Wiper Drive (Rev) Short ....1513
Troubleshooting of electrical system (E-mode) ....1515
E-1 Engine does not start (Engine does not crank) ....1515
E-2 Manual preheating does not work ....1521
E-3 Automatic preheating system does not work ....1524
E-4 While preheating is working, preheating monitor does not light up ....1526
E-5 When starting switch is turned to ON position, machine monitor displays nothing ....1528
E-6 While starting switch is turned to ON position (with engine stopped), engine oil level monitor lights up in yellow ....1531
E-7 While starting switch is turned to ON position (with engine stopped), radiator coolant level monitor lights up in yellow ....1532
E-8 Engine coolant temperature monitor lights up in white while engine is running ....1533
E-9 Hydraulic oil temperature monitor lights up in white while engine is running ....1534
E-10 Charge level monitor lights up in red while engine is running ....1535
E-11 Fuel level monitor lights up in red while engine is running ....1536
E-12 Air cleaner clogging monitor lights up in yellow while engine is running ....1537
E-13 Engine coolant temperature monitor lights up in red while engine is running ....1538
E-14 Hydraulic oil temperature monitor lights up in red while engine is running ....1539
E-15 Engine oil pressure monitor lights up in red while engine is running ....1540
E-16 Fuel gauge display does not move from minimum or maximum ....1541
E-17 Display of fuel gauge differs from actual fuel level ....1542
E-18 Engine coolant temperature gauge display does not move from minimum or maximum ....1543
E-19 Display of engine coolant temperature gauge differs from actual coolant temperature ....1544
E-20 Hydraulic oil temperature gauge display does not move from minimum or maximum ....1545
E-21 Display of hydraulic oil temperature gauge differs from actual oil temperature ....1547
E-22 Machine monitor does not display partially ....1548
E-23 Function switch does not operate ....1549
E-24 Automatic warm-up system does not work (in cold weather) ....1550
E-25 When auto-decelerator switch is operated, auto-decelerator monitor does not light up or does not go off ....1551
E-26 Auto-decelerator is not operated or canceled with lever ....1552
E-27 When working mode switch is operated, working mode selection screen is not displayed ....1553
E-28 When working mode is changed, setting of engine and hydraulic pump is not changed ....1554
E-29 When travel speed switch is operated, travel speed monitor does not change ....1555
E-30 When travel speed selection is changed, actual travel speed does not change ....1556
E-31 Alarm buzzer cannot be canceled ....1557
E-32 When starting switch is turned OFF, service meter is not displayed ....1558
E-33 Machine monitor cannot be set in service mode ....1559
E-34 Any of work equipment, swing and travel does not work ....1560
E-35 Any of work equipment, swing and travel cannot be locked ....1562
E-36 Upper structure does not swing while swing brake cancel switch is set to CANCEL position ....1564
E-37 Swing brake does not operate while swing brake cancel switch is set to NORMAL position ....1566
E-38 One-touch power maximizing function does not work properly or pilot monitor is not displayed ....1568
E-39 One-touch power maximizing function cannot be canceled ....1570
E-40 Alarm does not sound during travel ....1571
E-41 Alarm does not stop sounding while machine is stopped ....1573
E-42 Horn does not sound ....1574
E-43 Horn does not stop sounding ....1576
E-44 When wiper switch is operated, wiper monitor does not light up or go off ....1577
E-45 Wiper does not operate when wiper switch is operated ....1578
E-46 When window washer switch is operated, window washer does not operate ....1580
E-47 Boom LOWER indicator is not displayed properly with monitoring function ....1581
