Komatsu PC360LC-10, PC390LC-10 Hydraulic Excavator Service Repair Shop Manual - CEBM025204

This complete service repair workshop manual PDF download for the PC360LC-10 & PC390LC-10 Komatsu Hydraulic Excavator has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu PC360LC-10 - S/N: A32001 and up
Komatsu PC360LC-10 - S/N: K64001 and up
Komatsu PC390LC-10 - S/N: A30001 and up
ENGINE : 6D114E-5


TABLE OF CONTENTS :

01 GENERAL
10 STRUCTURE AND FUNCTION
20 STANDARD VALUE TABLES
30 TESTING AND ADJUSTING
40 TROUBLESHOOTING
50 DISASSEMBLY AND ASSEMBLY
60 MAINTENANCE STANDARD
80 AIR CONDITIONING
90 DIAGRAMS AND DRAWINGS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : CEBM025204
Total Pages : 1998


This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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PC360-390LC-10 Shop Manual CEBM025204

00 FORWARD
CONTENTS
SAFETY
Safety Notice
Important Safety Notice
General Precautions
Preparations For Work
Precautions During Work
GENERAL
HOW TO READ THE SHOP MANUAL
Volumes
Distribution And Updating
Filing Method
Revised Edition Mark
Revisions
Symbols
HOISTING INSTRUCTIONS
Hoisting
Making Signs
Precautions
Precautions for Sling Work
Precautions for Using Mobile Crane
Precautions for Using Overhead Hoist Crane
Selecting Wire Ropes
HANDLING ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENTS
Points to Remember When Handling Electric Equipment
Points to Remember When Handling Hydraulic Equipment
PUSH PULL COUPLER
Type 1
Disconnection
Connection
Type 2
Disconnection
Connection
Type 3
Disconnection
Connection
EXPLANATION OF MAINTENANCE STANDARD TERMS
HANDLING OF FUEL SYSTEM DEVICES
HANDLING OF INTAKE SYSTEM PARTS
STANDARD TIGHTENING TORQUE
Bolts And Nuts
Tightening Torque Of Hose Nuts
Tightening Torque Of Split Flange Bolts
Tightening Torque For Flared Nuts
Tightening Torques for Split Flanged Bolts
Tightening Torques For O-ring Boss Piping Joints
Table Of Tightening Torques For O-ring Boss Plugs
Tightening Torque For Hoses (Taper Seal Type And Face Seal Type)
Tightening Torque For Face Seal Joints
For 102, 107, and 114 Engine Series (Bolts and Nuts)
For 102, 107, and 114 Engine Series (Eye Joints)
For 102, 107, and 114 Engine Series (Taper Screws)
ELECTRIC WIRE CODE
Classification By Thickness
Classification By Color And Code
How To Read Electric Wire Code
PRECAUTIONS FOR OPERATIONS
Precautions when Carrying Out Removal Work
Precautions when Carrying Out Installation Work
Precautions when Completing the Operation
CONVERSION TABLES
Method Of Using The Conversion Table
COATING MATERIALS
LIST OF ABBREVIATIONS
List of Abbreviations Used in the Shop Manual
List of Abbreviations Used in the Circuit Diagrams

01 GENERAL
SPECIFICATION DIMENSION DRAWINGS
Dimensions
Working Ranges
SPECIFICATIONS
Engine
Undercarriage
Hydraulic System
WEIGHT TABLE
FUEL, COOLANT AND LUBRICANTS
Lubrication Chart