E-48 Arm OUT indicator is not displayed properly with monitoring function ....1582
E-49 Arm IN indicator is not displayed properly with monitoring function ....1583
E-50 Boom RAISE indicator is not displayed properly with monitoring function ....1584
E-51 Bucket CURL indicator is not displayed properly with monitoring function ....1585
E-52 Bucket DUMP indicator is not displayed properly with monitoring function ....1586
E-53 Swing indication is not displayed properly with monitoring function ....1587
E-54 Travel indication is not displayed properly with monitoring function ....1588
E-55 Service indication is not displayed properly with monitoring function ....1589
E-56 Attachment circuit is not switched ....1591
E-57 KOMTRAX system does not operate properly ....1592
E-58 Machine push-up function is not canceled ....1593
E-59 Machine push-up function does not work ....1595
Troubleshooting of hydraulic and mechanical system (H-mode) ....1596
Information described in troubleshooting table (H-mode) ....1596
List of Failure Mode and Cause ....1597
H-1 All of work equipment, swing and travel operation lacks speed or power ....1602
H-2 Engine speed lowers significantly or engine stalls ....1606
H-3 Any of work equipment, swing and travel does not work ....1609
H-4 Unusual sound is heard from around hydraulic pump ....1610
H-5 Fine control performance or response is poor ....1611
H-6 Speed or power of boom is low ....1613
H-7 Speed or power of arm is low ....1617
H-8 Speed or power of bucket is low ....1622
H-9 Work equipment does not move in single operation ....1626
H-10 Hydraulic drift of boom is large ....1627
H-11 Hydraulic drift of arm is large ....1628
H-12 Hydraulic drift of bucket is large ....1630
H-13 Time lag of work equipment is large ....1631
H-14 When part of work equipment is relieved singly, other parts of work equipment move ....1633
H-15 One-touch power maximizing function does not work ....1634
H-16 Machine push up function does not work ....1635
H-17 In combined operation of work equipment, equipment having heavier load moves slower ....1636
H-18 In combined operations of swing and boom RAISE, boom rising speed is low ....1637
H-19 In combined operations of swing and travel, travel speed drops largely ....1638
H-20 Machine does not travel straight ....1639
H-21 Travel speed is too low ....1642
H-22 Machine is hard to steer or travel power is low ....1644
H-23 Travel speed does not change, or travel speed is too low or high ....1647
H-24 One of tracks does not run ....1648
H-25 Upper structure does not swing in both right and left directions ....1650
H-26 Upper structure does not swing in only one direction. ....1651
H-27 Swing acceleration or swing speed is low in both directions (right and left) ....1652
H-28 Swing acceleration performance is poor or swing speed is slow in only one direction ....1653
H-29 Upper structure overruns remarkably when it stops swinging in both directions (right and left) ....1654
H-30 Upper structure overruns excessively when it stops swinging in only one direction ....1655
H-31 Shock is large when upper structure stops swinging ....1656
H-32 Large unusual noise is heard when upper structure stops swinging ....1657
H-33 When swing holding brake is applied, hydraulic drift of swing is large ....1658
H-34 When swing holding brake is released, hydraulic drift of swing is large ....1659
H-35 When additional attachment is installed, attachment circuit is not switched ....1660
H-36 Oil flow in attachment circuit cannot be controlled ....1661
Troubleshooting of engine (S-mode) ....1662
Information contained in troubleshooting table (S mode) ....1662
S-1 Engine does not crank when starting switch is turned to START position ....1663
S-2 The engine cranks but exhaust smoke does not come out ....1664