10 STRUCTION AND FUNCTION
ENGINE AND COOLING SYSTEM
Engine Related Parts
Cooling System
POWER TRAIN
Power Train
Swing Circle
Final Drive
PC360LC-10
PC390LC-10
UNDERCARRIAGE AND FRAME
Track Frame and Idler Cushion
HYDRAULIC SYSTEM
Hydraulic Component Layout
Valve Control
Hydraulic Tank
Oil Filler Cap
CLSS
Structure of CLSS
Basic principle
Main Pump
Operation
LS Valve
PC Valve
LS(PC)-EPC Valve
Control Valve
Functions and Operation by Valve
Hydraulic Circuit Diagram and Name of Valves
Unload Valve
Introduction of LS Pressure
LS By-Pass Plug
Pressure Compensation Valve
Shuttle Valve In Pressure Compensation Valve
Boom Regeneration Circuit
Arm Regeneration Circuit
Merge-Divider Valve
LS Selector Valve
Self-Pressure Reducing Valve
Travel Junction Valve
Travel PPC Shuttle Valve
Boom Hydraulic Drift Prevention Valve
Arm Hydraulic Drift Prevention Valve (If Equipped)
Suction Safety Valve for Drift Prevention Valve
Arm Quick Return Valve
Variable Back Pressure Valve
Main Relief Valve
Suction 2-Stage Safety Valve
Swing Motor
Swing Holding Brake
Relief Valve
Swing 2-Stage Relief Valve
Swing Motor Reverse Prevention Valve
Travel Motor - Type KMV180ADT-2 (PC360LC-10)
Operation of Travel Motor
Operation of Parking Brake
Brake Valve
Counterbalance Valve
Suction Safety Valve
Travel Motor - Type KMV200ADT-2 (PC390LC-10)
Operation of Travel Motor
Parking Brake
Brake Valve
Safety Valve
PPC Valve
Work Equipment and Swing PPC Valve
Travel PPC Valve
1st-Line Attachment PPC Valve (with EPC Valve) (If Equipped)
EPC Valve (If Equipped)
2nd-Line Attachment PPC Valve (If Equipped)
Solenoid Valve
Attachment Circuit Selector Valve (If Equipped)
Center Swivel Joint
Accumulator
PPC Accumulator
WORK EQUIPMENT
Work Equipment
Work Equipment Shim
Bucket Play Adjustment Shim
CAB AND ITS ATTACHMENTS
Cab Mount and Cab Tipping Stopper
ROPS Cab
ELECTRICAL SYSTEM
Electrical Control System
Machine Control System Diagram
Engine Control Function
Engine and Pump Combined Control Function
Pump and Valve Control Function
One-Touch Power Maximizing Function
Machine Push-Up Function
Auto-Deceleration Function
Engine Automatic Warm-Up Function
Overheat Prevention Function
Turbocharger Protection Function
Swing Control Function
Quick Warm-Up Function
Swing 2-Stage Relief Function
Travel Control Function
PPC Lock Function
Attachment Flow Control Function
System Component Part
Engine Controller
Pump Controller
Fuel Control Dial
Resister for PC-EPC valve
CAN Terminating Resistor
Engine Oil Pressure Switch
PPC Oil Pressure Switch
MACHINE MONITOR SYSTEM
Machine Monitor
Input and Output Signals
Display
Gauges
Caution Monitor
Pilot Monitor
Switches
Guidance ICON and Function Switch
Operator Mode Function
Service Mode Function
KOMTRAX SYSTEM
KOMTRAX terminal
Input and Output Signals
SENSORS
Ambient Pressure Sensor
Charge (Boost) Pressure and Temperature Sensor
Coolant Temperature Sensor
Ne (Crankshaft) Speed Sensor
Bkup (Camshaft) Speed Sensor
Common Rail Pressure Sensor
Exhaust Manifold Pressure Sensor
EGR Orifice Temperature Sensor
EGR Valve Lift Sensor
Turbo Speed Sensor
KVGT Position Sensor
Mass Air Flow and Temperature Sensor
KDPF Differential Pressure and Outlet Pressure Sensor
KDOC Inlet Temperature Sensor
KDOC Outlet Temperature Sensor
KDPF Outlet Temperature Sensor
Crankcase Pressure Sensor
Engine Oil Level Sensor
Fuel Level Sensor
Coolant Level Sensor
Hydraulic Oil Temperature Sensor
Front Pump Oil Pressure Sensor
Rear Pump Oil Pressure Sensor
PPC Oil Pressure Sensor
Air Cleaner Clogging Sensor
Front Pump Swash Plate Sensor
Rear Pump Swash Plate Sensor
Water-In-Fuel Sensor

20 STANDARD VALUE TABLES
STANDARD SERVICE VALUE TABLES
Standard Value Table for Engine Related Parts
Standard Value Table for Chassis Related Parts
Engine Speed
Travel of Control Valve Spool
Travel of Control Lever
Operating Effort of Control Lever and Pedal
Hydraulic Pressure
Swing
Travel
Work Equipment
Performance in Combined Operation
Pump Swash Plate Sensor
Main Pump
Posture of Machine for Measuring Performance and Measurement Procedure
Control Valve: Spool Stroke
Swing 1: Overrun When Stopping Swing, Time Taken to Start Swing, Time Taken to Swing
Swing 2: Hydraulic Drift of Swing
Travel 1: Travel Speed, Idle Running (Without Load)
Travel 2: Travel Speed (Actual Run), Travel Deviation
Travel 3: Travel Deviation
Travel 4: Hydraulic Drift of Travel
Work Equipment 1: Hydraulic Drift of Work Equipment
Work Equipment 2: Boom Speed
Work Equipment 3: Arm Speed
Work Equipment 4: Bucket Speed
Work Equipment 5: Boom Time Lag
Work Equipment 6: Arm Time Lag
Work Equipment 7: Bucket Time Lag