S-3 Fuel is being injected but engine does not start (incomplete combustion: engine cranks but does not start) ....1665
S-4 Startability is poor ....1666
S-5 Engine does not pick up smoothly ....1668
S-6 Engine stops during operation ....1670
S-7 Engine runs rough or is unstable ....1672
S-8 Engine lacks power ....1673
S-9 KDPF gets clogged in a short time ....1675
S-10 Engine oil consumption is excessive ....1677
S-11 Engine oil becomes contaminated early ....1678
S-12 Fuel consumption is excessive ....1679
S-13 Oil is in coolant (or coolant spurts or coolant level goes down) ....1680
S-14 Oil pressure drops ....1681
S-15 Fuel mixes into engine oil ....1682
S-16 Water mixes into engine oil (milky) ....1683
S-17 Coolant temperature rises too high (overheating) ....1684
S-18 Unusual noise is heard ....1685
S-19 Vibration is excessive ....1686
S-20 Air cannot be bled from fuel circuit ....1687
S-21 Frequent active regeneration ....1688
S-22 Active regeneration takes time ....1689
S-23 White smoke is exhausted during active regeneration ....1690
50 Disassembly and assembly ....1692
Table of contents ....1693
Related information on disassembly and assembly ....1695
How to read this manual ....1695
Coating materials list ....1697
Special tools list ....1701
Sketches of special tools ....1706
Engine and cooling system ....1709
Removal and installation of supply pump assembly ....1709
Removal and installation of injector assembly ....1719
Removal and installation of cylinder head assembly ....1735
Removal and installation of radiator assembly ....1757
Removal and installation of hydraulic oil cooler assembly ....1760
Removal and installation of aftercooler assembly ....1763
Removal and installation of engine and main pump assembly ....1764
Removal and installation of engine front seal ....1776
Removal and installation of engine rear seal ....1781
Removal and installation of fuel tank assembly ....1788
Removal and installation of engine hood assembly ....1790
Removal and installation of KDPF assembly ....1793
Disassembly and assembly of KDPF ....1800
Removal and installation of KCCV assembly ....1809
Removal and installation of air cleaner assembly ....1811
Removal and installation of air conditioner compressor assembly ....1813
Removal and installation of air conditioner condenser assembly ....1815
Power train system ....1817
Removal and installation of travel motor and final drive assembly ....1817
Disassembly and assembly of final drive ....1818
Removal and installation of swing motor and swing machinery assembly ....1827
Disassembly and assembly of swing machinery ....1829
Removal and installation of swing circle assembly ....1836
Undercarriage and frame ....1837
Separation and connection of track shoe assembly ....1837
Removal and installation of sprocket ....1840
Removal and installation of idler and idler cushion assembly ....1841
Disassembly and assembly of idler ....1842
Disassembly and assembly of idler cushion ....1845
Disassembly and assembly of track roller ....1847
Disassembly and assembly of carrier roller ....1849
Removal and installation of revolving frame assembly ....1852
Removal and installation of counterweight assembly ....1854
Hydraulic system ....1858
Removal and installation of center swivel joint assembly ....1858
Disassembly and assembly of center swivel joint ....1860
Removal and installation of hydraulic tank assembly ....1861
Removal and installation of main pump assembly ....1864
Removal and installation of control valve assembly ....1868
Disassembly and assembly of control valve ....1874
Disassembly and assembly of work equipment PPC valve ....1879
Disassembly and assembly of travel PPC valve ....1881
Work equipment ....1883
Removal and installation of bucket assembly ....1883
Removal and installation of arm assembly ....1884
Removal and installation of work equipment assembly ....1886
Disassembly and assembly of work equipment cylinder ....1889
Cab and its attachments ....1895
Removal and installation of operator's cab assembly ....1895
Removal and installation of operator cab glass (adhered glass) ....1900
Removal and installation of front window assembly ....1910
Removal and installation of floor frame assembly ....1916
Removal and installation of air conditioner unit assembly ....1922
Removal and installation of operator's seat ....1926
Removal and installation of seat belt ....1928
Removal and installation of front wiper assembly ....1930
Electrical system ....1937
Removal and installation of engine controller assembly ....1937
Removal and installation of pump controller assembly ....1940
Removal and installation of machine monitor assembly ....1943
Removal and installation of pump swash plate sensor ....1945
Removal and installation of mass air flow and temperature sensor ....1946
Removal and installation of KOMTRAX terminal assembly ....1947
60 Maintenance standard ....1950
Table of contents ....1951
Engine and cooling system ....1952
Engine mount ....1952
Cooling system ....1953
Power train system ....1954
Swing circle ....1954
Swing machinery ....1955
Final drive ....1957
Undercarriage and frame ....1959
Sprocket ....1959
Track frame and idler cushion ....1961
Idler ....1963
Track roller ....1965
Carrier roller ....1967
Track shoe ....1968
Hydraulic system ....1971
Hydraulic tank ....1971
Main pump ....1972
Control valve ....1973
Swing motor ....1983
Travel motor ....1985
PPC valve ....1988
Solenoid valve ....1999
Attachment circuit selector valve ....2000
Center swivel joint ....2001
Work equipment ....2002
Work equipment ....2002
Work equipment cylinder ....2011
80 Appendix ....2014
Table of contents ....2015
Air conditioner components ....2016
Precautions for refrigerant ....2016
Air conditioner component ....2017
Configuration and function of refrigeration cycle ....2020
Outline of refrigeration cycle ....2021
Air conditioner unit ....2023
Dual pressure switch ....2030
Air conditioner controller ....2031
Compressor ....2032
Condenser ....2033
Receiver drier ....2034
Sunlight sensor ....2035
Outer temperature sensor (outside air temperature sensor) ....2036
Procedure for testing and troubleshooting ....2037
Circuit diagram and arrangement of connector pins ....2039
System diagram ....2041
Input and output signals of the air conditioner controller ....2042
Parts and connectors layout ....2044
Layout of air conditioner related parts and connectors ....2045
Testing air leakage (duct) ....2048
Testing with self-diagnosis function ....2051
How to open the electrical system abnormality record screen in service mode of the machine monitor ....2052
Testing vent (mode) changeover ....2054
Testing FRESH/RECIRC air changeover ....2056
Testing sunlight sensor ....2057
Testing (dual) pressure switch for refrigerant ....2058
Testing relays ....2060
Troubleshooting chart 1 ....2061
Troubleshooting chart 2 ....2062
Information in troubleshooting table ....2065
Failure code list related to air conditioner ....2066
Failure code [879AKA] A/C Inner sensor Open Circuit ....2067
Failure code [879AKB] A/C Inner sensor Short Circuit ....2068
Failure code [879BKA] A/C Outer sensor Open Circuit ....2069
Failure code [879BKB] A/C Outer sensor Short Circuit ....2071
Failure code [879CKA] Ventilating sensor Open Circuit ....2073
Failure code [879CKB] Ventilating sensor Short Circuit ....2074
Failure code [879DKZ] Sunlight sensor Open or Short Circuit ....2075
Failure code [879EMC] Ventilating Damper Abnormality ....2077
Failure code [879FMC] Air Mix Damper Abnormality ....2078
Failure code [879GKX] Refrigerant Abnormality ....2079
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ....2080