30 TESTING AND ADJUSTING
GENERAL INFORMATION
Tools for Testing, Adjusting, and Troubleshooting
Sketch of Tools for Testing and Adjusting
ENGINE AND COOLING SYSTEM
Checking Engine Speed
Measuring Boost Pressure
Measuring Exhaust Gas Color
Measuring and Adjusting Valve Clearance
Testing
Adjustment
Measuring Compression Pressure
Measuring Blow-By Pressure
Measuring Engine Oil Pressure
Measuring EGR Valve and KVGT Oil Pressure
Measuring Fuel Pressure
Testing Low-Pressure Circuit (Main Fuel Filter Inlet Side)
Testing Low-Pressure Circuit (Pressure Difference)
Testing Return Circuit
Testing the Negative Pressure Circuit (At Fuel Supply Connector)
Testing the Negative Pressure Circuit (At Supply Pump)
Testing Fuel Feed Pump Outlet Pressure (At Supply Pump)
Measuring Fuel Delivery, Return and Leakage
Testing Supply Pump Delivery
Testing Supply Pump Return Rate
Testing Leakage from Pressure Limiter
Measuring Return Rate from Injector
Testing Delivery of Fuel Feed Pump
Bleeding Air from Fuel System
Bleeding Air
Checking Fuel Circuit for Leakage
Handling Cylinder Cut-Out Mode Operation
Handling No-Injection Cranking Operation
Checking and Adjusting Air Conditioner Compressor Belt Tension
Checking
Adjusting
Replacing Fan Belt
Replacing Alternator Belt
POWER TRAIN
Testing Swing Circle Bearing Clearance
Testing
UNDERCARRIAGE AND FRAME
Testing and Adjusting Track Shoe Tension
Testing
Adjusting
HYDRAULIC SYSTEM
Releasing Remaining Pressure from Hydraulic Circuit
Measuring and Adjusting of Oil Pressure in Work Equipment, Swing, and Travel Circuits
Testing
Measuring Method by Using Machine Monitor
Measuring Method by Using Oil Pressure Gauge
Combination of Pump, Actuator, and Valve
Measuring Unload Pressure
Measuring Work Equipment Relief Pressure
Measuring Swing Relief Pressure
Measuring Travel Relief Pressure
Work After Finishing Measurement
Adjusting
Adjusting Work Equipment and Travel Relief Pressure
Adjusting Boom LOWER Relief Pressure (On the Side Where High Pressure is Set)
Adjusting Boom LOWER Relief Pressure (On the Side Where Low Pressure is Set)
Adjusting Swing Relief Pressure
Measuring Oil Pressure in Control Circuit
Measuring with Machine Monitor
Measuring with Oil Pressure Gauge
Measuring and Adjusting Oil Pressure in Pump PC Control Circuit
Testing
Measuring PC Valve Output Pressure (Servo Piston Inlet Pressure) With Machine Monitor
Measuring PC-EPC Valve Output Pressure With the Machine Monitor
Measuring PC Valve Output Pressure (Servo Piston Inlet Pressure) With Oil Pressure Gauge
Measuring PC-EPC Valve Output Pressure With Oil Pressure Gauge
Adjusting
Measuring and Adjusting Oil Pressure in Pump LS Control Circuit
Testing
Measuring LS Valve Output Pressure (Servo Piston Inlet Pressure) With Machine Monitor
Measuring LS Differential Pressure with the Machine Monitor
Measuring LS-EPC Valve Output Pressure with the Machine Monitor
Measuring LS Valve Output Pressure (Servo Piston Inlet Pressure) with Oil Pressure Gauge
Measuring LS Differential Pressure with Oil Pressure Gauge
Measuring LS-EPC Valve Output Pressure with Oil Pressure Gauge
Adjusting
Measuring Solenoid Valve Output Pressure
Testing
Measuring with Machine Monitor
Measuring with Oil Pressure Gauge
Operating Condition
Measuring PPC Valve Output Pressure
Testing
Measuring with Machine Monitor
Measuring with Oil Pressure Gauge
Adjusting Play of Work Equipment and Swing PPC Valves
Adjusting
Testing Pump Swash Plate Sensor
Testing Output Voltage of Pump Swash Plate Sensor
Isolating the Parts Causing Hydraulic Drift in Work Equipment
Measuring Oil Leakage
Bleeding Air From Hydraulic Circuit
CAB AND ITS ATTACHMENTS
Checking Cab Tipping Stopper
Adjusting Mirrors
ELECTRICAL SYSTEM
Special Functions of Machine Monitor
Upper Part of machine monitor (display portion)
Upper Part of Machine Monitor (Switch Portion)
Lower Part of Machine Monitor (Switch Portion)
Ordinary Functions and Special Functions of Machine Monitor
Operator Mode (Outline)
Service Mode
Angle Adjustment of Rear View Camera
Handling Voltage Circuit of Engine Controller
Handling Battery Disconnect Switch
Testing Diodes
PM CLINIC
PM Clinic Service
Check Items Related to Engine
Check Items Related to Oil Pressure
Check Sheet