A-2 Troubleshooting for compressor and refrigerant system (Air is not cooled) ....2082
A-3 Troubleshooting for blower motor system (No air comes out or air flow is abnormal) ....2085
A-4 Troubleshooting for FRESH/RECIRC air changeover ....2087
Troubleshooting with gauge pressure ....2089
Connection of service tool ....2092
Precautions for disconnecting and connecting air conditioner piping ....2094
Handling of compressor oil ....2096
90 Diagrams and drawings ....2098
Table of contents ....2099
Hydraulic circuit diagram ....2100
Symbols in hydraulic circuit diagram ....2100
Hydraulic circuit diagram....2104
Electric circuit diagram ....2105
Symbols in electric circuit diagram ....2105
Electrical circuit diagram....2109
Air conditioner electrical circuit diagram....2115
SMEH3607M0 - Hydraulic Excavator PC360-7 Shop Manual....2126
COVER....2126
CONTENTS....2127
SAFETY....2129
FOREWORD....2131
01 GENERAL....2149
SPECIFICATION DIMENSION DRAWINGS....2150
SPECIFICATIONS....2152
WEIGHT TABLE....2154
FUEL, COOLANT AND LUBRICANTS....2156
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD....2157
Engine Related Parts....2158
Radiator Oil Cooler Aftercooler....2159
Power Train....2160
Final Drive....2162
Swing Machinery....2164
Swing Circle....2166
Track Frame Recoil Spring....2168
Idler....2170
Carrier roller....2172
Track roller....2173
Track Shoe....2174
Hydraulic Equipment Layout Drawing....2178
Hydraulic Tank....2180
Hydraulic Pump....2182
Variable Volume Valve....2203
Control Valve....2206
CLSS....2222
Self Pressure Reducing Valve....2225
Swing Motor....2228
Reverse Prevention Valve....2234
Center Swivel Joint....2236
Travel Motor....2237
Travel Junction Valve....2247
Travel PPC Shuttle Valve ....2250
Valve Control....2254
Work Equipment Swing PPC Valve....2255
Travel PPC Valve....2259
Service PPC Valve ....2268
Solenoid Valve....2271
PPC Accumulator....2273
Return Oil Filter....2274
Boom Hydraulic Drift Prevention Valve....2276
Quick Return Valve....2282
Lift Check Valve....2284
Attachment Circuit Selector Valve....2285
Hydraulic Cylinder....2288
Work Equipment....2290
Air Conditioner....2296
Engine Control....2297
Electronic Control System ....2305
Multi Monitor System....2329
7-Segment Monitor System....2349
Sensor....2356
20 TESTING AND ADJUSTING....2359
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS....2360
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS....2361
TESTING AND ADJUSTING....2369
TROUBLESHOOTING....2453
POINTS TO REMEMBER WHEN TROUBLESHOOTING....2454
SEQUENCE OF EVENTS IN TROUBLESHOOTING....2455
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE....2456
CHECKS BEFORE TROUBLESHOOTING....2464
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING....2465
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM....2470
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....2488
TROUBLESHOOTING WHEN SERVICE CODE "ELECTRICAL SYSTEM" AND FAILURE CODE "MECHANICAL SYSTEM" ARE INDICATED....2511
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)....2597
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)....2647
30 DISASSEMBLY AND ASSEMBLY....2671
HOW TO READ THIS MANUAL....2673
PRECAUTIONS WHEN PERFORMING OPERATION ....2675
SPECIAL TOOL LIST....2677
STARTING MOTOR ASSEMBLY ....2681
FUEL INJECTION PUMP ASSEMBLY ....2682
ENGINE FRONT SEAL....2686
ENGINE REAR SEAL....2687
CYLINDER HEAD ASSEMBLY ....2689
RADIATOR ASSEMBLY ....2695
HYDRAULIC OIL COOLER ASSEMBLY ....2697
ENGINE AND HYDRAULIC PUMP ASSEMBLIES ....2699
FINAL DRIVE ASSEMBLY ....2703
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY....2704
SWING MOTOR, SWING MACHINERY ASSEMBLY....2714
DISASSEMBLY AND ASSEMBLY OF SWING MOTOR, SWING MACHINERY ASSEMBLY....2715
CARRIER ROLLER ASSEMBLY....2723
TRACK ROLLER ASSEMBLY....2724
IDLER ASSEMBLY ....2725
RECOIL SPRING ASSEMBLY ....2728
SPROCKET ....2730
TRACK SHOE ASSEMBLY....2731
SWING CIRCLE ASSEMBLY....2733
REVOLVING FRAME ASSEMBLY ....2734
CENTER SWIVEL JOINT ASSEMBLY....2737
DISASSEMBLY AND ASSEMBLY OF CENTER SWIVEL JOINT ASSEMBLY....2739
HYDRAULIC TANK ASSEMBLY ....2740
CONTROL VALVE ASSEMBLY....2742
DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY....2745
HYDRAULIC PUMP ASSEMBLY ....2747
OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT....2750
WORK EQUIPMENT PPC VALVE ASSEMBLY....2751
TRAVEL PPC VALVE ASSEMBLY ....2752
HYDRAULIC CYLINDER ASSEMBLY ....2753
WORK EQUIPMENT ASSEMBLY ....2759
AIR CONDITIONER UNIT ASSEMBLY....2762
COUNTERWEIGHT ASSEMBLY ....2765
OPERATORS CAB ASSEMBLY ....2766
MONITOR ASSEMBLY....2768
GOVERNOR PUMP CONTROLLER ASSEMBLY ....2769
90 OTHERS....2771
Hydraulic Circuit Diagram....2772
Electrical Circuit Diagram (1/4)....2773
Electrical Circuit Diagram (2/4)....2774
Electrical Circuit Diagram (3/4)....2775
Electrical Circuit Diagram (4/4)....2776
TEN00521-03 - Hydraulic Excavator PC360LC-10 Operation & Maintenance Manual....2777
COVER....2777
FOREWORD ....2778
BEFORE READING THIS MANUAL ....2779
SAFETY INFORMATION ....2780
INTRODUCTION ....2781
USE OF MACHINE ....2781
DIRECTIONS OF MACHINE ....2781
VISIBILITY FROM OPERATORS SEAT ....2781
PRODUCT INFORMATION ....2782
PRODUCT IDENTIFICATION NUMBER (PIN)MACHINE SERIAL NO. PLATE ....2782
EPA REGULATIONS, ENGINE NUMBER PLATE ....2782
SERVICE METER LOCATION ....2783
YOUR MACHINE SERIAL NUMBERS AND DISTRIBUTOR ....2783
CONTENTS ....2784
SAFETY ....2788
SAFETY ....2789
SAFETY LABELS ....2791
LOCATION OF SAFETY LABELS ....2792
SAFETY LABELS ....2793
GENERAL PRECAUTIONS COMMON TO OPERATION AND MAINTENANCE ....2801
PRECAUTIONS BEFORE STARTING OPERATION ....2801
PREPARATIONS FOR SAFE OPERATION ....2802
FIRE PREVENTION ....2804
PRECAUTIONS WHEN GETTING ON OR OFF MACHINE ....2806
DO NOT GET CAUGHT IN WORK EQUIPMENT ....2807
PRECAUTIONS RELATED TO PROTECTIVE STRUCTURES ....2808
PROTECTION AGAINST FALLING, FLYING, OR INTRUDING OBJECTS ....2809
UNAUTHORIZED MODIFICATION ....2809
PRECAUTIONS RELATED TO ATTACHMENTS AND OPTIONS ....2810
PRECAUTIONS RELATED TO CAB GLASS ....2810
PRECAUTIONS WHEN RUNNING ENGINE INSIDE BUILDING ....2810
PRECAUTIONS FOR OPERATION ....2811
PRECAUTIONS FOR JOBSITE ....2811
STARTING ENGINE ....2814
OPERATION ....2817
TRANSPORTATION ....2824
TOWING ....2825
SAFETY RULES FOR LIFTING OPERATIONS ....2826
PRECAUTIONS FOR MAINTENANCE ....2827
PRECAUTIONS BEFORE STARTING INSPECTION AND MAINTENANCE ....2827
PRECAUTIONS FOR INSPECTION AND MAINTENANCE ....2831
OPERATION ....2838
GENERAL VIEW ....2839
GENERAL VIEW OF MACHINE ....2839
GENERAL VIEW OF CAB ....2841
GENERAL VIEW OF CONTROLS AND GAUGES ....2842
EXPLANATION OF COMPONENTS ....2844
MACHINE MONITOR ....2844
SWITCHES ....2917
CONTROL LEVERS AND PEDALS ....2925
OPENING AND CLOSING CEILING WINDOW ....2928
OPENING AND CLOSING CAB FRONT WINDOW ....2929
EMERGENCY ESCAPE HAMMER ....2934
DOOR LOCK ....2935
OPEN AND CLOSE ENGINE HOOD ....2936
CAB DOOR HINGE ....2939
CAP WITH LOCK ....2940
DRINK BOX ....2943
MAGAZINE BOX ....2943
CUP HOLDER ....2943
ASHTRAY ....2944
HANDLING AIR CONDITIONER ....2945
HANDLING RADIO ....2957
AUXILIARY ELECTRIC POWER ....2962
FUSE ....2963
FUSIBLE LINK ....2965
TOOL BOX ....2966
GREASE PUMP HOLDER ....2966
FIRE EXTINGUISHER ....2966
BATTERY DISCONNECT SWITCH ....2967
SYSTEM OPERATING LAMP ....2968
HANDLING KOMATSU DIESEL PARTICULATE FILTER (KDPF) ....2969
HANDLING KOMATSU CLOSED CRANKCASE VENTILATION (KCCV) ....2978
HANDLING MACHINES EQUIPPED WITH KOMTRAX ....2979
MACHINE OPERATIONS AND CONTROLS ....2981
CHECKS AND ADJUSTMENT BEFORE STARTING ENGINE ....2981
STARTING ENGINE ....3002
OPERATIONS AND CHECKS AFTER STARTING ENGINE ....3005
STOPPING ENGINE ....3017
MACHINE OPERATION ....3018
STEERING MACHINE ....3022
SWINGING MACHINE ....3024