40 TROUBLESHOOTING
GENERAL INFORMATION ON TROUBLESHOOTING
Points to Remember When Troubleshooting
Sequence of Events in Troubleshooting
Checks Before Troubleshooting
Testing Procedure Before Troubleshooting
Walk-Around Check
Checking in Accordance with Checking Procedure
Preparation Work for Troubleshooting of Electrical System
Preparation Work
Classification and Procedure for Troubleshooting
Classification of Troubleshooting
Procedure for Troubleshooting
Symptom of Probable Failure and Troubleshooting No.
Information Mentioned in Troubleshooting Table
Diagnostic Procedure for Wiring Harness Open Circuit of Pressure Sensor System
Connector list
Layout of connectors
Connection Table for Connector Pin Numbers
T-Branch Box and T-Branch Adapter Table
Fuse List and Location
Connection Table of Fuse Box
Locations of Fusible Links
Location of Fuse Box and Fuse Numbers
Precautions for Cleaning and Replacing KDPF (KCSF, KDOC)
FAILURE CODE (DISPLAY OF CODE)
Failure Codes Table
879AKA - A/C Inner Sensor Open Circuit
879AKB - A/C Inner Sensor Short Circuit
879BKA - A/C Outer Sensor Open Circuit
879BKB - A/C Outer Sensor Short Circuit
879CKA - Ventilating Sensor Open Circuit
879CKB - Ventilating Sensor Short Circuit
879DKZ - Sunlight Sensor Open or Short Circuit
879EMC - Ventilation Damper Abnormality
879FMC - Air Mix Damper Abnormality
879GKX - Refrigerant Abnormality
989L00 - Engine Controller Lock Caution 1
989M00 - Engine Controller Lock Caution 2
989N00 - Engine Controller Lock Caution 3
A1U0N3 - KDPF Dry Request (HC Release) 1
A1U0N4 - KDPF Dry Request (HC Release) 2
AA10NX - Air Cleaner Clogging
AB00KE - Charge Voltage Low
B@BAZG - Engine Oil Pressure Low
B@BAZK - Eng Oil Level Low
B@BCNS - Engine Coolant Overheat
B@BCZK - Radiator Coolant Level Low
B@HANS - Hyd Oil Overheat
CA115 - Eng Ne and Bkup Speed Sens Error
CA122 - Chg Air Press Sensor High Error
CA123 - Chg Air Press Sensor Low Error
CA131 - Throttle Sensor High Error
CA132 - Throttle Sensor Low Error
CA144 - Coolant Temp Sens High Error
CA145 - Coolant Temp Sens Low Error
CA153 - Chg Air Temp Sensor High Error
CA154 - Chg Air Temp Sensor Low Error
CA187 - Sensor 2 Supply Volt Low Error
CA221 - Ambient Press Sensor High Error
CA222 - Ambient Press Sensor Low Error
CA227 - Sensor 2 Supply Volt High Error
CA234 - Eng Overspeed
CA238 - Ne Speed Sensor Supply Volt Error
CA239 - Ne Speed Sens Supply Volt High Error
CA271 - IMV/PCV1 Short Error
CA272 - IMV/PCV1 Open Error
CA281 - Pump Press Balance Error
CA295 - Ambient Press Sens In Range Error
CA322 - Inj #1 (L#1) Open/Short Error
CA323 - Inj #5 (L#5) Open/Short Error
CA324 - Inj #3 (L#3) Open/Short Error
CA325 - Inj #6 (L#6) Open/Short Error
CA331 - Inj #2 (L#2) Open/Short Error
CA332 - Inj #4 (L#4) Open/Short Error
CA343 - ECM Critical Internal Failure
CA351 - Injectors Drive Circuit Error
CA352 - Sensor 1 Supply Volt Low Error
CA356 - Mass Air Flow Sensor High Error
CA357 - Mass Air Flow Sensor Low Error
CA386 - Sensor 1 Supply Volt High Error
CA428 - Water in Fuel Sensor High Error
CA429 - Water in Fuel Sensor Low Error
CA435 - Eng Oil Press Sw Error
CA441 - Battery Voltage Low Error
CA442 - Battery Voltage High Error
CA449 - Rail Press Very High Error
CA451 - Rail Press Sensor High Error
CA452 - Rail Press Sensor Low Error
CA488 - Chg Air Temp High Torque Derate
CA515 - Rail Press Sens Sup Volt High Error
CA516 - Rail Press Sens Sup Volt Low Error
CA553 - Rail Press High Error 1
CA555 - Crankcase Press High Error 1
CA556 - Crankcase Press High Error 2
CA559 - Rail Press Low Error 1
CA595 - Turbo Speed High Error 2
CA687 - Turbo Speed Low Error
CA689 - Eng Ne Speed Sensor Error
CA691 - Intake Air Temp Sens High Error
CA692 - Intake Air Temp Sens Low Error
CA697 - ECM Int Temp Sensor High Error
CA698 - ECM Int Temp Sensor Low Error
CA731 - Eng Bkup Speed Sens Phase Error
CA778 - Eng Bkup Speed Sensor Error
CA1117 - Persistent Data Lost Error
CA1664 - KDOC Malfunction
CA1691 - Regeneration Ineffective
CA1695 - Sensor 5 Supply Volt High Error
CA1696 - Sensor 5 Supply Volt Low Error
CA1843 - Crankcase Press Sens High Error
CA1844 - Crankcase Press Sens Low Error
CA1879 - KDPF Differential P Sensor High Error
CA1881 - KDPF Differential P Sensor Low Error
CA1883 - KDPF Differential P Sens In Range Error
CA1921 - KDPF Soot Load High Error 1
CA1922 - KDPF Soot Load High Error 2
CA1942 - Crankcase Press Sens In Range Error
CA1993 - KDPF Differential Pressure Low Error
CA2185 - Throt Sensor Sup Volt High Error
CA2186 - Throt Sensor Sup Volt Low Error
CA2249 - Rail Press Very Low Error
CA2265 - Fuel Feed Pump Open Error
CA2266 - Fuel Feed Pump Short Error
CA2271 - EGR Valve Pos Sens High Error
CA2272 - EGR Valve Pos Sens Low Error
CA2288 - Turbo Speed High Error 1
CA2311 - IMV Solenoid Error
CA2349 - EGR Valve Solenoid Open Error
CA2353 - EGR Valve Solenoid Short Error
CA2357 - EGR Valve Servo Error
CA2373 - Exhaust Manifold Press Sens High error
CA2374 - Exhaust Manifold Press Sens Low Error
CA2375 - EGR Orifice Temp Sens High Error
CA2376 - EGR Orifice Temp Sens Low Error
CA2381 - KVGT Pos Sens High Error
CA2382 - KVGT Pos Sens Low Error
CA2383 - KVGT Solenoid Open Error
CA2386 - KVGT Solenoid Short Error
CA2387 - KVGT Valve Servo Error
CA2554 - Exh Manifold Press Sens In Range Error
CA2555 - Grid Htr Relay Open Circuit Error
CA2556 - Grid Htr Relay Volt High Error
CA2637 - KDOC Blocked
CA2639 - Manual Stationary Regeneration Request
CA2961 - EGR Orifice Temp High Error 1
CA2973 - Chg Air Press Sensor In Range Error
CA3133 - KDPF Outlet Press Sens High Error
CA3134 - KDPF Outlet Press Sens Low Error
CA3135 - KDPF Outlet Press Sens In Range Error
CA3251 - KDOC Inlet Temp High Error
CA3253 - KDOC Temp Error - Non Regeneration
CA3254 - KDOC Outlet Temp High Error 1
CA3255 - KDPF Temp Error - Non Regeneration
CA3256 - KDPF Outlet Temp High Error 1
CA3311 - KDOC Outlet Temp High Error 2
CA3312 - KDPF Outlet Temp High Error 2
CA3313 - KDOC Inlet Temp Sensor Low Error
CA3314 - KDOC Inlet Temp Sens High Error
CA3315 - KDOC Inlet Temp Sens In Range Error
CA3316 - KDOC Outlet Temp Sens Low Error
CA3317 - KDOC Outlet Temp Sens High Error
CA3318 - KDOC Outlet Temp Sens In Range Error
CA3319 - KDPF Outlet Temp Sens High Error
CA3321 - KDPF Outlet Temp Sens Low Error
CA3322 - KDPF Outlet Temp Sens In Range Error
CA3419 - Mass Air Flow (MAF) Sensor Sup Volt High Error
CA3421 - Mass Air Flow (MAF) Sensor Sup Volt Low Error
CA3741 - Rail Press Valve Trip Error
D110KB - Battery Relay Output Voltage
D19JKZ - Personal Code Relay Abnormality
D811MC - KOMTRAX Error
D862KA - GPS Antenna Open Circuit
D8AQKR - CAN2 Discon (KOMTRAX)
DA20MC - Pump Controller
DA22KK - Pump Solenoid Power Low Error
DA25KP - 5 V Sensor 1 Power Abnormality
DA29KQ - Model Selection Abnormality
DA2QKR - CAN2 Discon ( Pump Con)
DA2RKR - CAN1 Discon ( Pump Con)
DAF0MB - Monitor Memory Error
DAF0MC - Monitor Error
DAF8KB - Camera Power Supply Short Circuit
DAF9KQ - Model Selection Abnormality
DAFGMC - GPS Module Error
DAFQKR - CAN2 Discon
DAZ9KQ - A/C Model Selection Abnormality
DAZQKR - CAN2 Discon (AC)
DB2QKR - CAN2 Discon (Engine Con)
DB2RKR - CAN1 Discon (Engine Con)
DGH2KB - Hyd Oil Sensor Short Circuit
DHA4KA - Air Cleaner Clog Sensor Open Circuit
DHPAMA - F Pump Press Sensor Abnormality
DHPBMA - R Pump Press Sensor Abnormality
DHS3MA - Arm In PPC Press Sensor Abnormality
DHS4MA - Bucket Curl PPC Press Sensor Abnormality
DHS8MA - Boom Raise PPC Press Sensor Abnormality
DHS9MA - Boom Lower PPC Press Sensor Abnormality
DHSAMA - Swing RH PPC Press Sensor Abnormality
DHSBMA - Swing LH PPC Press Sensor Abnormality
DHSCMA - Arm Out PPC Press Sensor Abnormality
DHSDMA - Bucket Dump PPC Press Sensor Abnormality
DHSFMA - Travel Fwd LH PPC Press Sensor Abnormality
DHSGMA - Travel Fwd RH PPC Press Sensor Abnormality
DHSHMA - Travel Rev LH PPC Press Sensor Abnormality
DHSJMA - Travel Rev RH PPC Press Sensor Abnormality
DKR0MA - F Pump Swash Plate Sensor Abnormality
DKR1MA - R Pump Swash Plate Sensor Abnormality
DV20KB - Travel Alarm Short Circuit
DW43KA - Travel Speed Sol Open Circuit
DW43KB - Travel Speed Sol Short Circuit
DW45KA - Swing Brake Sol Open Circuit
DW45KB - Swing Brake Sol Short Circuit
DW91KA - Travel Junction Sol Open Circuit
DW91KB - Travel Junction Sol Short Circuit
DWA2KA - Attachment Sol Open Circuit
DWA2KB - Attachment Sol Short Circuit
DWK0KA - 2-Stage Relief Sol Open Circuit
DWK0KB - 2-Stage Relief Sol Short Circuit
DWK2KA - Variable Back Press Sol Open Circuit
DWK2KB - Variable Back Press Sol Short Circuit
DWK8KA - Swing Press C/O Sol Open Circuit
DWK8KB - Swing Press C/O Sol Short Circuit
DXA8KA - PC-EPC (F) Sol Open Circuit
DXA8KB - PC-EPC (F) Sol Short Circuit
DXA9KA - PC-EPC (R) Sol Open Circuit
DXA9KB - PC-EPC (R) Sol Short Circuit
DXE0KA - LS-EPC Sol Open Circuit
DXE0KB - LS-EPC Sol Short Circuit
DXE4KA - Attachment Flow EPC Open Circuit
DXE4KB - Attachment Flow EPC Short Circuit
DXE5KA - Merge-divide Main Sol Open Circuit
DXE5KB - Merge-divide Main Sol Short Circuit
DXE6KA - Merge-divide LS Sol Open Circuit
DXE6KB - Merge-divide LS Sol Short Circuit
DY20KA - Wiper Working Abnormality
DY20MA - Wiper Parking Abnormality
DY2CKB - Washer Drive Short Circuit
DY2DKB - Wiper Drive (Fwd) Short Circuit
DY2EKB - Wiper Drive (Rev) Short Circuit
ELECTRICAL SYSTEM (E-MODE)
E-1 Engine Does Not Start (Engine Does Not Rotate)
E-2 Manual Pre-Heating System Does Not Work
E-3 Automatic Pre-Heating System Does Not Work
E-4 Pre-Heating Monitor Does Not Light Up When Pre-Heater is Operated
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Displays Nothing
E-6 When Starting Switch is Turned to ON Position (Before Starting Engine), Engine Oil Level Monitor Lights Up in Yellow
E-7 When Starting Switch is Turned to ON Position (Before Starting Engine), Radiator Coolant Level Monitor Lights Up in Yellow
E-8 Coolant Temperature Monitor Lights Up in White While Engine is Running
E-9 Hydraulic Oil Temperature Monitor Lights Up in White While Engine is Running
E-10 Charge Level Monitor Lights Up While Engine is Running
E-11 Fuel Level Monitor Lights Up in Red While Engine is Running
E-12 Air Cleaner Clogging Monitor Lights Up in Yellow While Engine is Running
E-13 Engine Coolant Temperature Monitor Lights Up in Red While Engine is Running
E-14 Hydraulic Oil Temperature Monitor Lights Up in Red While Engine is Running
E-15 Engine Oil Pressure Monitor Lights Up in Red While Engine is Running
E-16 Fuel Gauge Display Does Not Move from Minimum or Maximum
E-17 Display of Fuel Gauge Differs from Actual Fuel Level
E-18 Coolant Temperature Gauge Indicate Either Min or Max and Does Not Move
E-20 Hydraulic Oil Temperature Gauge Indicate Either Min or Max and Does Not Move
E-21 Hydraulic Oil Temperature Gauge Differs from Actual oil Temperature
E-22 Machine Monitor Does Not Display Partially
E-23 Function Switch Does Not Work
E-24 Automatic Pre-Heating System Does Not Work (In Cold Weather)
E-25 Auto-Deceleration Monitor Does Not Light Up or Does Not Go Out When Auto-Deceleration Switch is Operated
E-26 Auto-Deceleration is Not Actuated or Canceled When Lever is Operated
E-27 Working Mode Selector Screen Selection Screen is Not Displayed When Working Mode Switch is Operated
E-28 Engine or Hydraulic Pump Setting Does Not Change When Working Mode is Changed
E-29 Travel Speed Monitor Does Not Change When Travel Speed Switch is Operated
E-32 Travel Speed Does Not Change When Travel Speed is Shifted
E-31 Alarm Buzzer Does Not Stop Sounding
E-32 When Starting Switch is Turned OFF, Service Meter is Not Displayed
E-33 Machine Monitor Service Mode Cannot be Selected
E-34 Any of Work Equipment, Swing and Travel Does Not Work
E-35 Any of Work Equipment, Swing and Travel Can Not be Locked
E-36 Machine Can Not Swing While Swing Brake Cancel Switch is Canceled
E-37 Swing Brake Does Not Operate While Swing Brake Cancel Switch is set to NORMAL position
E-38 One-Touch Power Maximizing Function Does Not Work Or Pilot Monitor is Not Displayed
E-39 One-Touch Power Maximizing Function Cannot be Released
E-40 Travel Alarm Does Not Sound When Machine Travels
E-41 Travel Alarm Does Not Stop Sounding When Machine Stops
E-42 Horn Does Not Sound
E-43 Horn Does Not Stop Sounding
E-44 Wiper Monitor Does Not Light Up or Go Out When Wiper Switch is Operated
E-45 Wiper Does Not Operate When Wiper Switch is Operated
E-46 Window Washer Does Not Operate When Window Washer Switch is Operated
E-47 Boom LOWER Indication is Not Displayed Properly With Monitoring Function
E-48 Arm DUMP Indication is Not Displayed Properly With Monitoring Function
E-49 Arm IN Indication is Not Displayed Properly With Monitoring Function
E-50 BooM RAISE Indication is Not Displayed Properly With Monitoring Function
E-51 Bucket CURL Indication is Not Displayed Properly With Monitoring Function
E-52 Bucket DUMP Indication is Not Displayed Properly With Monitoring Function
E-53 Swing Indication is Not Displayed Properly With Monitoring Function
E-54 Travel Indication is Not Displayed Properly With Monitoring Function
E-55 Attachment is Not Displayed Properly With Monitoring Function
E-56 Attachment Hydraulic Circuit Cannot be Changed
E-57 KOMTRAX System Does Not Work Properly
E-58 Machine Push-up Function is Not Canceled
HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)
Information Mentioned in Troubleshooting Table (H Mode)
Failure Mode and Cause Table
H-1 All of Work Equipment, Swing and Travel Operation Lacks Speed or Power
H-2 Engine Speed Lowers Significantly or Engine Stalls
H-3 Any of Work Equipment, Swing and Travel Does Not Work
H-4 Unusual Sound is Heard from Around Hydraulic Pump
H-5 Fine Control Performance or Response is Poor
H-6 Boom Operation Lacks Speed or Power
H-7 Arm Operation Lacks Speed or Power
H-8 Bucket Operation Lacks Speed or Power
H-9 Work Equipment Does Not Move in Single Operation
H-10 Hydraulic Drift of Boom is Large
H-11 Hydraulic Drift of Arm is Large
H-12 Hydraulic Drift of Bucket is Large
H-13 Time Lag of Work Equipment is Large
H-14 When Part of Work Equipment is Relieved Singly, Other Parts of Work Equipment Move
H-15 One-Touch Power Maximizing Function Does Not Work
H-16 Machine Push Up Function Does Not Work
H-17 In Combined Operation of Work Equipment, Equipment Having Heavier Load Moves Slower
H-18 In Combined Operations of Swing and Boom RAISE, Boom Rising Speed is Low
H-19 In Combined Operations of Swing and Travel, Travel Speed Drops Largely
H-20 Machine Does Not Travel Straight
H-21 Travel Speed is Too Low
H-22 Machine is hard to Steer or Travel Power is Low
H-23 Travel Speed Does Not Change, or Travel Speed is Too Low or High
H-24 One of Tracks Dose Not Run
H-25 Upper Structure Does Not Swing to the Right or Left
H-26 Upper Structure Swing Only to the Right or Left
H-27 Swing Acceleration is Poor or Swing Speed is Low (Either Right and Left)
H-28 Swing Aceleration is Poor or Swing Speed is Low in Only One Direction
H-29 Upper Structure Overruns Excessively When it Stops Swinging (Both Right and Left)
H-30 Upper Structure Overruns Excessively When it Stops Swinging (Either Right or Left)
H-31 Shock is Large When Upper Structure Stops Swinging
H-32 Large Unusual Noise is Heard When Upper Structure Stops Swinging
H-33 When Swing Holding Brake is Applied, Hydraulic Drift of Swing is Large
H-34 When Swing Holding Brake is Released, Hydraulic Drift Of Swing is Large
H-35 When additional attachment is installed, attachment circuit is not switched
H-36 Oil Flow in Attachment Circuit Cannot be Controlled
ENGINE (S-MODE)
Information Mentioned in Troubleshooting Table (S-Mode)
S-1 When Starting Switch is Turned to START Position, Engine Does Not Crank
S-2 When Engine Cranks, Exhaust Smoke Does Not Come Out
S-3 Fuel is Being Injected But Engine Does Not Start (Incomplete Combustion: Engine Cranks but Does Not Start)
S-4 Startability is Poor
S-5 Engine Does Not Pick Up Smoothly
S-6 Engine Stops During Operation
S-7 Engine Runs Rough or is Unstable
S-8 Engine Lacks Power
S-9 Exhaust Smoke is Black (KDPF Clogs Up Early)
S-10 Engine Oil Consumption is Excessive
S-11 Oil Becomes Contaminated Early
S-12 Fuel Consumption is Excessive
S-13 Oil is in Coolant (or Coolant Spurts or Coolant Level Goes Down)
S-14 Oil Pressure Drops
S-15 Fuel is Contaminated in Engine Oil
S-16 Coolant Mixes in Engine Oil (Oil Becomes Cloudy White)
S-17 Coolant Temperature Rises Too High (Overheating)
S-18 Unusual Noise is Heard
S-19 Vibration is Excessive
S-20 Air Cannot be Bled from Fuel Circuit
S-21 Automatic Regeneration is Operated Frequently
S-22 Active Regeneration is Operated for Long
S-23 White Smoke Comes Out in the Process of Active Regeneration