WORK EQUIPMENT CONTROLS AND OPERATIONS ....3025
WORKING MODE ....3027
PROHIBITED OPERATIONS ....3030
RULES FOR OPERATION ....3035
TRAVELING ON SLOPES ....3037
ESCAPE FROM MUD ....3039
RECOMMENDED APPLICATIONS ....3040
REPLACING AND INVERTING BUCKET ....3042
WHEN PARKING MACHINE ....3045
AFTER DAILY WORK COMPLETION ....3046
LOCKING ....3047
TRANSPORTATION ....3048
TRANSPORTATION PROCEDURE ....3048
LOADING AND UNLOADING WITH TRAILER ....3049
LIFT MACHINE ....3058
SPREAD AND NARROW TRACK FRAME GAUGE ....3060
COLD WEATHER OPERATION ....3062
COLD WEATHER OPERATION INFORMATION ....3062
AFTER DAILY WORK COMPLETION ....3064
AFTER COLD WEATHER SEASON ....3064
LONG-TERM STORAGE ....3065
BEFORE STORAGE ....3065
DURING STORAGE ....3065
AFTER STORAGE ....3066
STARTING MACHINE AFTER LONG-TERM STORAGE ....3066
TROUBLES AND ACTIONS ....3067
RUNNING OUT OF FUEL ....3067
PHENOMENA THAT ARE NOT FAILURES ....3068
TOWING MACHINE ....3069
LIGHTWEIGHT TOWING HOLE ....3070
SEVERE JOB CONDITION ....3070
DISCHARGED BATTERY ....3071
OTHER TROUBLE ....3075
MAINTENANCE ....3080
RULES FOR MAINTENANCE ....3081
SERVICE METER READING ....3081
KOMATSU GENUINE REPLACEMENT PARTS ....3081
KOMATSU GENUINE LUBRICANTS ....3081
ALWAYS USE CLEAN WASHER FLUID ....3081
FRESH AND CLEAN LUBRICANTS ....3081
CHECK DRAINED OIL AND USED FILTER ....3081
CAUTION FOR REFILLING OIL OR FUEL ....3081
WELDING INSTRUCTIONS ....3081
DO NOT DROP THINGS INSIDE MACHINE ....3081
DUSTY JOBSITES ....3082
AVOID MIXING OIL ....3082
LOCKING INSPECTION COVERS ....3082
BLEEDING AIR FROM HYDRAULIC CIRCUIT ....3082
PRECAUTIONS WHEN INSTALLING HYDRAULIC HOSES ....3082
CHECKS AFTER INSPECTION AND MAINTENANCE ....3082
FUEL AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE ....3082
CLOSE ENGINE HOOD SECURELY ....3082
OUTLINE OF SERVICE ....3083
HANDLING OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC ....3083
HANDLING ELECTRICAL COMPONENTS ....3087
STANDARD TIGHTENING TORQUE FOR BOLTS AND NUTS ....3088
TIGHTENING TORQUE LIST ....3088
MAINTENANCE SCHEDULE ....3089
MAINTENANCE SCHEDULE TABLE ....3089
MAINTENANCE INTERVAL FOR HYDRAULIC BREAKER ....3091
MAINTENANCE PROCEDURE ....3092
INITIAL 250 HOURS MAINTENANCE (ONLY AFTER THE FIRST 250 HOURS) ....3092
WHEN REQUIRED ....3093
CHECKS BEFORE STARTING ....3123
EVERY 50 HOURS MAINTENANCE ....3124
EVERY 250 HOURS MAINTENANCE ....3125
EVERY 500 HOURS MAINTENANCE ....3129
EVERY 1000 HOURS MAINTENANCE ....3146
EVERY 2000 HOURS MAINTENANCE ....3152
EVERY 4000 HOURS MAINTENANCE ....3160
EVERY 4500 HOURS MAINTENANCE ....3162
EVERY 5000 HOURS MAINTENANCE ....3163
EVERY 8000 HOURS MAINTENANCE ....3165
SPECIFICATIONS ....3166
SPECIFICATIONS ....3167
ATTACHMENTS AND OPTIONS ....3170
GENERAL PRECAUTIONS FOR SAFETY ....3171
PRECAUTIONS WHEN SELECTING ....3171
READ THE OPERATION AND MAINTENANCE MANUAL THOROUGHLY ....3171
PRECAUTIONS WHEN REMOVING OR INSTALLING ....3171
PRECAUTIONS WHEN USING ....3172
BUCKET WITH HOOK ....3173
HOOK CONDITION ....3173
PROHIBITED OPERATIONS ....3173
MACHINE READY FOR INSTALLATION OF ATTACHMENT ....3174
EXPLANATION OF COMPONENTS ....3174
HYDRAULIC CIRCUIT ....3177
REMOVAL AND INSTALLATION OF ATTACHMENT ....3182
ATTACHMENT OPERATIONS ....3185
LONG TERM STORAGE ....3188
SPECIFICATIONS ....3188
ATTACHMENTS AND OPTIONS ....3189
ATTACHMENT COMBINATIONS ....3189
TRACK SHOES SELECTION ....3191
RECOMMENDED ATTACHMENT OPERATIONS ....3192
HYDRAULIC BREAKER ....3192
REPLACEMENT PARTS ....3196
SAFETY CRITICAL PARTS ....3197
SAFETY CRITICAL PARTS LIST ....3197
CONSUMABLE PARTS ....3198
CONSUMABLE PARTS LIST ....3198
RECOMMENDED FUEL, COOLANT, AND LUBRICANT ....3199
LUBRICATION CHART ....3199
FUEL, COOLANT, AND LUBRICANTS TO MATCH THE AMBIENT TEMPERATURE ....3201
RECOMMENDED BRANDS AND QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL ....3203
INDEX ....3204