50 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS SECTION
Removal and Installation of Assemblies
Special Tools
Removal
Installation
Disassembly and Assembly of Assemblies
Special Tools
Disassembly
Assembly
Coating Materials List
SPECIAL TOOLS LIST
Sketches of Special Tools
CONNECTOR REPAIR PROCEDURES
Stripping Insulation
Wire Inspection
Contact Terminal Removal (HD30 Type)
Crimping Contact Terminal (HD30 Type)
Insertion of Contact Terminal (HD30 Type)
Contact Terminal Removal (DT Type)
Crimping Contact Terminal (DT Type)
Insertion of Contact Terminal (DT Type)
ENGINE AND COOLING SYSTEM
Supply Pump Assembly
Removal
Installation
Fuel Injector Assembly
Removal
Installation
Cylinder Head Assembly
Removal
Installation
Radiator Assembly
Removal
Installation
Hydraulic Oil Cooler Assembly
Removal
Installation
Aftercooler Assembly
Removal
Installation
Engine and Main Pump Assembly
Removal
Installation
Engine Front Oil Seal
Removal
Installation
Engine Rear Oil Seal
Removal
Installation
Fuel Tank Assembly
Removal
Installation
Engine Hood Assembly
Removal
Installation
KDPF Assembly
Removal
Installation
Disassembly
Assembly
KCCV Assembly
Removal
Installation
Air Cleaner Assembly
Removal
Installation
Air Conditioner Compressor Assembly
Removal
Installation
Air Conditioner Condenser Assembly
Removal
Installation
POWER TRAIN
Travel Motor and Final Drive Assembly
Removal
Installation
Final Drive (PC360LC-10)
Disassembly
Assembly
Final Drive (PC390LC-10)
Removal
Installation
Disassembly
Assembly
Swing Motor and Swing Machinery Assembly (PC360LC-10)
Removal
Installation
Swing Motor and Swing Machinery (PC390LC-10)
Removal
Installation
Swing Machinery (PC360LC-10)
Disassembly
Assembly
Swing Machinery (PC390LC-10)
Disassembly
Assembly
Swing Circle Assembly (PC360LC-10)
Removal
Installation
Swing Circle Assembly (PC390LC-10)
Removal
Installation
UNDERCARRIAGE AND FRAME
Track Shoe Assembly
Separation
Installation
Sprocket
Removal
Installation
Idler and Idler Cushion Assembly
Removal
Installation
Idler
Disassembly
Assembly
Idler Cushion (PC360LC-10)
Disassembly
Assembly
Idler Cushion (PC390LC-10)
Disassembly
Assembly
Track Roller
Disassembly
Assembly
Carrier Roller
Disassembly
Assembly
Revolving Frame Assembly
Removal
Installation
Counterweight Assembly
Removal
Installation
HYDRAULIC SYSTEM
Center Swivel Joint Assembly
Removal
Installation
Disassembly
Disassembly
Assembly
Hydraulic Tank Assembly
Removal
Installation
Main Pump Assembly
Removal
Installation
Control Valve Assembly
Removal
Installation
Disassembly
Replacing Procedures of Pressure Compensation Valve Seal
Assembly
Work Equipment PPC Valve
Disassembly
Assembly
Travel PPC Valve
Disassembly
Assembly
WORK EQUIPMENT
Bucket Assembly
Removal
Installation
Arm Assembly
Removal
Installation
Work Equipment Assembly
Removal
Installation
Work Equipment Cylinder
Disassembly
Assembly
CAB AND ITS ATTACHMENTS
Operator's Cab Assembly
Removal
Installation
Operator Cab Glass (Fixed Glass)
Removal
Installation
Front Window Assembly
Removal
Installation
Floor Frame Assembly
Removal
Installation
Air Conditioner Unit Assembly
Removal
Installation
Operator's Seat
Removal
Installation
Seat Belt
Removal
Installation
Front Wiper Assembly
Removal
Installation
ELECTRIC SYSTEM
Engine Controller Assembly
Removal
Installation
Pump Controller Assembly
Removal
Installation
Machine Monitor Assembly
Removal
Installation
Pump Swash Plate Sensor
Removal
Installation
Mass Air Flow and Temperature Sensor
Removal
Installation
KOMTRAX Terminal Assembly
Removal
Installation

60 MAINTENANCE STANDARD
ENGINE AND COOLING SYSTEM
Engine Mounts
Cooling System
POWER TRAIN
Swing Circle
Swing Machinery
Final Drive
PC360LC-10
PC390LC-10
Sprocket
PC360LC-10
PC390LC-10
UNDERCARRIAGE AND FRAME
Track Frame and Idler Cushion
Idler
PC360LC-10
PC390LC-10
Track Roller
PC360LC-10
PC390LC-10
Carrier Roller
PC360LC-10
PC390LC-10
Track Shoe
PC360LC-10
PC390LC-10
Triple Grouser Shoe
PC360LC-10
PC390LC-10
HYDRAULIC SYSTEM
Hydraulic Tank
Main Pump
Control Valve
General View
Sectional View (1/5)
Sectional View (2/5)
Sectional View (3/5)
Sectional View (4/5)
Sectional View (5/5)
Swing Motor
Travel Motor
PPC Valve
Work Equipment and Swing PPC Valve
Travel PPC Valve
1st-Line Attachment PPC Valve (with EPC Valve)
EPC Valve
2nd-Line Attachment PPC Valve
Solenoid Valve
Attachment Circuit Selector Valve
Center Swivel Joint
WORK EQUIPMENT
Dimensions of Components
Dimensions of Arm
Boom Cylinder
Arm Cylinder
Bucket Cylinder

80 AIR CONDITIONER
AIR CONDITIONER
Precautions for Refrigerant
Air Conditioner Component
Structure and Function of Refrigeration System
Overview of Refrigeration System
Air Conditioner Unit
Function
Functions of Major Components
Dual Pressure Switch
Air Conditioner Controller
Air Conditioner Compressor
Air Conditioner Condenser
Receiver Drier
Sunlight Sensor
Outside Air Temperature Sensor
Procedure for Testing and Troubleshooting
Basic Inspection and Troubleshooting Sequence
Air Conditioner Circuit Diagram and Arrangement of Connector Pins
System Diagram
Air Conditioner Controller Input and Output Signals
Parts and Connectors Layout
Layout of Air Conditioner Related Parts and Connectors
Testing Air Leakage (Duct)
Testing with Self-Diagnosis Function
How to Enter Air Conditioner “Electrical Systems” Screen in Service Mode of the Machine Monitor
Testing Vent (Mode) Changeover
Testing FRESH/RECIRC Air Changeover
Testing Sunlight Sensor
Testing (Dual) Pressure Switch for Refrigerant
Testing Relay
Troubleshooting Chart 1
Troubleshooting Chart 2
Information Mentioned in Troubleshooting Table
Information in Troubleshooting Table
Failure Code List Related to Air Conditioner
879AKA - A/C Inner Sensor Open Circuit
879AKB - A/C Inner Sensor Short Circuit
879BKA - A/C Outer Sensor Open Circuit
879BKB - A/C Outer Sensor Short Circuit
879CKA - Ventilating Sensor Open Circuit
879CKB - Ventilating Sensor Short Circuit
879DKZ - Sunlight Sensor Open or Short Circuit
879EMC - Ventilation Damper Abnormality
879FMC - Air Mix Damper Abnormality
879GKX - Refrigerant Abnormality
A-1 Troubleshooting for Power Supply System (The Air Conditioner Does Not Operate)
A-2 Troubleshooting of Compressor System (Air is Not Cooled)
A-3 Troubleshooting of Blower Motor System (Air Does Not Come Out or Air Flow is Normal)
A-4 Troubleshooting for FRESH/RECIRC Air Changeover
Troubleshooting with Gauge Pressure
[Measurement Condition for Pressure]
Testing Refrigerant Pressure
Check
Precautions for Disconnecting and Connecting Refrigerant Piping
Disconnection
Connection
Tightening Torque for Joint Portion of Refrigerant Piping
Handling of Compressor Oil
Oil Level Control of Compressor
Refilling of Compressor Oil

90 DIAGRAMS AND SCHEMATICS
HYDRAULIC SYSTEM
Hydraulic Circuit Symbols
Hydraulic Circuit Diagram
ELECTRICAL SYSTEM
Electrical Symbols
Air Conditioner Electrical Diagram
Electrical Circuit Diagram (1/6)
Electrical Circuit Diagram (2/6)
Electrical Circuit Diagram (3/6)
Electrical Circuit Diagram (4/6)
Electrical Circuit Diagram (5/6)
Electrical Circuit Diagram (6/6)

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